CN116408575B - Method, device and system for locally scanning and eliminating workpiece reflection interference - Google Patents
Method, device and system for locally scanning and eliminating workpiece reflection interference Download PDFInfo
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- 230000008030 elimination Effects 0.000 claims abstract description 20
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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
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1602—Programme controls characterised by the control system, structure, architecture
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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
- B25J9/1602—Programme controls characterised by the control system, structure, architecture
- B25J9/1605—Simulation of manipulator lay-out, design, modelling of manipulator
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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
- B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
- B25J9/1697—Vision controlled systems
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T17/00—Three dimensional [3D] modelling, e.g. data description of 3D objects
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Abstract
When the target area is locally scanned, the laser is controlled to project at least two coded line lasers to the target area in a time-sharing way, and light rays generated when the at least two coded line lasers are projected to the target area are mutually different. According to the embodiment of the disclosure, different codes can be generated according to the surface shape of the workpiece, corresponding partial images are shot when line lasers with different codes are projected, and the partial images with different reflection characteristics are processed by adopting a corresponding reflection elimination algorithm, so that a better interference elimination effect is achieved.
Description
Technical Field
The present disclosure relates to, but is not limited to, computer vision technology, and more particularly to a method, apparatus, and automated welding system for locally scanning, eliminating workpiece reflection interference.
Background
Welding technology is one of the very important technological means in industrial production, and has wide application in various fields. With the rapid development of computer technology, artificial intelligence and other scientific technologies, the requirements of automation and intellectualization levels of the welding technology in the industrial field are continuously improved, and the use of an automatic welding processing system taking a welding robot as a main body is increasing.
At present, the vision-guided robot automatic welding technology adopts laser as an external auxiliary light source to obtain laser stripes for representing a welding line structure, and the laser stripes are generally divided into two modes of scanning before welding and scanning while welding, wherein the two modes need to scan workpieces to be welded by using a mechanical arm with a laser. However, in the process of carrying out local high-precision scanning on the welding seam, when line laser is projected onto a workpiece, if the shape of the workpiece is complex or the surface of the workpiece is smooth, reflection is generated to form lines and light spots, and when reflected light is in the visual field range of a laser line scanning camera, the local high-precision scanning is interfered, so that imaging is unclear, and the requirement on accurate positioning of the welding seam cannot be met.
Disclosure of Invention
The following is a summary of the subject matter described in detail herein. This summary is not intended to limit the scope of the claims.
An embodiment of the present disclosure provides a local scanning method, including:
determining a target area to be scanned of the workpiece based on the three-dimensional model of the workpiece;
When the target area is locally scanned, the laser is controlled to project at least two coded line lasers to the target area in a time-sharing mode, and light rays generated when the at least two coded line lasers are projected to the target area are different from each other.
An embodiment of the present disclosure further provides a local scanning apparatus, including a memory and a processor, where the memory stores a computer program, and the processor can implement the local scanning method according to any embodiment of the present disclosure when executing the computer program.
According to the local scanning method and the local scanning device, different code line lasers are projected to the target area in a time-sharing mode, different light rays are generated in the target area, and reflected light interference caused by more light projected at one time can be reduced. And simultaneously, the position to be scanned can be covered comprehensively through time-sharing projection.
An embodiment of the present disclosure further provides a method for eliminating workpiece reflection interference, including:
Acquiring a three-dimensional model of a workpiece;
According to the local scanning method of any embodiment of the disclosure, controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, and controlling a first camera to shoot the target area when each coded line laser is projected by the laser, so as to obtain a plurality of local images;
And processing the plurality of partial images through a reflection elimination algorithm, and synthesizing the processed plurality of partial images with the three-dimensional model to obtain the enhanced three-dimensional model of the workpiece.
An embodiment of the present disclosure further provides an apparatus for removing workpiece reflection interference, including a memory and a processor, where the memory stores a computer program, and the processor can implement a method for removing workpiece reflection interference according to any embodiment of the present disclosure when executing the computer program.
