CN115415704B - Intelligent welding and 3D camera detection equipment - Google Patents
Intelligent welding and 3D camera detection equipment Download PDFInfo
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- CN115415704B CN115415704B CN202211162540.0A CN202211162540A CN115415704B CN 115415704 B CN115415704 B CN 115415704B CN 202211162540 A CN202211162540 A CN 202211162540A CN 115415704 B CN115415704 B CN 115415704B
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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
- B23K37/0252—Steering means
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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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- 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
- G01N21/94—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 application belongs to the field of welding equipment, relates to a data analysis technology, and is used for solving the problem that the existing welding machine needs manual visual inspection and recognition of welding effect after welding 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; the middle part of the shell is fixedly provided with a baffle, four corners of the bottom of the baffle are fixedly provided with supporting legs, and four corners of the top of the baffle are fixedly provided with side frames; according to the application, the welded workpiece is automatically transmitted through the conveying mechanism, the welding position of the welded workpiece is positioned by the two-dimensional camera, the welding position is automatically welded by the six-axis manipulator and the welding machine, the actions of the six-axis manipulator can be sequentially controlled, and the joint angle or track of the axis can be controlled by a program or a sensor without mechanical adjustment.
Description
Technical Field
The application 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 machine has various kinds, including single-point single-function, single-point double-function, single-point multifunctional (the welding machine has only one welding head, and can be used for welding any angle between 90 degrees and 180 degrees after the form of the positioning plate is changed), and also two-point, three-point, four-point, even six-point welding machines, four-angle welding machines and the like. The welding function and the work efficiency of the welding machines of different kinds are also different.
The existing PCBA welding is basically desktop type, a welding module with a simpler 3-axis operation and a gantry type frame are combined, 360-degree rotary welding cannot be met, and the welding effect is mostly manually detected and identified after the welding is finished.
The application provides a solution to the technical problem.
Disclosure of Invention
The application aims to provide intelligent welding and 3D camera detection equipment which is used for solving the problem that the existing welding machine needs to manually perform visual inspection and identify welding effects after welding;
the technical problems to be solved by the application are as follows: how to provide an intelligent welding and 3D camera check out test set that can carry out automatic supervision to welding effect.
The aim of the application can be achieved by the following technical scheme:
the intelligent welding and 3D camera detection device comprises a shell, wherein a conveying mechanism, a detection mechanism and a welding mechanism are arranged inside the shell, and a control mechanism is arranged outside the shell; the middle part of the shell is fixedly provided with a baffle, four corners of the bottom of the baffle are fixedly provided with supporting legs, and four corners of the top of the baffle are fixedly provided with side frames;
the conveying mechanism comprises a conveying rail, the conveying rail is fixedly arranged on the top surface of the partition board, clamping grooves are formed in the conveying rail, buckles are arranged on two sides of a welding area and a detection area of the conveying rail, limiting blocks are arranged on 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;
the welding mechanism comprises a base, the base is fixedly arranged on the top surface of the partition board, a six-axis manipulator is arranged at 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 implementation mode of the application, the bracket is arranged on the surface of the side frame, a supporting plate is arranged at one end of the bracket far away from the side frame, a host and a display are arranged at the top of the supporting plate, a processor is arranged in the host, the processor is in communication connection with a controller, and the output end of the controller is electrically connected with the six-axis mechanical arm, 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 application, the 2D analysis module is configured to receive a captured image of a two-dimensional camera and monitor and analyze a welding position of a workpiece to be welded: marking a shooting image transmitted by a two-dimensional camera 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, acquiring a gray level threshold value through a storage module, and comparing the gray level value of the pixel grid with the gray level 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 median value is smaller than the selected threshold value, judging that the welding position of the welded workpiece is marked abnormally, sending a marked abnormal signal to a processor by the 2D analysis module, and sending the marked abnormal signal to the alarm module and the display after the processor receives the marked 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, determining that stains exist on the surface of the welded workpiece, sending a surface abnormality signal to a processor by the 2D analysis module, and sending the surface abnormality signal to an alarm signal and a display after the processor receives the surface abnormality signal; and the alarm module receives the marked abnormal signal or the surface abnormal signal and then carries out alarm processing.
As a preferred embodiment of the present application, the specific process of comparing the gray value of the pixel grid with the gray threshold value sequentially includes: 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 value, marking the corresponding pixel grid as a marking grid; 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 the 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 marking value is greater than or equal to the marking threshold value, marking the corresponding marking set as a selected set.
