CN115415704A - Intelligent welding and 3D camera detection equipment - Google Patents
Intelligent welding and 3D camera detection equipment Download PDFInfo
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- CN115415704A CN115415704A CN202211162540.0A CN202211162540A CN115415704A CN 115415704 A CN115415704 A CN 115415704A CN 202211162540 A CN202211162540 A CN 202211162540A CN 115415704 A CN115415704 A CN 115415704A
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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
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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
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- 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
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/94—Investigating contamination, e.g. dust
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- 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
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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Abstract
The invention belongs to the field of welding equipment, relates to a data analysis technology, and is used for solving the problems that the appearance visual inspection and the welding effect identification need to be carried out manually after the welding of the existing welding machine is finished, in particular to intelligent welding and 3D camera detection equipment which comprises a machine shell, wherein a conveying mechanism, a detection mechanism and a welding mechanism are arranged in the machine shell, and a control mechanism is arranged outside the machine shell; a partition plate is fixedly arranged in the middle of the shell, supporting legs are fixedly arranged at four corners of the bottom of the partition plate, and side frames are fixedly arranged at four corners of the top of the partition plate; the six-axis manipulator and the welding machine can automatically weld the welding position, the six-axis manipulator can be sequentially controlled, the joint angle or the track of the axis can be controlled by a program or a sensor without mechanical adjustment.
Description
Technical Field
The invention belongs to the field of welding equipment, relates to a data analysis technology, and particularly relates to intelligent welding and 3D camera detection equipment.
Background
The welding machines have various types, such as single-point single-function, single-point double-function and single-point multi-function (the welding machine also has only one welding head, and can weld at any angle between 90 degrees and 180 degrees after the form of the positioning plate is changed), two-point, three-point, four-point or even six-point welding machines, four-corner welding machines and the like. Different types of welders also have different welding functions and work efficiencies.
Current PCBA welding all is the desktop formula basically, and the welding module and the planer-type frame combination of 3 axle operations that are comparatively simple form, can't satisfy 360 spin welding, and mostly the manual work carries out outward appearance visual inspection and discernment welding effect after the welding is accomplished.
In view of the above technical problem, the present application proposes a solution.
Disclosure of Invention
The invention aims to provide intelligent welding and 3D camera detection equipment, which is used for solving the problems that the appearance visual inspection and the welding effect identification need to be carried out manually after the welding of the existing welding machine is finished;
the technical problems to be solved by the invention are as follows: how to provide an intelligent welding and 3D camera check out test set that can carry out automatic monitoring to the welding effect.
The purpose of the invention can be realized by the following technical scheme:
an intelligent welding and 3D camera detection device comprises a machine shell, wherein a conveying mechanism, a detection mechanism and a welding mechanism are arranged inside the machine shell, and a control mechanism is arranged outside the machine shell; a partition plate is fixedly arranged in the middle of the machine shell, supporting legs are fixedly arranged at four corners of the bottom of the partition plate, and side frames are fixedly arranged at four corners of the top of the partition plate;
the conveying mechanism comprises a conveying rail, the conveying rail is fixedly installed on the top surface of the partition board, a clamping groove is formed in the conveying rail, buckles are arranged on the two sides of a welding area and a detection area of the conveying rail, limiting blocks are arranged on the two sides of the welding area of the conveying rail, and an air cylinder is arranged at one end, far away from the two limiting blocks, of the conveying rail;
the welding mechanism comprises a base, the base is fixedly installed on the top surface of the partition plate, a six-axis manipulator is arranged on the top of the base, and a welding machine is arranged at one end, far away from the base, of the six-axis manipulator;
the detection mechanism comprises a two-dimensional camera and a three-dimensional camera, the two-dimensional camera is arranged on one side of the conveying track, and the three-dimensional camera is arranged above the conveying track.
