CN115070298A - Efficient double-wire welding path generation system and path generation method - Google Patents
Efficient double-wire welding path generation system and path generation method Download PDFInfo
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- CN115070298A CN115070298A CN202210858423.1A CN202210858423A CN115070298A CN 115070298 A CN115070298 A CN 115070298A CN 202210858423 A CN202210858423 A CN 202210858423A CN 115070298 A CN115070298 A CN 115070298A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0252—Steering means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
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Abstract
The invention discloses a high-efficiency double-wire welding path generation system and a path generation method, which relate to the technical field of welding and comprise the following steps: the welding line recognition, extraction and library adjustment module is used for sequentially carrying out visual sensing detection on the workpiece by the visual system, acquiring image information, extracting welding line characteristics, searching a database, and calling a welding line model with the highest similarity and relevant welding process data. The welding line model knowledge base and the welding line identification extraction need to be obtained through a large number of visual identification tests, the welding process database needs to be obtained through welding tests according to different groove forms and assembly conditions, the welding line identification extraction adjustment base, the welding line intelligent welding track path posture planning, the automatic generation of a robot welding program, the simulation issuing and the like need to be guaranteed through software algorithm design, and verification and optimization are carried out through tests, the welding quality and the welding precision of a double-wire welding path are guaranteed, the problems of dislocation and false welding are avoided, and the welding efficiency is improved to the maximum extent.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a high-efficiency double-wire welding path generation system and a path generation method.
Background
Welding: also known as fusion bonding, welding, is a manufacturing process and technique for joining metals or other thermoplastic materials such as plastics by heating, high temperature or high pressure, and welding is accomplished by three ways: the welding-heating to joint the work piece to make it melt locally to form molten pool, the molten pool is cooled and solidified and then jointed, if necessary, it can be added with molten filler for assistance, it is suitable for welding processing of various metals and alloys, it has no need of pressure, and the pressure welding-welding process must apply pressure to the welding piece, belonging to the processing of various metal materials and partial metal materials, and the soldering-welding adopts the metal material whose melting point is lower than that of base metal as soldering material, and uses the liquid soldering material to wet the base metal, fill the gap of joint, and mutually diffuse with the base metal to implement linking welding piece, and is suitable for welding processing of various materials, and also suitable for the welding processing of different metals or heterogeneous materials and modern welding energy source are various, including gas flame, electric arc, laser, electron beam, friction and ultrasonic wave, etc.
The TCP of the welding gun of the traditional single wire welding process is one point, the TCP of the welding gun of the high-efficiency double wire welding process is a line segment consisting of two points, one point and a welding seam track are relatively simple to fit, the difficulty of accurately welding the line segment and the welding seam track is greatly increased, a certain welding inclination angle is required during welding, the difficulty is more exponentially improved, the problem of TCP calibration of the welding gun cannot be solved, and the multi-posture adaptability of the TCP of the welding gun cannot be adapted.
Disclosure of Invention
The invention aims to provide an efficient double-wire welding path generation system and a path generation method, and solves the problems in the background art.
In order to achieve the purpose, the invention is realized by the following technical scheme: an efficient twin wire weld path generation system comprising:
and the visual system sequentially performs visual sensing detection on the workpiece, acquires image information, extracts weld joint characteristics, searches a database, and calls a weld joint model with the highest similarity and related welding process data.
The welding seam model knowledge base and the welding process database comprise: a weld knowledge base and an assembly weld function process database.
And the intelligent welding track path and posture planning module for the welding line plans the welding path and the posture of the welding gun of the robot by taking the extracted welding line track as a planning basis after the workpiece identification and the welding line track extraction.
The robot welding program automatic generation and simulation issuing module automatically generates and simulates the robot welding program and issues the module to form a robot welding series (or 1 complete) program, then the system performs program conversion to form a robot running program executable by the robot, and performs robot running accessibility and anti-collision verification at the background.
The welding line recognition extraction and library adjusting module is in signal connection with the welding line model knowledge base and the welding process database, the welding line recognition extraction and library adjusting module is in signal connection with the welding line intelligent welding track path attitude planning module, the welding process database is in bidirectional signal connection with the welding line intelligent welding track path attitude planning module, and the robot welding program automatically generates and simulates the issuing module and is in signal connection with the welding line intelligent welding track path attitude planning module.