According to the method and the device for eliminating the workpiece reflection interference, different coded line lasers are transmitted to the target area in a time-sharing mode and shot respectively, different light rays are generated in the target area, and the reflection light interference caused by projecting more light rays at one time can be reduced. And simultaneously, the target area is shot through time-sharing projection and each projection, the position to be scanned can be covered on the whole surface, and the obtained multiple parts can be overlapped to obtain a clear image of the target area.
An embodiment of the present disclosure also provides an automatic welding system, including:
A robot with a mechanical arm;
The first camera and the laser are arranged on the mechanical arm, and the mechanical arm is arranged to drive the first camera and the laser to move so as to perform local scanning;
The image processing and controlling device is electrically connected with the robot, the first camera and the laser and is configured to execute the local scanning method according to any embodiment of the disclosure, wherein the target area is a weld area on the workpiece.
The automatic welding system of the embodiment of the disclosure uses the scanning method of the embodiment of the disclosure to locally scan the welding seam area, so that the reflection interference generated in the scanning process can be eliminated, and a high-precision local image of the welding seam area can be obtained.
The embodiment of the disclosure has good effect on eliminating the reflection interference of the tool with complex shape and strong reflection material in the welding scanning process.
Other aspects will become apparent upon reading and understanding the accompanying drawings and detailed description.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate and do not limit the invention.
FIG. 1 is a schematic illustration of an automated welding system according to an embodiment of the present disclosure;
FIG. 2 is a schematic illustration of an end effector and workpiece weld area according to an embodiment of the present disclosure;
FIG. 3 is a flow chart of a partial scan method according to an embodiment of the present disclosure;
FIG. 4 is a schematic diagram of segments corresponding to multiple sets of codes according to an embodiment of the present disclosure;
FIG. 5 is a schematic diagram of multiple sets of codes generated from curves in accordance with an embodiment of the present disclosure;
FIG. 6 is a flow chart of a method of eliminating workpiece light reflection interference in accordance with an embodiment of the present disclosure;
FIG. 7 is a schematic diagram of a laser and first camera co-scanning in accordance with an embodiment of the present disclosure;
FIG. 8A is a schematic view of the relationship between incident light and reflected light during a partial scan, and FIG. 8B is a schematic view of the relationship between incident light and reflected light after adjusting the incident angle;
Fig. 9 is a schematic diagram of a local scanning apparatus according to an embodiment of the present disclosure.
Detailed Description
The present disclosure describes a number of embodiments, but the description is illustrative and not limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the embodiments described in the present disclosure.
In the description of the present disclosure, words such as "exemplary" or "such as" are used to mean serving as an example, instance, or illustration. Any embodiment described as "exemplary" or "e.g." in this disclosure should not be taken as preferred or advantageous over other embodiments. "and/or" herein is a description of an association relationship of an associated object, meaning that there may be three relationships, e.g., a and/or B, which may represent: a exists alone, A and B exist together, and B exists alone. "plurality" means two or more than two. In addition, in order to facilitate the clear description of the technical solutions of the embodiments of the present disclosure, the words "first", "second", etc. are used to distinguish the same item or similar items having substantially the same function and effect. It will be appreciated by those of skill in the art that the words "first," "second," and the like do not limit the number and order of execution, and that the words "first," "second," and the like do not necessarily differ.
In describing representative exemplary embodiments, the specification may have presented the method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As will be appreciated by those of ordinary skill in the art, other sequences of steps are possible. Accordingly, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. Furthermore, the claims directed to the method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the embodiments of the present disclosure.