As a preferred embodiment of the invention, the bracket is arranged on the surface of the side frame, one end of the bracket, which is far away from the side frame, is provided with the supporting plate, the top of the supporting plate is provided with the host computer and the display, the inside of the host computer is provided with the processor, the processor is in communication connection with the controller, and the output end of the controller is electrically connected with the six-axis manipulator, the welding machine and the conveying track; meanwhile, the side surface of the side frame is also provided with a control button;
the processor is also in communication connection with a 2D analysis module, a 3D analysis module, an alarm module and a storage module.
As a preferred embodiment of the present invention, the 2D analysis module is configured to receive the captured image of the two-dimensional camera and perform monitoring analysis on the welding position of the welded workpiece: marking a shot image transmitted by a two-dimensional camera as an analysis image, amplifying the analysis image into a pixel grid image, carrying out gray scale conversion on the pixel grid image to obtain a gray value of a pixel grid, obtaining a gray threshold value through a storage module, and comparing the gray value of the pixel grid with the gray threshold value in sequence to obtain a selected set; marking the number of the selected sets as a selected median value, acquiring a selected threshold value through a storage module, and comparing the selected median value with the selected threshold value: if the selected value is smaller than the selected threshold value, judging that the mark of the welding position of the welded workpiece is abnormal, sending a mark abnormal signal to a processor by a 2D analysis module, and sending the mark abnormal signal to an alarm module and a display after the processor receives the mark abnormal signal; if the selected value is equal to the selected threshold value, positioning and analyzing the welding position of the welded workpiece; if the selected value is larger than the selected threshold value, judging that stains exist on the surface of the welded workpiece, sending a surface abnormal signal to a processor by the 2D analysis module, and sending the surface abnormal signal to an alarm signal and a display after the processor receives the surface abnormal signal; and the alarm module carries out alarm processing after receiving the marked abnormal signal or the surface abnormal signal.
As a preferred embodiment of the present invention, the specific process of sequentially comparing the gray-scale values of the pixel cells with the gray-scale threshold value includes: if the gray value is smaller than the gray threshold, marking the corresponding pixel grid as a normal grid; if the gray value is greater than or equal to the gray threshold, marking the corresponding pixel grid as a marking grid; and (3) performing correlation analysis on the mark grids: marking a set formed by adjacent marking grids as a marking set, marking the element number of the marking set as a marking value of the marking set, acquiring a marking threshold value through a storage module, and comparing the marking value with the marking threshold value: if the marking value is smaller than the marking threshold value, marking the corresponding marking set as a common set; and if the mark value is greater than or equal to the mark threshold value, marking the corresponding mark set as the selected set.
As a preferred embodiment of the invention, the specific process of positioning and analyzing the welding position of the welded workpiece comprises the following steps: the method comprises the steps of establishing a rectangular coordinate system by taking the length and the width of a shot image of a two-dimensional camera as an X axis and a Y axis, setting a pre-welding position in the rectangular coordinate system, obtaining the coincidence rate of elements in a selected set and the pre-welding position and marking the coincidence rate as a coincidence value when the element running value in the selected set is at the pre-welding position, obtaining a coincidence threshold value through a storage module, judging that the welding position of a workpiece to be welded is coincident with the pre-welding position when the coincidence value is larger than or equal to the coincidence threshold value, sending a welding signal to a processor by a 2D analysis module, sending the welding signal to a controller by the processor after receiving the welding signal, controlling an air cylinder to stretch out by the controller after receiving the welding signal, and controlling a six-axis manipulator and a welding machine to weld the workpiece to be welded by the controller.