Further, the welding seam identification, extraction and library adjustment module sequentially carries out visual sensing detection on the workpiece based on a visual system, obtains image information, extracts welding seam characteristics, searches a database, calls a welding seam model with the highest similarity and relevant welding process data, simultaneously extracts a welding seam outline image and a welding seam track, compares the welding seam outline image and the welding seam track with the data called the database for verification, and confirms the welding seam track welded by the robot
Furthermore, the welding seam model knowledge base and the welding process database also have data of importing, creating, storing and managing all welding seam three-dimensional models or welding seam rules, the optimal welding process of various welding seams through batch production verification, the welding process which is designed or passes test verification but is not subjected to batch production verification, the welding seam welding design rules and the like, and the database module converts the product model through an algorithm, carries out parameterization management and is used as a basis for effectively comparing and analyzing actual workpiece and workpiece model data in the later period of the visual scanning recognition system and is also used as a basis for planning software of all tracks, postures and paths.
Furthermore, the intelligent welding track path attitude planning module of the welding line is also used for designing the welding process and parameters of each welding line according to the grade of the welding process given by the database and the driving mode of the data and the model by combining the called welding process and forming a robot welding series program.
Further, the robot welding program automatic generation and simulation issuing module is further used for respectively pushing the robot operation programs to the robot controllers to form robot programs to be executed.
A path generating method of an efficient twin-wire welding path generating system is applied to any one of the efficient twin-wire welding path generating systems, and comprises the following steps:
firstly, utilizing a welding seam identification extraction and library adjustment module to determine the path of a welding seam, and then interacting the extracted data with a welding seam model knowledge base and a welding process database to obtain the optimal welding process and welding seam model.
And step two, sending the welding process and the welding seam model data to a welding seam intelligent welding track path attitude planning module, and planning the welding path and the welding gun attitude of the robot by taking the extracted welding seam track as a planning basis after workpiece identification and welding seam track extraction.
And step three, designing the welding process and parameters of each welding line according to the data and the model driving mode, and forming a robot welding series program.
And step four, sending the path data planned by the intelligent welding track path attitude planning module of the welding seam to an automatic generation and simulation issuing module of a robot welding program, carrying out data simulation, and sending data after the data is qualified.
And step five, respectively pushing the robot running program to each robot controller to form a robot program to be executed, and finally performing a welding process.
Further, the method comprises the following steps: according to the operation steps in the first step, the welding seam track obtained by the welding seam identification extraction and library adjusting module is changed into the movement track of the welding gun, and besides special execution software, a vision system, a robot external shaft and a robot TCP (welding gun tail end) need to be integrated into a common coordinate system through a special calibration method to form a whole.
Further, the method comprises the following steps: according to the operation steps in the second step, the stereoscopic vision measurement identification module based on hand-eye calibration of the welding line identification extraction and library adjustment module is the basis of high-precision three-dimensional measurement, the modules mainly comprise a high-resolution board card camera, a high-speed image acquisition board card, an image processing control module and the like, the calibration process is optimized, a space circle fitting method is provided for carrying out hand-eye calibration of a standard ball, so that an optical plane can be any plane equation, the eye calibration precision of a standard ball is improved, the adaptive range of a structural part is expanded, for a large-scale complex component, multiple breadth reconstruction is carried out in cooperation with multi-module three-dimensional imaging, and then multi-view angle splicing is carried out to obtain the panoramic appearance.
Further, the method comprises the following steps: according to the operation steps in the fourth step, 180 or 360 attitude data are compiled in the line segment direction formed by the two welding wires of the TCP and stored in a database, and when the intelligent welding track path attitude planning module of the welding line is executed, the optimal welding gun attitude is automatically matched according to an algorithm to generate the welding track.
Further, the method comprises the following steps: according to the operation steps in the fifth step, the welding process adopts a self-adaptive laser sensor to process the high-resolution full-frame image and track the welding seam.
The invention provides a high-efficiency double-wire welding path generation system and a path generation method. The method has the following beneficial effects:
according to the efficient double-wire welding path generation system and the using method, a welding seam model knowledge base and welding seam identification extraction need to be obtained through a large number of visual identification tests, a welding process database needs to be obtained through welding tests according to different groove forms and assembly conditions, a welding seam identification extraction and adjustment base, welding seam intelligent welding path posture planning, automatic generation of a robot welding program, simulation issuing and the like, and needs to be guaranteed through software algorithm design, verification and optimization are carried out through tests, the welding quality and precision of a double-wire welding path are guaranteed, the problems of dislocation and false welding are avoided, and the welding efficiency is improved to the maximum extent.