As a preferred embodiment of the present application, the specific process of performing positioning analysis on the welding position of the workpiece to be welded includes: 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, acquiring the coincidence rate of elements in a selected set and the pre-welding position when the elements in the selected set operate the pre-welding position, marking the coincidence rate as a coincidence value, acquiring a coincidence threshold value through a storage module, judging that the welding position of a welded workpiece coincides with the pre-welding position when the coincidence value is greater 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 after the processor receives the welding signal, controlling a cylinder to extend after the controller receives the welding signal, and simultaneously controlling a six-axis manipulator and a welding machine to weld the welded workpiece by the controller.
As a preferred embodiment of the present application, the 3D analysis module is configured to receive a captured image of a three-dimensional camera and monitor and analyze a welding effect of a workpiece to be welded: the method comprises the steps of obtaining a selected set of images shot by a three-dimensional camera in the same mode as a 2D analysis process, marking the selected set as a monitoring set, obtaining the element number of the monitoring set, marking the element number as a monitoring value, obtaining a 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 meets the requirement, and analyzing the welding effect of the welded workpiece; if the monitoring value is greater than or equal to the monitoring threshold value, the two-dimensional camera positioning accuracy is judged to be not met, the 3D analysis module sends a positioning abnormal signal to the processor, and the processor sends the positioning abnormal signal to the alarm module and the display after receiving the positioning abnormal signal.
As a preferred embodiment of the present application, the specific process of analyzing the welding effect of the welded workpiece includes: summing the gray values of the elements in the monitoring set, averaging to obtain a monitoring representation value, acquiring a monitoring representation threshold value through a storage module, and comparing the monitoring representation value with the monitoring representation threshold value: if the monitoring representation value is smaller than the monitoring representation threshold value, judging that the welding effect of the welded workpiece does not meet the requirement, sending an effect abnormal signal to a processor by the 3D analysis module, and sending the effect abnormal signal to the alarm module and the display after the processor receives the effect abnormal signal; if the monitoring representation value is larger than or equal to the monitoring representation threshold value, judging that the welding effect of the welded workpiece meets the requirement;
and the alarm module receives the positioning abnormal signal or the effect abnormal signal and then carries out alarm processing.
As a preferred embodiment of the present application, the working method of the intelligent welding and 3D camera detection device includes the following steps:
step one: the method comprises the steps that a welded workpiece is placed on a conveying track to be conveyed, a two-dimensional camera is used for scanning the welding position of the welded workpiece, after the welding position is scanned, a controller controls an air cylinder to extend out, and the welded workpiece is intercepted by 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, and after the welding is finished, the controller controls the cylinder to shrink, and the welded workpiece after the welding is finished is continuously conveyed on the conveying track;
step three: when the welded workpiece is conveyed to the lower part of 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 application has the following beneficial effects:
1. the welding position of the welded workpiece is automatically transmitted through the conveying mechanism, the welding position of the welded workpiece is positioned through the two-dimensional camera, the welding position is automatically welded through the six-axis mechanical arm and the welding machine, the actions of the six-axis mechanical arm can be controlled sequentially, the joint angle or track of the shaft can be controlled by a program or a sensor without depending on mechanical adjustment, and therefore the degree of automation of welding equipment is improved, and the working pressure of workers is reduced;
2. the 2D analysis module can monitor and analyze the welding position of the welded workpiece, and combines the image shooting technology and the image processing technology to perform positioning analysis on the welding position, monitor the surface state of the welded workpiece while positioning, and timely alarm when stains exist on the surface of the welded workpiece, so that the interference of the surface stains on 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 same as that of the 2D analysis module, meanwhile, the accuracy of the welding position is fed back, and when the accuracy of the welding position does not meet the requirement, the welding accuracy and the welding effect are timely fed back, so that the welding accuracy and the welding effect are guaranteed.
Drawings
In order to more clearly illustrate the embodiments of the application or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the application, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a front view of a structure according to a first embodiment of the present application;
FIG. 2 is a left side view of a first embodiment of the present application;
FIG. 3 is a side view of a structure according to a first embodiment of the present application;
FIG. 4 is an enlarged schematic view of the structure A in FIG. 3 according to the present application;
FIG. 5 is a flow chart of a method according to a second embodiment of the present application;
fig. 6 is a system block diagram of a third embodiment of the present application.
1. A housing; 101. a partition plate; 102. a support leg; 103. a side frame; 2. a conveying mechanism; 201. a conveying rail; 202. a clamping groove; 203. a buckle; 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. welding machine; 5. a control mechanism; 501. a bracket; 502. a supporting plate; 503. a host; 504. a display.