As a preferred embodiment of the present invention, the 3D analysis module is configured to receive the captured image of the three-dimensional camera and monitor and analyze the welding effect of the welded workpiece: acquiring a selected set of images shot by the three-dimensional camera in the same way as the 2D analysis process, marking the selected set as a monitoring set, acquiring the number of elements of the monitoring set, marking the elements as monitoring values, acquiring the monitoring threshold values through a storage module, and comparing the monitoring values with the monitoring threshold values: if the monitoring value is smaller than the monitoring threshold value, judging that the positioning accuracy of the two-dimensional camera meets the requirement, and analyzing the welding effect of the welded workpiece; if the monitoring value is larger than or equal to the monitoring threshold value, the two-dimensional camera positioning accuracy is judged not to meet the requirement, the 3D analysis module sends a positioning abnormal signal to the processor, and the processor receives the positioning abnormal signal and then sends the positioning abnormal signal to the alarm module and the display.
As a preferred embodiment of the invention, the specific process for analyzing the welding effect of the welded workpiece comprises the following steps: summing the gray values of the elements in the monitoring set, averaging to obtain a monitoring performance value, obtaining a monitoring performance threshold value through a storage module, and comparing the monitoring performance value with the monitoring performance threshold value: if the monitoring performance value is smaller than the monitoring performance threshold value, the welding effect of the welded workpiece is judged not to meet the requirement, the 3D analysis module sends an effect abnormal signal to the processor, and the processor sends the effect abnormal signal to the alarm module and the display after receiving the effect abnormal signal; if the monitoring performance value is larger than or equal to the monitoring performance threshold value, judging that the welding effect of the welded workpiece meets the requirement;
and the alarm module carries out alarm processing after receiving the positioning abnormal signal or the effect abnormal signal.
As a preferred embodiment of the present invention, the working method of the intelligent welding and 3D camera detection device includes the following steps:
the method comprises the following steps: the method comprises the following steps that a welded workpiece is placed on a conveying rail to be conveyed, the welding position of the welded workpiece is scanned through a two-dimensional camera, after the welding position is scanned, a controller controls a cylinder to extend out, and the welded workpiece is intercepted through a limiting block;
step two: the controller controls the six-axis manipulator and the welding machine to weld at the welding position of the welded workpiece, after welding is completed, the controller controls the cylinder to contract, and the welded workpiece after welding is continuously conveyed on the conveying track;
step three: when the welded workpiece is conveyed to the position below the three-dimensional camera, the welding effect of the welded workpiece is detected through the three-dimensional camera, and the detection result is sent to the processor.
The invention has the following beneficial effects:
1. the automatic conveying of the welded workpiece is carried out through the conveying mechanism, the welding position of the welded workpiece is positioned through the two-dimensional camera, the six-axis manipulator and the welding machine carry out automatic welding on the welding position, the actions of the six-axis manipulator can be sequentially controlled, the joint angle or track of the axis can be controlled by a program or a sensor without mechanical adjustment, and therefore the automation degree of the welding equipment is improved, and the working pressure of workers is reduced;
2. the welding position of the welded workpiece can be monitored and analyzed through the 2D analysis module, the welding position is positioned and analyzed by combining an image shooting technology and an image processing technology, the surface state of the welded workpiece is monitored while the welding position is positioned, an alarm is given in time when stains exist on the surface of the welded workpiece, the interference of the stains on the surface to the welding effect is avoided, and the welding effect is improved;
3. the welding effect of the welded workpiece can be monitored and analyzed through the 3D analysis module, the welding effect is monitored through the analysis process which is the same as that of the 2D analysis module, meanwhile, the accuracy of the welding position is fed back, and the welding position is fed back timely when the accuracy of the welding position does not meet requirements, so that the welding accuracy and the welding effect are guaranteed.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the prior art descriptions will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a front view of a first embodiment of the present invention;
FIG. 2 is a left side view of the structure of the first embodiment of the present invention;
FIG. 3 is a side view of the structure of the first embodiment of the present invention;
FIG. 4 is an enlarged view of the structure at A in FIG. 3 according to the present invention;
FIG. 5 is a flowchart of a method according to a second embodiment of the present invention;
fig. 6 is a system block diagram of a third embodiment of the present invention.