Drawings
FIG. 1 is a general system diagram of an efficient twin wire welding path generation system and method of the present invention;
fig. 2 is a schematic diagram of a high-efficiency twin-wire welding path generation system and a path generation method according to the present invention.
In fig. 1: 1. a welding seam identification, extraction and library adjustment module; 2. a weld model knowledge base and a welding process database; 3. a welding seam intelligent welding track path attitude planning module; 4. and the robot welding program automatically generates and simulates a delivery module.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Examples of which are illustrated in the accompanying drawings, wherein like 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 drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
The invention will be further illustrated with reference to the following examples and drawings:
referring to fig. 1-2, the present invention provides a technical solution: an efficient twin wire weld path generation system comprising:
the welding line recognition, extraction and library adjustment module 1 is used for sequentially carrying out visual sensing detection on a workpiece by a visual system, acquiring image information, extracting welding line characteristics, searching a database, and calling a welding line model with the highest similarity and relevant welding process data;
the welding seam model knowledge base and the welding process database 2, wherein the welding seam model knowledge base and the welding process database 2 comprise: weld joint knowledge base and assembly weld joint function process database
The intelligent welding track path and attitude planning module 3 of the welding line plans the welding path and the welding gun attitude of the robot by taking the extracted welding line track as the planning basis after the workpiece identification and the welding line track extraction;
the robot welding program automatic generation and simulation issuing module 4, after the robot welding program automatic generation and simulation issuing module 4 forms a robot welding series or 1 complete program, the system performs program conversion to form a robot running program executable by the robot, and performs robot running accessibility and anti-collision verification at the background;
the welding seam recognition extraction and library adjusting module 1 is in signal connection with the welding seam model knowledge base and the welding process database 2, the welding seam recognition extraction and library adjusting module 1 is in signal connection with the welding seam intelligent welding track path attitude planning module 3, the welding seam model knowledge base and the welding process database 2 are in bidirectional signal connection with the welding seam intelligent welding track path attitude planning module 3, a robot welding program automatically generates and simulates signal connection between the issuing module 4 and the welding seam intelligent welding track path attitude planning module 3, a new wear-resistant composite steel plate (whole or local part) is laid inside the carriage hopper, two types of welding seams can be formed between the steel plate and the steel plate, one type is a butt welding seam of a square groove (two steel plates are arranged adjacently, a small amount of gaps are reserved as the welding seams), and the type of welding seams needs full welding; the other type is fillet groove, namely fillet weld formed by a single steel plate and a bottom plate, and the fillet weld needs to be welded. Above two kinds of welding seams all need carry out multilayer multi-channel welding, and the railway carriage or compartment fill bottom has irregular radian, and whole bottom surface height is different, has solved the welding seam groove state and has: the complex size is large; the measurement field environment is complex, and the interference of the background object is serious, so that the background object and the target in the shot image are difficult to distinguish; the illumination factor is not controllable, and the target boundary in the image has no obvious gray gradient change and the like, so that the problems of difficult visual identification and difficult laser tracking are caused.
Specifically, the weld joint recognition extraction and library adjustment module 1 sequentially carries out visual sensing detection on workpieces based on a visual system, acquires image information, extracts weld joint characteristics, searches a database, calls a weld joint model with the highest similarity and relevant welding process data, simultaneously extracts a weld joint outline image and a weld joint track, compares the weld joint outline image and the weld joint track with the data called the database for verification, and confirms the weld joint track welded by the robot
Specifically, the weld model knowledge base and the welding process database 2 also have data such as importing, creating, storing and managing all weld three-dimensional models or weld rules, optimal welding processes of various welds through batch production verification, welding processes which are designed or pass test verification but not subjected to batch production verification, and assembly weld welding design rules; the database module converts the product model through an algorithm, carries out parameterization management, is used as the basis for effective comparison and analysis of the actual workpiece and workpiece model data in the later period of the visual scanning recognition system, and is also the basis of all track, attitude and path planning software.
Specifically, the intelligent welding track path attitude planning module 3 is further configured to design a welding process and parameters of each welding line according to a welding process grade given by the database and according to a data and model driving mode by combining the retrieved welding process, and form a robot welding series program.
Specifically, the robot welding program automatic generation and simulation issuing module 4 is further configured to respectively push the "robot operation program" to each robot controller, so as to form a robot program to be executed.