Fig. 1 shows an automatic welding system based on visual measurement, to which the embodiments of the present disclosure may be applied, as shown in the drawing, the system includes two parts, a first part being a detection and execution device 1 and the other part being an image processing and control device 2, wherein the detection and execution device 1 includes a robot 11 as an execution mechanism, the robot having a mechanical arm, and an end of the mechanical arm is provided with an end execution mechanism 12 for realizing local scanning of a weld joint area and executing welding. Also shown is a workpiece 14 to be welded, which is merely illustrative and may be encountered in more complex work pieces in practice. In order to obtain a three-dimensional model of the workpiece 14, a 3D camera 13 is provided above the workpiece 14, and the workpiece 14 may be globally scanned to generate a three-dimensional model of the workpiece 14. The image processing and controlling device 2 includes a host computer 21, and can receive the data and the image uploaded by the detecting and executing device 1, process the data and the image correspondingly, send the processing result to the control module 22, and the control module 22 makes a decision based on the processing structure of the data and the image, generates a control instruction and sends the control instruction to the robot 11 for executing, thereby realizing automatic welding. The 3D camera 13 may use various 3D cameras, may be installed outside the mechanical arm to perform global scanning on the workpiece 14 to be welded, and establish a three-dimensional model of coarse positioning of the actual workpiece according to the global scanning result, so as to obtain shape information of the workpiece. And simultaneously, various RGB cameras can be used for collecting photometric stereo images of the workpiece 14 to be welded, so as to obtain the surface materials and textures of the workpiece. Combining the shape and surface texture results in a complete three-dimensional model of the workpiece 14.
As shown in fig. 2, the end effector 12 includes a welding gun 31 provided on a robot arm, a first camera 34 provided integrally, and a laser 33. The laser 33 may be a encodable line laser, the first camera 34 may be a 2D camera such as an RGB camera, and the first camera 34 and the laser 33 are mounted at the end of a robotic arm for localized high precision scanning of the workpiece weld area. In this figure, a simple workpiece is used in place of the relatively complex workpiece 14 of fig. 1 for ease of viewing. The workpiece includes two steel plates and a weld region 32 of the central member. When the workpiece is locally scanned, the mechanical arm drives the laser 33 and the first camera 34 to move along a local scanning track, the laser 33 projects ray laser to the welding line area 32, and a complete laser line is formed in the welding line area 32 and moves along with the movement of the laser so as to cover the whole welding line area 32. At the same time, the first camera 34 continuously photographs the weld region 32, thereby obtaining a partial image of the weld region 32. The local image can be synthesized with the three-dimensional model of the workpiece to obtain an enhanced three-dimensional model with clearer and more accurate local characteristics of the workpiece, and the enhanced three-dimensional model is used for guiding the robot to finish subsequent high-precision welding. By performing the weld extraction in the generated complete three-dimensional model, the local scan trajectory may be generated from the extracted weld.
In the process of the line laser vision guiding welding, if the shape of a workpiece is complex or the surface is smooth, reflection interference can occur during local scanning, the quality of a local image shot by a camera is seriously influenced, and the subsequent welding precision can be influenced.
Aiming at the problem of poor adaptability of the traditional vision-guided welding method to workpieces with complex shapes or smooth surfaces, the embodiment of the disclosure provides a local scanning method, as shown in fig. 3, which comprises the following steps:
step 110, determining a target area to be scanned of a workpiece based on a three-dimensional model of the workpiece;
And 120, when the target area is locally scanned, controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, wherein light rays generated when the at least two coded line lasers are projected to the target area are different from each other.
The embodiment of the disclosure takes local scanning in the welding process as an example, and the target area to be scanned of the workpiece is a welding line area. It will be readily appreciated that the local scanning methods of the embodiments of the present disclosure may also be applicable to scanning other target areas of a workpiece surface. The principle for eliminating reflected light is the same whether scanning the weld area or other areas. The other region may be any region on the workpiece, for example, in order to obtain a clearer local image of the workpiece, or further refine a three-dimensional model of the workpiece according to the local image, or may perform local scanning on any region on the surface of the workpiece.
The workpiece of the embodiment of the disclosure can be a workpiece on a factory production line, but is not limited to the workpiece, and can also be various articles produced in a non-production line.
According to the local scanning method and the local scanning device, different code line lasers are projected to the target area in a time-sharing mode, different light rays are generated in the target area, and reflected light interference caused by more light projected at one time can be reduced. And simultaneously, the position to be scanned can be covered comprehensively through time-sharing projection.