1. A housing; 101. a partition plate; 102. a support leg; 103. a side frame; 2. a conveying mechanism; 201. a conveying track; 202. a card slot; 203. buckling; 204. a limiting block; 3. a detection mechanism; 301. a two-dimensional camera; 302. a three-dimensional camera; 4. a welding mechanism; 401. a base; 402. a six-axis manipulator; 403. a welding machine; 5. a control mechanism; 501. a bracket; 502. a support plate; 503. a host; 504. a display.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the 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 invention.
Example one
As shown in fig. 1-4, an intelligent welding and 3D camera detection device comprises a casing 1, wherein a conveying mechanism 2, a detection mechanism 3 and a welding mechanism 4 are arranged inside the casing 1, and a control mechanism 5 is arranged outside the casing 1; a partition plate 101 is fixedly installed in the middle of the machine shell 1, supporting legs 102 are fixedly installed at four corners of the bottom of the partition plate 101, and side frames 103 are fixedly installed at four corners of the top of the partition plate 101.
The external frame body of the machine shell 1 is formed by assembling a 1.2MM thick metal plate structure, the color of the equipment frame body is made of international Lawrence color as a primary color, the paint selects a label meeting ESD standards (the impedance value is not more than 10 x 6 after curing), the product flow is from left to right, an electric control module of a welding machine 403 module is embedded in the left side of the equipment and close to the middle position, the welding machine is installed at the top of a six-axis manipulator 402, a power supply and a signal line in the middle are embedded in the manipulator, a linkage switch of equipment hardware is arranged below the right side of the equipment, and an emergency stop switch is arranged above the left side of the equipment.
The conveying mechanism 2 comprises a conveying track 201, the conveying track 201 comprises a feeding area, a welding area and a detection area, and the welded workpiece sequentially passes through the feeding area, the welding area and the detection area to be welded and detected; conveying track 201 fixed mounting is at the top surface of baffle 101, conveying track 201 is inside to be provided with draw-in groove 202, conveying track 201's weld zone all is provided with buckle 203 with the detection zone both sides, conveying track 201's weld zone both sides all are provided with stopper 204, the one end that two stopper 204 kept away from mutually is provided with the cylinder, carry out automated transfer to being welded the work piece through conveying mechanism 2, two-dimensional camera 301 fixes a position the welding position of being welded the work piece.
The welding mechanism 4 comprises a base 401, the base 401 is fixedly installed on the top surface of the partition board 101, a six-axis manipulator 402 is arranged on the top of the base 401, a welding machine 403 is arranged at one end, far away from the base 401, of the six-axis manipulator 402, the six-axis manipulator 402 and the welding machine 403 automatically weld the welding position, the actions of the six-axis manipulator 402 can be sequentially controlled, the joint angles or tracks of the axes can be controlled by a program or a sensor without mechanical adjustment, and therefore the automation degree of welding equipment is improved, and the working pressure of workers is reduced; the six-axis manipulator 402 is mainly characterized by flexible starting, is an important component in a flexible manufacturing system, can be reprogrammed along with the change of the working environment of the industrial robot and the change of a workpiece, and is suitable for the application of small-batch and multi-variety flexible manufacturing production lines with balanced efficiency.
The detection mechanism 3 comprises a two-dimensional camera 301 and a three-dimensional camera 302, the two-dimensional camera 301 is arranged on one side of the conveying track 201, the three-dimensional camera 302 is arranged above the conveying track 201, the two-dimensional camera 301 and the three-dimensional camera 302 are both high-speed and high-precision scanning measurement equipment, the most advanced structured light non-contact photogrammetry principle in the world at present is applied, a composite non-contact measurement technology combining a structured light technology, a phase measurement technology and a computer vision technology is adopted, and the detection mechanism is a necessary tool for product development and quality detection.