Detailed Description
The technical solutions of the present application will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present application, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Example 1
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; the middle part of the shell 1 is fixedly provided with a baffle plate 101, four corners of the bottom of the baffle plate 101 are fixedly provided with supporting legs 102, and four corners of the top of the baffle plate 101 are fixedly provided with side frames 103.
The external frame of the shell 1 is assembled by a 1.2MM thick sheet metal structure, the color of the equipment frame is formed by taking international Lorenter color as a primary color, the paint is selected to be a mark conforming to an ESD standard (the impedance value after solidification is less than or equal to 10 x 6), the product flow is from left to right, an electric control module of a welder 403 module is embedded at the middle position near the left side of the equipment, a welder is arranged at the top of a six-axis manipulator 402, a middle power supply and a signal wire are embedded in the manipulator, a linkage switch of equipment hardware is arranged at the lower right side of the equipment, and an emergency stop switch is arranged at the upper 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 a workpiece to be welded sequentially passes through the feeding area, the welding area and the detection area for welding and detection; the conveying track 201 is fixedly installed on the top surface of the partition plate 101, clamping grooves 202 are formed in the conveying track 201, buckles 203 are arranged on two sides of a welding area and a detection area of the conveying track 201, limiting blocks 204 are arranged on two sides of the welding area of the conveying track 201, an air cylinder is arranged at one end, away from the two limiting blocks 204, of each conveying track, the workpieces to be welded are automatically conveyed through the conveying mechanism 2, and a two-dimensional camera 301 is used for positioning the welding positions of the workpieces to be welded.
The welding mechanism 4 comprises a base 401, the base 401 is fixedly arranged 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 of the six-axis manipulator 402 far away from the base 401, the six-axis manipulator 402 and the welding machine 403 automatically weld welding positions, the actions of the six-axis manipulator 402 can be controlled sequentially, the joint angles or tracks of the axes can be controlled by a program or a sensor without depending on mechanical adjustment, and further the automation degree of welding equipment is improved, and the working pressure of workers is reduced; the six-axis manipulator 402 has the greatest characteristic of flexible starting, an important component in a flexible manufacturing system, and the industrial robot can be reprogrammed along with the change of the working environment and the change of a workpiece, so that the six-axis manipulator is suitable for small-batch and multi-variety flexible manufacturing production lines with balanced and high efficiency.
The detection mechanism 3 comprises a two-dimensional camera 301 and a three-dimensional camera 302, wherein 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 high-speed high-precision scanning measurement equipment, the most advanced structured light non-contact photographic measurement principle is applied to the world at present, and a composite non-contact measurement technology combining a structured light technology, a phase measurement technology and a computer vision technology is adopted, so that the detection mechanism is a necessary tool for product development and quality detection.
The control mechanism 5 comprises a bracket 501, wherein the bracket 501 is arranged on the surface of the side frame 103, a supporting plate 502 is arranged at one end of the bracket 501 far away from the side frame 103, a host 503 and a display 504 are arranged at the top of the supporting plate 502, a processor is arranged in 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; while the side of the side frame 103 is also provided with control buttons.
Example two
As shown in fig. 5, a working method of the intelligent welding and 3D camera detection device includes the following steps:
step one: the welded workpiece is placed on a conveying track 201 to be conveyed, the welding position of the welded workpiece is scanned by 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 by 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, and after the welding is finished, the controller controls the cylinder to shrink, 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 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.
Example III
As shown in fig. 6, in the present embodiment, the processor is further communicatively connected to a 2D analysis module, a 3D analysis module, an alarm module, and a storage module.
The 2D analysis module is configured to receive the photographed image of the two-dimensional camera 301 and monitor and analyze a welding position of the workpiece to be welded: the photographed image transmitted by the two-dimensional camera 301 is marked as an analysis image, the analysis image is amplified into a pixel grid image, the pixel grid image is subjected to gray level conversion to obtain a gray level value of the pixel grid, a 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 value, marking the corresponding pixel grid as a normal grid; if the gray value is greater than or equal to the gray threshold value, marking the corresponding pixel grid as a marking grid; 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 the 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 greater than or equal to the marking threshold value, marking the corresponding marking 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 median value is smaller than the selected threshold value, judging that the welding position of the welded workpiece is marked abnormally, sending a marked abnormal signal to a processor by the 2D analysis module, and sending the marked abnormal signal to the alarm module and the display 504 after the processor receives the marked 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 greater than the selected threshold, determining that stains exist on the surface of the welded workpiece, sending a surface abnormality signal to a processor by the 2D analysis module, and sending the surface abnormality signal to an alarm signal and a display 504 after the processor receives the surface abnormality signal; the alarm module receives the marked abnormal signal or the surface abnormal signal and then carries out alarm processing; the 2D analysis module can monitor and analyze the welding position of the welded workpiece, combines the image shooting technology and the image processing technology to perform positioning analysis on the welding position, monitors the surface state of the welded workpiece while positioning, gives an alarm in time when stains exist on the surface of the welded workpiece, avoids interference of the surface stains on the welding effect, and improves the welding effect.