In an exemplary embodiment of the disclosure, the at least two codes are generated according to a surface shape of the workpiece, each code of the at least two codes corresponds to at least one line segment, the at least two codes include at least one group of codes, and all line segments corresponding to the same group of codes can be combined into one complete laser line;
wherein, at least one line segment corresponding to one code refers to at least one line segment of a light line generated when the coded line laser is projected to the target area.
In one example of this embodiment, at least one set of codes includes a first code and a second code that are complementary to each other, and at least one line segment corresponding to the first code and at least one line segment corresponding to the second code can be combined into the complete laser line.
Fig. 4 shows 2 sets of codes, one set being labeled code 1 and the complement of code 1, and the other set being labeled code 2 and the complement of code 2. The complements of coding scheme 1 and coding scheme 1, and the complements of coding scheme 2 and coding scheme 2 are complements of each other. And thus may also be referred to as a first code and a second code in a set of codes. While a complete laser line is shown in fig. 4, in this disclosure, the complete laser line may also be considered as a laser line corresponding to a particular code, where only one code in a set of codes. The laser line projected according to the code is formed as the one complete laser line, which means that the laser line formed in the target area by the line laser projected by the laser without the code function is not segmented and is not shortened. The complete laser line may also be understood as a union of all code-corresponding line segments in a group comprising a plurality of codes, i.e. the line segments corresponding to the same group of a plurality of codes may be combined into the complete laser line.
The at least one line segment corresponding to the one code not only represents the number of line segments, but also defines the positions of the line segments. The codes corresponding to the same number of line segments but different positions are different codes.
In the other two sets of codes, the code pattern 1 in the first set of codes corresponds to two line segments spaced apart from each other, and the two line segments are in the shape of a light line generated when the coded line laser is projected onto a target area, and are located at two sides with respect to the complete laser line. The complement of coding scheme 1 corresponds to a line segment that is located at an intermediate position relative to the full laser line, corresponding to the gap position between the two line segments of coding scheme 1. The positions of the two ends of the line segment corresponding to the complement of the coding scheme 1 correspond to the positions of the two ends of the line segment opposite to the two line segments of the coding scheme 1, and may be just connected. However, this is not required, and a small amount of overlap or gap between adjacent segments is also possible after merging, and the length of the overlap or gap may be set according to the needs of the production, and the disclosure is not limited thereto.
Similarly, coding scheme 2 in the second coding includes three spaced line segments, while the complement of coding scheme 2 includes two spaced line segments. The positions of the two line segments correspond to the positions of two gaps between the three line segments of the encoding mode 2, and a small amount of overlapping parts exist. Combining the complementary codes of the coding mode 2 and the coding mode 2 into a line according to the position, so as to obtain the 'complete laser line'.
Since the light lines generated when at least two types of coded line lasers are projected onto the target area are different from each other, there are codes which do not correspond to the complete laser lines, and the coded line lasers project less light, so that the generated reflection interference is less.
The term "eliminating the reflection interference" as used herein does not mean that the reflection interference is completely removed, but that a portion of the reflection interference is removed, i.e., the reflection interference is reduced.
In order to obtain a code line laser that is adapted to the shape of the workpiece surface, in an exemplary embodiment of the present disclosure, the at least two codes are generated as follows: at a plurality of positions of the local scanning track, determining a curve generated by intersecting a laser projection plane generated by scanning at each position with the three-dimensional model surface through simulation, and generating at least one group of codes corresponding to the position according to the shape of the curve;
when the target area is locally scanned, the laser is controlled to project at least two coded line lasers to the target area in a time sharing way, and the method comprises the following steps: and in the process of driving the laser to move along the local scanning track, controlling the laser to project the at least one group of codes corresponding to the position to the target area in a time-sharing manner at each position.
In an exemplary embodiment of the present disclosure, the local scan trajectory is generated by: generating the welding seam area according to the joint of the plates in the three-dimensional model, generating initial local scanning positions and postures of all scanning points according to the welding seam area and the welding gun model, and combining the local scanning positions and postures of all the scanning points into the local scanning track in sequence. The plurality of positions of the local scan trajectory may be the local scan positions, but the present disclosure is not limited thereto, and may be positions where the local scan positions are corrected.