The control mechanism 5 comprises a bracket 501, the bracket 501 is arranged on the surface of the side frame 103, a supporting plate 502 is arranged at one end, away from the side frame 103, of the bracket 501, a host 503 and a display 504 are arranged at the top of the supporting plate 502, a processor is arranged inside the host 503, the processor is in communication connection with a controller, and the output end of the controller is electrically connected with the six-axis manipulator 402, the welding machine 403 and the conveying track 201; meanwhile, the side surface of the side frame 103 is provided with a control button.
Example two
As shown in fig. 5, a working method of the intelligent welding and 3D camera detection device includes the following steps:
the method comprises the following steps: the method comprises the following steps that a welded workpiece is placed on a conveying rail 201 to be conveyed, the welding position of the welded workpiece is scanned through a two-dimensional camera 301, after the welding position is scanned, a controller controls an air cylinder to extend out, and the welded workpiece is intercepted through a limiting block 204;
step two: the controller controls the six-axis manipulator 402 and the welding machine 403 to weld at the welding position of the welded workpiece, after the welding is finished, the controller controls the cylinder to contract, and the welded workpiece after the welding is finished is continuously conveyed on the conveying track 201;
step three: when the welded workpiece is conveyed below the three-dimensional camera 302, the welding effect of the welded workpiece is detected by the three-dimensional camera 302, and the detection result is sent to the processor.
EXAMPLE III
As shown in fig. 6, in this embodiment, the processor is further communicatively connected with a 2D analysis module, a 3D analysis module, an alarm module, and a storage module.
The 2D analysis module is used for receiving the shot image of the two-dimensional camera 301 and monitoring and analyzing the welding position of the welded workpiece: the shot image transmitted by the two-dimensional camera 301 is marked as an analysis image, the analysis image is amplified into a pixel grid image, gray level conversion is carried out on the pixel grid image to obtain the gray level value of a pixel grid, the gray level threshold value is obtained through the storage module, and the gray level value of the pixel grid is sequentially compared with the gray level threshold value: if the gray value is smaller than the gray threshold, marking the corresponding pixel grid as a normal grid; if the gray value is greater than or equal to the gray threshold, marking the corresponding pixel grid as a marking grid; and (3) performing association analysis on the mark grids: marking a set formed by adjacent marking grids as a marking set, marking the element number of the marking set as a marking value of the marking set, acquiring a marking threshold value through a storage module, and comparing the marking value with the marking threshold value: if the marking value is smaller than the marking threshold value, marking the corresponding marking set as a common set; if the mark value is larger than or equal to the mark threshold value, marking the corresponding mark set as a selected set; marking the number of the selected sets as a selected median value, acquiring a selected threshold value through a storage module, and comparing the selected median value with the selected threshold value: if the selected value is smaller than the selected threshold value, the welding position mark of the welded workpiece is judged to be abnormal, the 2D analysis module sends a mark abnormal signal to the processor, and the processor receives the mark abnormal signal and then sends the mark abnormal signal to the alarm module and the display 504; if the selected value is equal to the selected threshold value, positioning and analyzing the welding position of the welded workpiece; if the selected value is larger than the selected threshold value, judging that stains exist on the surface of the welded workpiece, sending a surface abnormal signal to the processor by the 2D analysis module, and sending the surface abnormal signal to an alarm signal and the display 504 after the processor receives the surface abnormal signal; the alarm module carries out alarm processing after receiving the marking abnormal signal or the surface abnormal signal; the 2D analysis module can monitor and analyze the welding position of the welded workpiece, and the welding position is positioned and analyzed by combining an image shooting technology and an image processing technology, so that the surface state of the welded workpiece is monitored while positioning is carried out, an alarm is timely given when stains exist on the surface of the welded workpiece, the interference of the stains on the surface to the welding effect is avoided, and the welding effect is improved.