A path generating method of an efficient twin-wire welding path generating system is applied to any one of the efficient twin-wire welding path generating systems, and comprises the following steps:
firstly, utilizing a welding seam identification extraction and library adjustment module 1 to determine a path of a welding seam, and then interacting the extracted data with a welding seam model knowledge base and a welding process database 2 to obtain an optimal welding process and a welding seam model;
step two, sending the welding process and the welding seam model data to a welding seam intelligent welding track path attitude planning module 3, and planning a welding path and a welding gun attitude of the robot by taking the extracted welding seam track as a planning basis after workpiece identification and welding seam track extraction;
thirdly, designing welding processes and parameters of all welding seams according to data and a model driving mode, and forming a robot welding series program;
step four, sending the path data planned by the intelligent welding track path attitude planning module 3 of the welding seam to an automatic generation and simulation issuing module 4 of a robot welding program, carrying out data simulation, and sending data after the data is qualified;
and step five, respectively pushing the robot running program to each robot controller to form a robot program to be executed, and finally performing a welding process.
Specifically, according to the operation steps in the step one, the welding seam track obtained by the welding seam identification extraction and the visual identification of the library adjusting module 1 is changed into the movement track of the welding gun, and besides special execution software, a visual system, a robot external shaft and the tail end of a robot TCP welding gun are integrated into a common coordinate system through a special calibration method to form a whole.
Specifically, according to the operation steps in the second step, the three-dimensional vision measurement identification module based on hand-eye calibration of the welding seam identification, extraction and library adjustment module 1 is the basis of high-precision three-dimensional measurement, the modules mainly comprise a high-resolution board card camera, a high-speed image acquisition board card, an image processing control module and the like, the calibration process is optimized, a space circle fitting method is provided for carrying out hand-eye calibration of a standard ball, an optical plane can be any plane equation, the eye calibration precision of a standard player is improved, the adaptive range of a structural part is expanded, a plurality of breadth reconstruction is carried out in cooperation with multi-module three-dimensional imaging aiming at a large-scale complex component, and then multi-view angle splicing is carried out to obtain the panoramic appearance.
Specifically, according to the operation steps in the fourth step, 180 or 360 attitude data are compiled in the line segment direction formed by two welding wires of the TCP and stored in the database, and when the intelligent welding track path attitude planning module 3 for the welding line is executed, the optimal welding gun attitude is automatically matched according to an algorithm to generate the welding track.
Specifically, according to the operation steps in the fifth step, the welding process adopts a self-adaptive laser sensor to process high-resolution full-frame images and track welding seams, an SLPr tracking system adopts a latest intelligent sensor, a megapixel high-resolution camera, a unique automatic laser control system and a special optical system are integrated in the sensor, the high quality and the stability of the generated welding seam laser stripe images are ensured, and high-speed image processing and welding seam tracking are ensured by special digital image processing software and hardware in the sensor.
The above is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, many variations and modifications can be made without departing from the inventive concept of the present invention, which falls into the protection scope of the present invention.
Claims (10)
1. An efficient twin wire weld path generation system, comprising:
the welding line recognition, extraction and library adjustment module (1) is used for sequentially carrying out visual sensing detection on a workpiece by a visual system, acquiring image information, extracting welding line characteristics, searching a database, and calling a welding line model with the highest similarity and relevant welding process data;
a weld model knowledge base and a welding process database (2), the weld model knowledge base and the welding process database (2) comprising: a weld joint knowledge base and an assembly weld joint functional process database;
the intelligent welding track path and posture planning module (3) for the welding line is used for planning the welding path and the welding gun posture of the robot by taking the extracted welding line track as a planning basis after the workpiece identification and the welding line track extraction;
the robot welding program automatic generation and simulation issuing module (4), after the robot welding program automatic generation and simulation issuing module (4) forms a robot welding series (or 1 complete) program, the system performs program conversion to form a robot running program executable by the robot, and performs robot running accessibility and anti-collision verification at the background;
the welding line recognition extraction and library adjustment module (1) is in signal connection with the welding line model knowledge base and the welding process database (2), the welding line recognition extraction and library adjustment module (1) is in signal connection with the welding line intelligent welding track path attitude planning module (3), the welding process database (2) is in bidirectional signal connection with the welding line intelligent welding track path attitude planning module (3), and the robot welding program automatically generates and simulates to give out a signal connection between the module (4) and the welding line intelligent welding track path attitude planning module (3).