Referring to fig. 1 and 2, during a partial scan, the robotic arm may translate the laser and the first camera, which may be accomplished in multiple steps, each of which may be a fraction of a millimeter or less. At each location, embodiments of the present disclosure may dynamically adaptively encode because the workpiece surface shape may change. The encoding process can be realized through simulation and stored by an image processing and control device according to the three-dimensional model of the workpiece, the local scanning track, the position and the gesture of the first camera, the position and the gesture of the laser and other parameters before the local scanning. If the operation speed can meet the requirement, the operation and the coding can be performed in the scanning process. In this way, during the movement of the laser along the local scanning trajectory, the coded line laser can be projected onto the target area at the upper position. Since the same group can have a plurality of codes and one or more groups of codes, the laser can be controlled to project in a time-sharing way, one code line laser can be projected at a time, and meanwhile, the first camera is matched with shooting, so that partial images shot during the projection of all code line lasers can be obtained, each partial image can have a clearer area, and a complete clear partial image can be obtained through superposition processing. The image superimposing process, which is not described herein, may be performed in various manners in the prior art, and the present disclosure is not limited thereto.
Because the reflection light is generated in a great relation with the shape of the surface on which the projection light is projected, other materials of the surface on which the projection light is projected, and the line laser form a line on the surface of the workpiece, the curve of the intersection of the laser projection plane and the surface of the workpiece can be obtained to judge the property of the reflection light. Thereby performing adaptive encoding. The embodiment can dynamically code the line laser according to the specific workpiece shape, thereby better eliminating the reflection interference of the projected light in the workpiece scanning process.
For a simple plane, after projecting a light bar, the resulting reflection is typically also a light bar. For more complex workpiece surfaces, there are pits and depressions, and a light line is projected to the positions of the pits and depressions, so that light spot reflection is easily generated. The position of these pits and depressions may exhibit a change in slope at the intersection with the laser projection plane, for example where the slope value is greater (relative to the surface of the land on which the workpiece is located) at relatively steep points. If the sign of the slope changes, it is indicated that there is an inflection point at this location. The relatively steep locations or locations where inflection points are present can be distinguished from other locations and projected with differently encoded line lasers. In this way, the reflected light generated by the reduced intensity of the projected light is correspondingly reduced, and the reflected light generated by the different positions has different characteristics, such as linear, light spot, divergent, concentrated, and the like. By projecting and shooting the line lasers with different codes respectively, the reflection light with different properties can be distinguished, and in particular, the boundary of the reflection light with different properties can be accurately distinguished. In subsequent image processing, corresponding reflected light cancellation algorithms can be employed for the different reflected light and cancellation of the ground reflected light. For example, for the reflected light of the light spot shape, a reflected light elimination algorithm more effective for eliminating the light spot can be adopted, for the reflected light of the line shape, a reflected light elimination algorithm more effective for eliminating the reflected light of the line shape can be adopted, so that after the reflected light is processed in a targeted manner, the effect of eliminating the reflected light can be greatly improved, and a clearer local image can be obtained.
In an exemplary embodiment of the present disclosure, a manner of generating codes according to the magnitude of the slope value is adopted, specifically, a plurality of value intervals may be set, and a code is generated for at least one line segment formed by points on the curve where the slope value belongs to the same value interval, so that the code corresponds to the at least one line segment, and all generated codes are compiled into a group.
In this embodiment, according to the slope value of the curve, a line segment formed by points with a large slope value and a line segment formed by points with a small slope value are encoded respectively, so that at least two encoded line lasers can be projected to the positions of the line segments with different slope values in a time-sharing manner. The steeper line segment and the flatter line segment are separated, and the reflected light generated by the steeper line segment and the flatter line segment respectively is different, so that the respective coding shooting is beneficial to the reflected light elimination processing in the subsequent images, and the effect of the reflected light elimination is improved.