The specific process of positioning and analyzing the welding position of the welded workpiece comprises the following steps: the method comprises the steps of establishing a rectangular coordinate system by taking the length and the width of a shot image of a two-dimensional camera 301 as an X axis and a Y axis, setting a pre-welding position in the rectangular coordinate system, obtaining the coincidence rate of elements in a selected set and the pre-welding position and marking the coincidence rate as a coincidence value when the element running value in the selected set is at the pre-welding position, obtaining a coincidence threshold value through a storage module, judging that the welding position of a workpiece to be welded is coincident with the pre-welding position when the coincidence value is larger than or equal to the coincidence threshold value, sending a welding signal to a processor by a 2D analysis module, sending the welding signal to a controller by the processor after receiving the welding signal, controlling an air cylinder to stretch out after receiving the welding signal by the controller, and controlling a six-axis manipulator 402 and a welding machine 403 to weld the workpiece to be welded by the controller.
The 3D analysis module is used for receiving the shot image of the three-dimensional camera 302 and monitoring and analyzing the welding effect of the welded workpiece: acquiring a selected set of images shot by the three-dimensional camera 302 in the same way as the 2D analysis process, marking the selected set as a monitoring set, acquiring the number of elements of the monitoring set, marking the elements as monitoring values, acquiring monitoring threshold values through a storage module, and comparing the monitoring values with the monitoring threshold values: if the monitoring value is smaller than the monitoring threshold value, judging that the positioning accuracy of the two-dimensional camera 301 meets the requirement, and analyzing the welding effect of the welded workpiece; if the monitoring value is larger than or equal to the monitoring threshold value, the positioning accuracy of the two-dimensional camera 301 is judged not to meet the requirement, the 3D analysis module sends a positioning abnormal signal to the processor, and the processor receives the positioning abnormal signal and then sends the positioning abnormal signal to the alarm module and the display 504; the specific process for analyzing the welding effect of the welded workpiece comprises the following steps: summing the gray values of the elements in the monitoring set, averaging to obtain a monitoring performance value, acquiring a monitoring performance threshold value through a storage module, and comparing the monitoring performance value with the monitoring performance threshold value: if the monitoring performance value is smaller than the monitoring performance threshold value, the welding effect of the welded workpiece is judged not to meet the requirement, the 3D analysis module sends an effect abnormal signal to the processor, and the processor sends the effect abnormal signal to the alarm module and the display 504 after receiving the effect abnormal signal; if the monitoring performance value is larger than or equal to the monitoring performance threshold value, judging that the welding effect of the welded workpiece meets the requirement; the alarm module carries out alarm processing after receiving the positioning abnormal signal or the effect abnormal signal; the welding effect of the welded workpiece is monitored and analyzed, the welding effect is monitored through the analysis process which is the same as that of the 2D analysis module, meanwhile, the accuracy of the welding position is fed back, and the welding position is fed back timely when the accuracy of the welding position does not meet requirements, so that the welding accuracy and the welding effect are guaranteed.
When the intelligent welding and 3D camera detection equipment works, a welded workpiece is placed on a conveying rail 201 to be conveyed, a two-dimensional camera 301 is used for scanning the welding position of the welded workpiece, a controller controls an air cylinder to extend out after the welding position is scanned, and the welded workpiece is intercepted through a limiting block 204; the controller controls the six-axis manipulator 402 and the welding machine 403 to weld at the welding position of the welded workpiece, after welding is completed, the controller controls the cylinder to contract, and the welded workpiece after welding is continuously conveyed on the conveying track 201; when the welded workpiece is conveyed to the position below the three-dimensional camera 302, the welding effect of the welded workpiece is detected by the three-dimensional camera 302, and the detection result is sent to the processor.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims (8)
1. The intelligent welding and 3D camera detection equipment comprises a machine shell (1) and is characterized in that a conveying mechanism (2), a detection mechanism (3) and a welding mechanism (4) are arranged inside the machine shell (1), and a control mechanism (5) is arranged outside the machine shell (1); a partition plate (101) is fixedly installed in the middle of the machine shell (1), supporting legs (102) are fixedly installed at four corners of the bottom of the partition plate (101), and side frames (103) are fixedly installed at four corners of the top of the partition plate (101);
the conveying mechanism (2) comprises a conveying rail (201), the conveying rail (201) is fixedly installed on the top surface of the partition board (101), a clamping groove (202) is formed in the conveying rail (201), two sides of a welding area and a detection area of the conveying rail (201) are provided with buckles (203), two sides of the welding area of the conveying rail (201) are provided with limiting blocks (204), and one end, far away from each other, of each limiting block (204) is provided with an air cylinder;
the welding mechanism (4) comprises a base (401), the base (401) is fixedly installed on the top surface of the partition plate (101), a six-axis manipulator (402) is arranged on the top of the base (401), and a welding machine (403) is arranged at one end, far away from the base (401), of the six-axis manipulator (402);
the detection mechanism (3) comprises a two-dimensional camera (301) and a three-dimensional camera (302), the two-dimensional camera (301) is arranged on one side of the conveying track (201), and the three-dimensional camera (302) is arranged above the conveying track (201).