2. An efficient twin wire weld path generation system as defined in claim 1 wherein: the welding line recognition, extraction and library adjustment module (1) sequentially carries out visual sensing detection on workpieces based on a visual system, acquires image information, extracts welding line characteristics, searches a database, calls a welding line model with the highest similarity and relevant welding process data, simultaneously extracts welding line outline images and welding line tracks, compares the welding line outline images and the welding line tracks with the data called the database for verification, and confirms the welding line tracks of the robot.
3. The high efficiency twin wire weld path generation system of claim 1, wherein: the welding seam model knowledge base and the welding process database (2) also have data of importing, newly building, storing and managing all welding seam three-dimensional models or welding seam rules, the optimal welding process of various welding seams which pass batch production verification, the welding process which is designed or passes test verification but is not subjected to batch production verification, and the like, and the welding design rules of assembly welding seams and the like; the database module converts the product model through an algorithm, carries out parameterization management, is used as the basis for effective comparison and analysis of the actual workpiece and workpiece model data in the later period of the visual scanning recognition system, and is also the basis of all track, attitude and path planning software.
4. The high efficiency twin wire weld path generation system of claim 1, wherein: the intelligent welding track path attitude planning module (3) of the welding seam is also used for designing the welding process and parameters of each welding seam according to the welding process grade given by the database and the data and model driving mode by combining the called welding process and forming a robot welding series program.
5. The high efficiency twin wire weld path generation system of claim 1, wherein: the robot welding program automatic generation and simulation issuing module (4) is also used for respectively pushing robot operation programs to each robot controller to form a robot program to be executed.
6. A path generating method of an efficient twin-wire welding path generating system, which is applied to the efficient twin-wire welding path generating system of any one of claims 1 to 5, and comprises the following steps:
s1, firstly, utilizing a welding seam identification extraction and library adjustment module (1) to determine the path of the welding seam, and then interacting the extracted data with a welding seam model knowledge base and a welding process database (2) to obtain the optimal welding process and welding seam model;
s2, sending the welding process and the welding seam model data to a welding seam intelligent welding track path attitude planning module (3), and planning the welding path and the welding gun attitude of the robot by taking the extracted welding seam track as a planning basis after workpiece identification and welding seam track extraction;
s3, designing welding processes and parameters of all welding seams according to data and model driving modes, and forming a robot welding series program;
s4, sending the path data planned by the intelligent welding track path attitude planning module (3) of the welding seam to a robot welding program automatic generation and simulation issuing module (4), carrying out data simulation, and sending data after the data is qualified;
and S5, respectively pushing the robot running programs to each robot controller to form the robot programs to be executed, and finally performing the welding process.
7. The path generation method of an efficient twin wire weld path generation system of claim 6, comprising the steps of: according to the operation steps in the S1, the welding seam track obtained by the welding seam identification extraction and library adjusting module (1) is changed into the movement track of the welding gun, and besides special execution software, a vision system, a robot external shaft and a robot TCP (welding gun tail end) need to be integrated into a common coordinate system through a special calibration method to form a whole.
8. The path generation method of an efficient twin wire weld path generation system of claim 6, comprising the steps of: according to the operation steps in S2, the welding seam recognition, extraction and library adjustment module (1) is based on the stereoscopic vision measurement and recognition module calibrated by hands and eyes, the module mainly comprises a high-resolution board card camera, a high-speed image acquisition board card, an image processing control module and the like, the calibration process is optimized, a space circle fitting method is provided for calibrating the hands and eyes of a standard ball, an optical plane can be any plane equation, the calibration precision of the eyes of a standard ball is improved, the adaptive range of a structural part is expanded, for a large-scale complex component, a plurality of breadth reconstructions are carried out by cooperating with multi-module three-dimensional imaging, and then multi-view angle splicing is carried out to obtain the panoramic appearance.
9. The path generation method of an efficient twin wire weld path generation system of claim 6, comprising the steps of: according to the operation steps in the S4, 180 or 360 posture data are compiled in the line segment direction formed by the two welding wires of the TCP and stored in a database, and when the intelligent welding track path posture planning module (3) for the welding line is executed, the optimal welding gun posture is automatically matched according to an algorithm to generate a welding track.
10. The path generation method of an efficient twin wire weld path generation system of claim 6, comprising the steps of: according to the operation step in S5, the welding process uses an adaptive laser sensor to process and track the high resolution full frame image.
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