In an exemplary embodiment of the present disclosure, another way of generating codes according to a curve shape is used, specifically, when the curve includes one or more inflection points, generating at least one line segment of a space at the curve position according to the inflection points, regenerating a first code corresponding to the at least one line segment, encoding the first code and the complement of the first code into a group, where the complement of the first code corresponds to other line segments on the curve than the at least one line segment
The present embodiment generates different codes based on different inflection points. In particular, there may be at least two different generating modes, where the generating modes may be used to generate multiple sets of codes at one location, or only one generating mode may be used to generate a set of codes at one location.
In one example of this embodiment, at least one line segment of the interval is generated in one of the following ways, see fig. 5.
The first way is to generate a line segment at a location of an inflection point, the line segment including the inflection point and having a predetermined length. Referring to fig. 5, the curve at the uppermost position of fig. 5 is the curve where the laser projection plane intersects the surface of the workpiece. The 2 nd and 3 rd sets of codes in fig. 5 are two sets of codes generated according to this rule, one of the 2 nd sets of codes corresponds to one inflection point position on the left side of the curve, and one of the 3 rd sets of codes corresponds to one inflection point position on the right side of the curve, and the other of the 2 nd and 3 rd sets of codes is a complement of the code corresponding to the line segment at the inflection point position. The two are combined to obtain a complete laser line.
The second way is to generate a plurality of line segments at the positions of the inflection points, wherein each line segment contains a corresponding inflection point and has a predetermined length. This way is not illustrated in the figure, but reference can be made to the set of codes consisting of coding mode 2 and the complement of coding mode 2 shown in fig. 4. By associating the positions of the complements of coding scheme 2 with the positions of the two inflection points in fig. 5, a set of codes generated in this way can be obtained.
The third way is to generate a line segment between two adjacent inflection points, both ends of which are a predetermined length from the corresponding inflection point. This way, see fig. 5, for the 4 th set of codes, where a segment corresponding to one code in the 4 th set of codes is located in a position between two inflection points, and there is a certain distance between two ends and the two inflection points. The other code in the 4 th set of codes is the complement of the code.
A fourth way is to generate a segment covering two adjacent inflection points, both ends of the segment being a predetermined length from the corresponding inflection point. This way, reference is made to fig. 5, which shows the 1 st set of codes, where a line segment corresponding to one code in the 1 st set of codes corresponds to the position of two inflection points in the curve and both ends exceed the two inflection points by a certain length. The other code in group 1 codes is the complement of that code.
It should be noted that, in the embodiment of the disclosure, when generating a corresponding line segment according to the inflection point and generating a corresponding code according to the line segment, the distance between two ends of the line segment and the corresponding inflection point may be set. If the length is too long, the boundary is not clear, if the length is too short, the line segment is too short, and the projected light line after coding is too short, so that the irradiation effect is affected. In particular, it can be empirically set in combination with actual operations.
The line formed after the line laser is projected onto the surface of the workpiece may have a certain width, and when the width reaches a certain value, the area where the line laser intersects with the surface of the workpiece may be regarded as a curved surface, and at this time, the determination of the inflection point may still be performed by using a curve taken out from the curved surface. For the way line segments are distinguished by slope values, the slope values may be changed to those used for the surface.
Correspondingly, the embodiment of the disclosure further provides a local scanning device, as shown in fig. 9, which comprises a memory 5 and a processor 6, wherein a computer program is stored in the memory 5, and the processor 6 can implement the local scanning method according to any embodiment of the disclosure when executing the computer program.
According to the local scanning device disclosed by the embodiment of the disclosure, different light rays are generated in the target area by time-sharing projection of line lasers with different codes to the target area, so that reflected light interference caused by one-time projection of more light rays can be reduced. And simultaneously, the position to be scanned can be covered comprehensively through time-sharing projection. Further, by setting different codes according to the surface shape of the workpiece, surfaces with different reflection characteristics can be respectively projected and shot, and then are processed by different reflection elimination algorithms, so that a better reflection elimination effect can be achieved.