2. The intelligent welding and 3D camera detection equipment according to claim 1, wherein the control mechanism (5) comprises a bracket (501), the bracket (501) is arranged on the surface of the side frame (103), a supporting plate (502) is arranged at one end, away from the side frame (103), of the bracket (501), a host (503) and a display (504) are arranged at the top of the supporting plate (502), a processor is arranged inside the host (503), the processor is in communication connection with a controller, and the output end of the controller is electrically connected with the six-axis manipulator (402), the welder (403) and the conveying track (201); meanwhile, the side surface of the side frame (103) is also provided with a control button;
the processor is also in communication connection with a 2D analysis module, a 3D analysis module, an alarm module and a storage module.
3. The intelligent welding and 3D camera detection device according to claim 2, wherein the 2D analysis module is used for receiving the captured image of the two-dimensional camera (301) and monitoring and analyzing the welding position of the welded workpiece: the method comprises the steps of marking a shot image transmitted by a two-dimensional camera (301) as an analysis image, amplifying the analysis image into a pixel grid image, carrying out gray level conversion on the pixel grid image to obtain a gray level value of a pixel grid, obtaining a gray level threshold value through a storage module, comparing the gray level value of the pixel grid with the gray level threshold value in sequence and obtaining a selected set; marking the number of the selected sets as a selected median value, acquiring a selected threshold value through a storage module, and comparing the selected median value with the selected threshold value: if the selected value is smaller than the selected threshold value, judging that the mark of the welding position of the welded workpiece is abnormal, sending a mark abnormal signal to a processor by the 2D analysis module, and sending the mark abnormal signal to an alarm module and a display (504) after the processor receives the mark abnormal signal; if the selected value is equal to the selected threshold value, positioning and analyzing the welding position of the welded workpiece; if the selected value is larger than the selected threshold value, judging that stains exist on the surface of the welded workpiece, sending a surface abnormal signal to a processor by the 2D analysis module, and sending the surface abnormal signal to an alarm signal and a display (504) after the processor receives the surface abnormal signal; and the alarm module carries out alarm processing after receiving the marked abnormal signal or the surface abnormal signal.
4. The intelligent welding and 3D camera detection device of claim 3, wherein the specific process of comparing the gray values of the pixel grids with the gray threshold sequentially comprises: if the gray value is smaller than the gray threshold value, marking the corresponding pixel grid as a normal grid; if the gray value is greater than or equal to the gray threshold, marking the corresponding pixel grid as a marking grid; and (3) performing correlation analysis on the mark grids: marking a set formed by adjacent marking grids as a marking set, marking the element number of the marking set as a marking value of the marking set, acquiring a marking threshold value through a storage module, and comparing the marking value with the marking threshold value: if the marking value is smaller than the marking threshold value, marking the corresponding marking set as a common set; if the marking value is larger than or equal to the marking threshold value, the corresponding marking set is marked as the selected set.