The specific process for carrying out positioning analysis on the welding position of the welded workpiece comprises the following steps: the length and width of the shot image of the two-dimensional camera 301 are used as the X axis and the Y axis to establish a rectangular coordinate system, a pre-welding position is set in the rectangular coordinate system, when the element operation value in the selected set is the pre-welding position, the coincidence rate of the element in the selected set and the pre-welding position is obtained and marked as the coincidence value, the coincidence threshold value is obtained through the storage module, when the coincidence value is larger than or equal to the coincidence threshold value, the welding position of the welded workpiece is judged to coincide with the pre-welding position, the 2D analysis module sends a welding signal to the processor, the processor sends the welding signal to the controller after receiving the welding signal, the controller controls the cylinder to stretch out after receiving the welding signal, and meanwhile, the controller controls the six-axis manipulator 402 and the welding machine 403 to weld the welded workpiece.
The 3D analysis module is configured to receive a captured image of the three-dimensional camera 302 and monitor and analyze a welding effect of the welded workpiece: the selected set of the images captured by the three-dimensional camera 302 is acquired in the same manner as the 2D analysis process and marked as a monitoring set, the element number of the monitoring set is acquired and marked as a monitoring value, the monitoring threshold is acquired through the storage module, and the monitoring value is compared with the monitoring threshold: 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 greater than or equal to the monitoring threshold, determining that the positioning accuracy of the two-dimensional camera 301 does not meet the requirement, sending a positioning abnormal signal to a processor by the 3D analysis module, and sending the positioning abnormal signal to the alarm module and the display 504 after the processor receives the positioning abnormal signal; 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 representation value, acquiring a monitoring representation threshold value through a storage module, and comparing the monitoring representation value with the monitoring representation threshold value: if the monitoring representation value is smaller than the monitoring representation threshold value, judging that the welding effect of the welded workpiece does not meet the requirement, sending an effect abnormal signal to a processor by the 3D analysis module, and sending the effect abnormal signal to the alarm module and the display 504 after the processor receives the effect abnormal signal; if the monitoring representation value is larger than or equal to the monitoring representation threshold value, judging that the welding effect of the welded workpiece meets the requirement; the alarm module receives the positioning abnormal signal or the effect abnormal signal and then carries out alarm processing; the welding effect of the welded workpiece is monitored and analyzed, the welding effect is monitored through the same analysis process as the 2D analysis module, meanwhile, the accuracy of the welding position is fed back, and when the accuracy of the welding position does not meet the requirement, the welding position is fed back timely, so that the welding accuracy and the welding effect are guaranteed.
When the intelligent welding and 3D camera detection device works, a workpiece to be welded is placed on the conveying track 201 to be conveyed, the welding position of the workpiece to be welded is scanned through the two-dimensional camera 301, after the welding position is scanned, the controller controls the air cylinder to extend out, and the workpiece to be welded is intercepted through the 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, and after the welding is finished, the controller controls the cylinder to shrink, and the welded workpiece after the welding is finished 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 through the three-dimensional camera 302, and the detection result is sent to the processor.
The foregoing is merely illustrative of the structures of this application and various modifications, additions and substitutions for those skilled in the art can be made to the described embodiments without departing from the scope of the application or from the scope of the application as defined in the accompanying claims.
In the description of the present specification, the descriptions of the terms "one embodiment," "example," "specific example," and the like, 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 present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. 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 application disclosed above are intended only to assist in the explanation of the application. The preferred embodiments are not intended to be exhaustive or to limit the application to the precise form 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 application and the practical application, to thereby enable others skilled in the art to best understand and utilize the application. The application is limited only by the claims and the full scope and equivalents thereof.