An embodiment of the present disclosure further provides a method for eliminating reflective interference of a workpiece, as shown in fig. 6, including:
Step 210, obtaining a three-dimensional model of a workpiece, according to the local scanning method of any embodiment of the disclosure, controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, and controlling a first camera to shoot the target area when the laser projects each coded line laser, so as to obtain a plurality of local images;
And 220, processing the plurality of partial images through a reflection elimination algorithm, and synthesizing the processed plurality of partial images with the three-dimensional model to obtain an enhanced three-dimensional model of the workpiece.
Fig. 7 is a schematic diagram showing the partial scanning performed by the first camera 34 and the laser 33 in cooperation. In the figure 34 is mounted vertically with its lens directed to the part of the target area to be photographed at the current position. The laser 33 is disposed on the first camera 34 side, and is capable of projecting a line laser beam to a target region position facing the first camera 34. The attitude of the laser 33 may be varied, for example, may be rotated, so as to project the projection light to the workpiece surface positions at different depths h1, h2, h 3.
According to the method for eliminating the workpiece reflection interference, the line lasers with different codes are transmitted to the target area in a time-sharing mode and shot respectively, different light rays are generated in the target area, and the reflection light interference caused by projecting more light rays at one time can be reduced. And simultaneously, the target area is shot through time-sharing projection and each projection, the position to be scanned can be covered on the whole surface, and the obtained multiple parts can be overlapped to obtain a clear image of the target area.
It will be readily appreciated that in the case of a complex shape of the workpiece surface, the workpiece surface may reflect the projected light into the field of view of the first camera, as shown in fig. 8A, assuming that the reflected light enters the video range of the first camera by two reflections. As shown in fig. 8B, after changing the angle of the incident light, the second reflected light disappears, and the reflected light does not enter the field of view of the first camera. Whereas the angle of the incident light can be changed by adjusting the position and attitude of the laser.
Considering that line laser is projected onto a target workpiece to generate lines or light spots in the process of local high-precision scanning, reflection can be generated if the surface of the target workpiece is smoother, and reflected light can interfere with the local high-precision scanning if the reflected light is in the visual field of a 2D camera. Accordingly, in an exemplary embodiment of the present disclosure, there is provided a process of eliminating light reflection interference by adjusting a pose, that is, the method further includes:
Acquiring the positions and the postures of the laser and the first camera during local scanning and the surface shape information of the three-dimensional model, and performing simulation of the local scanning based on the acquired information;
Under the condition that the reflected light generated by the projected light of the laser on the surface of the workpiece can enter the visual field range of the first camera through simulation, the position and/or the posture of the laser and/or the first camera are adjusted so that the reflected light in the visual field range is reduced or eliminated;
And if the adjustment is successful, updating the positions and the attitudes of the laser and the first camera in the local scanning to the adjusted positions and attitudes.
Thereafter, the laser is controlled to project at least two coded line lasers to the target area in a time-sharing manner according to the adjusted position and posture. Some of the reflected light will disappear at this point. If the position and/or the posture of the laser are limited by the adjustable range or the local scanning track, the reflected light cannot be completely prevented from entering the visual field range of the first camera, and the reflected light can be adjusted as much as possible so as to reduce the entering amount of the reflected light.
That is, in this embodiment, after a motion process of the line laser on the three-dimensional model is established in the overall three-dimensional model according to the local scanning track, laser reflection simulation is performed according to the shape and the material, and the reflection is reduced and projected to the 2D camera field of view by changing the robot posture, so as to reduce the reflection influence.
The surface of the workpiece does not necessarily generate reflected light, so that the operation of adjusting the position and the posture according to the reflected light is not necessarily performed, but whether the reflected light is generated or not can be simply judged by a user and configuration information is input, and the image processing and control device can judge whether the adjustment is performed or not according to the configuration information. The judgment can also be automatically carried out, namely, the image processing and control device can judge whether the workpiece can reflect light when being scanned locally according to the acquired material and/or texture information of the surface of the workpiece, and if so, the information is acquired again to carry out the simulation judgment and the position adjustment processing. Otherwise these treatments do not need to be performed.