5. The intelligent welding and 3D camera detection device as claimed in claim 3, wherein the specific process of performing positioning analysis on the welding position of the workpiece to be welded comprises: the method comprises the steps of establishing a rectangular coordinate system by taking the length and the width of a shot image of a two-dimensional camera (301) as an X axis and a Y axis, setting a pre-welding position in the rectangular coordinate system, obtaining the coincidence rate of elements in a selected set and the pre-welding position and marking the coincidence rate as a coincidence value when the element running value in the selected set is at the pre-welding position, obtaining a coincidence threshold value through a storage module, judging that the welding position of a workpiece to be welded is coincident with the pre-welding position when the coincidence value is larger than or equal to the coincidence threshold value, sending a welding signal to a processor by a 2D analysis module, sending the welding signal to a controller by the processor after receiving the welding signal, controlling an air cylinder to stretch out after the controller receives the welding signal, and controlling a six-axis manipulator (402) and a welder (403) to weld the workpiece to be welded by the controller.
6. The intelligent welding and 3D camera detection device as claimed in claim 3, wherein the 3D analysis module is used for receiving the shot image of the three-dimensional camera (302) and monitoring and analyzing the welding effect of the welded workpiece: acquiring a selected set of images shot by a three-dimensional camera (302) in the same way as the 2D analysis process, marking the selected set as a monitoring set, acquiring the element number of the monitoring set, marking the element number as a monitoring value, acquiring the monitoring threshold value through a storage module, and comparing the monitoring value with the monitoring threshold value: if the monitoring value is smaller than the monitoring threshold value, judging that the positioning accuracy of the two-dimensional camera (301) meets the requirement, and analyzing the welding effect of the welded workpiece; if the monitoring value is larger than or equal to the monitoring threshold value, the positioning accuracy of the two-dimensional camera (301) is judged not to meet the requirement, the 3D analysis module sends a positioning abnormal signal to the processor, and the processor receives the positioning abnormal signal and then sends the positioning abnormal signal to the alarm module and the display (504).
7. The intelligent welding and 3D camera detection equipment as claimed in claim 6, wherein the specific process of analyzing the welding effect of the welded workpiece comprises: summing the gray values of the elements in the monitoring set, averaging to obtain a monitoring performance value, acquiring a monitoring performance threshold value through a storage module, and comparing the monitoring performance value with the monitoring performance threshold value: if the monitoring performance value is smaller than the monitoring performance threshold value, the welding effect of the welded workpiece is judged not to meet the requirement, the 3D analysis module sends an effect abnormal signal to the processor, and the processor sends the effect abnormal signal to the alarm module and the display (504) after receiving the effect abnormal signal; if the monitoring performance value is larger than or equal to the monitoring performance threshold value, judging that the welding effect of the welded workpiece meets the requirement;
and the alarm module carries out alarm processing after receiving the positioning abnormal signal or the effect abnormal signal.
8. The intelligent welding and 3D camera inspection device of any one of claims 1-7, wherein the method of operating the intelligent welding and 3D camera inspection device comprises the steps of:
the method comprises the following steps: the method comprises the following steps that a welded workpiece is placed on a conveying rail (201) to be conveyed, the welding position of the welded workpiece is scanned through a two-dimensional camera (301), after the welding position is scanned, a controller controls an air cylinder to extend out, and the welded workpiece is intercepted through a limiting block (204);
step two: the controller controls the six-axis manipulator (402) and the welding machine (403) to weld at the welding position of the welded workpiece, after welding is completed, the controller controls the cylinder to contract, and the welded workpiece after welding is continuously conveyed on the conveying track (201);
step three: when the welded workpiece is conveyed to the position below the three-dimensional camera (302), the welding effect of the welded workpiece is detected through the three-dimensional camera (302), and the detection result is sent to the processor.
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