Claims (5)
1. The intelligent welding and 3D camera detection device 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); the middle part of the shell (1) is fixedly provided with a partition board (101), four corners of the bottom of the partition board (101) are fixedly provided with supporting legs (102), and four corners of the top of the partition board (101) are fixedly provided with side frames (103);
the conveying mechanism (2) comprises a conveying track (201), the conveying track (201) is fixedly arranged on the top surface of the partition board (101), clamping grooves (202) are formed in the conveying track (201), buckles (203) are arranged on two sides of a welding area and a detection area of the conveying track (201), limiting blocks (204) are arranged on two sides of the welding area of the conveying track (201), and air cylinders are arranged at one ends, far away from the limiting blocks (204), of the conveying track;
the welding mechanism (4) comprises a base (401), the base (401) is fixedly arranged on the top surface of the partition board (101), a six-axis manipulator (402) is arranged at 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), wherein 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);
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, far 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 in 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 also provided with a control button;
the processor is also connected with a 2D analysis module, a 3D analysis module, an alarm module and a storage module in a communication way;
the 2D analysis module is used for receiving the photographed image of the two-dimensional camera (301) and monitoring and analyzing the welding position of the welded workpiece: marking a shooting 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, acquiring a gray level threshold value through a storage module, and comparing the gray level value of the pixel grid with the gray level 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 welding position of the welded workpiece is marked abnormally, sending a marked abnormal signal to a processor by the 2D analysis module, and sending the marked abnormal signal to the alarm module and the display (504) after the processor receives the marked 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, determining that stains exist on the surface of the welded workpiece, sending a surface abnormality signal to a processor by the 2D analysis module, and sending the surface abnormality signal to an alarm signal and a display (504) after the processor receives the surface abnormality signal; the alarm module receives the marked abnormal signal or the surface abnormal signal and then carries out alarm processing;
the specific process of comparing the gray value of the pixel grid with the gray threshold value sequentially comprises the following steps: 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 value, marking the corresponding pixel grid as a marking grid; 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 the 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 marking value is greater than or equal to the marking threshold value, marking the corresponding marking set as a selected set.
2. The intelligent welding and 3D camera inspection apparatus of claim 1, wherein the specific process of performing a positional analysis of 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, acquiring 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 elements in the selected set are operated to the pre-welding position, acquiring a coincidence threshold value through a storage module, judging that the welding position of a welded workpiece is coincident with the pre-welding position when the coincidence value is greater 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 after the processor receives the welding signal, controlling a cylinder to stretch out after the controller receives the welding signal, and simultaneously controlling a six-axis manipulator (402) and a welding machine (403) to weld the welded workpiece.
3. The intelligent welding and 3D camera inspection device according to claim 1, wherein the 3D analysis module is configured to receive a captured image of a three-dimensional camera (302) and monitor and analyze a welding effect of a workpiece to be welded: the method comprises the steps of obtaining a selected set of images shot by a three-dimensional camera (302) in the same mode of a 2D analysis process, marking the selected set as a monitoring set, obtaining the element number of the monitoring set, marking the element number as a monitoring value, obtaining a 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 three-dimensional camera (302) meets the requirement, and analyzing the welding effect of the welded workpiece; if the monitoring value is greater than or equal to the monitoring threshold value, the positioning accuracy of the three-dimensional camera (302) is judged to be not met, the 3D analysis module sends a positioning abnormal signal to the processor, and the processor sends the positioning abnormal signal to the alarm module and the display (504) after receiving the positioning abnormal signal.
4. The intelligent welding and 3D camera inspection apparatus of claim 3, wherein the specific process of analyzing the welding effect of the workpiece to be welded comprises: summing the gray values of the elements in the monitoring set, averaging to obtain a monitoring representation value, acquiring a monitoring representation threshold value through a storage module, and comparing the monitoring representation value with the monitoring representation threshold value: if the monitoring representation value is smaller than the monitoring representation threshold value, judging that the welding effect of the welded workpiece does not meet the requirement, sending an effect abnormal signal to a processor by the 3D analysis module, and sending the effect abnormal signal to the alarm module and the display (504) after the processor receives the effect abnormal signal; if the monitoring representation value is larger than or equal to the monitoring representation threshold value, judging that the welding effect of the welded workpiece meets the requirement;
and the alarm module receives the positioning abnormal signal or the effect abnormal signal and then carries out alarm processing.
5. The intelligent welding and 3D camera inspection apparatus according to any one of claims 1-4, wherein the method of operation of the intelligent welding and 3D camera inspection apparatus comprises the steps of:
step one: the method comprises the steps that a welded workpiece is placed on a conveying track (201) to be conveyed, a two-dimensional camera (301) is used for scanning the welding position of the welded workpiece, after the welding position is scanned, a controller controls an air cylinder to extend out, and the welded workpiece is intercepted by 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, and after the welding is finished, the controller controls the air cylinder to shrink, 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 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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