In an exemplary embodiment of the present disclosure, the acquiring a three-dimensional model of a workpiece includes:
performing global scanning on the workpiece through a 3D camera or performing local scanning on the workpiece for a plurality of times through a plurality of 2D cameras to obtain a three-dimensional coarse positioning model of the workpiece;
acquiring a photometric stereo image of the workpiece through a 2D camera to obtain a surface model of the workpiece, wherein the surface model contains material and/or texture information of the surface of the workpiece;
And synthesizing the rough positioning model and the surface model into a three-dimensional model of the workpiece.
In an exemplary embodiment of the present disclosure, if a manner of generating codes according to the surface shape of the workpiece is adopted, different reflection cancellation algorithms may be adopted for processing partial images corresponding to different codes in the same group; wherein, a local image corresponding to the code refers to one or more local images shot by the first camera when the coded line laser is projected.
In an exemplary embodiment of the disclosure, the synthesizing the processed plurality of local images with the three-dimensional model includes:
Superposing the processed multiple partial images, and synthesizing the obtained partial image with the three-dimensional model of the workpiece to obtain an enhanced three-dimensional model of the workpiece; or alternatively
And respectively synthesizing the processed multiple partial images with the three-dimensional model of the workpiece, and superposing the synthesized multiple three-dimensional models to obtain the enhanced three-dimensional model of the workpiece.
An embodiment of the present disclosure further provides an apparatus for removing workpiece reflection interference, referring to fig. 9, including a memory and a processor, where the memory stores a computer program, and the processor can implement a method for removing workpiece reflection interference according to any embodiment of the present disclosure when executing the computer program. The local scanning device and the device for eliminating the workpiece reflection interference in the embodiment of the disclosure can be general processors, and comprise a central processing unit (Central Processing Unit, CPU for short), a network processor (Network Processor, NP for short) and the like; but may also be a Digital Signal Processor (DSP), application Specific Integrated Circuit (ASIC), an off-the-shelf programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic device, discrete hardware components. The disclosed methods, steps, and logic blocks in the embodiments of the present invention may be implemented or performed. A general purpose processor may be a microprocessor or the processor may be any conventional processor or the like.
According to the device for eliminating the workpiece reflection interference, different coded line lasers are transmitted to the target area in a time-sharing mode and shot respectively, different light rays are generated in the target area, and reflection light interference caused by projecting more light rays at one time can be reduced. And simultaneously, the target area is shot through time-sharing projection and each projection, the position to be scanned can be covered on the whole surface, and the obtained multiple parts can be overlapped to obtain a clear image of the target area.
According to the embodiment of the disclosure, a three-dimensional model obtained by coarse positioning of a 3D camera and a surface material model obtained by acquisition of an optical stereo image can be used for synthesizing a complete workpiece model with surface material textures, dynamic light reflection simulation is carried out on a generated scanning track through the model, and a method for correcting the scanning track according to a dynamic light simulation result is adopted. The method for coding the line laser can also be used for coding the line laser according to the intersection line shape of the line laser and the workpiece model, so that the effect of obviously eliminating the reflection interference is achieved.
An embodiment of the present disclosure further provides an automatic welding system, as shown in fig. 1 and 2, including:
A robot 11 with a mechanical arm;
a first camera 34 and a laser 33 mounted on the mechanical arm, the mechanical arm being configured to move the first camera 34 and the laser 33 for local scanning;
The image processing and control device 2, electrically connected to the robot 11, the first camera 34 and the laser 33, is configured to perform the local scanning method according to any of the embodiments of the present disclosure, wherein the target area is a weld area on the workpiece.
In an exemplary embodiment of the present disclosure, the automatic welding system further includes: a 3D camera or a plurality of 2D cameras arranged to scan the workpiece to generate a three-dimensional model of the workpiece; the image processing and control device is further configured to perform the method of eliminating workpiece reflection interference according to any of the embodiments of the present disclosure.
The automatic welding system of the embodiment of the disclosure uses the scanning method of the embodiment of the disclosure to locally scan the welding seam area, so that the reflection interference generated in the scanning process can be eliminated, and a high-precision local image of the welding seam area can be obtained.
The method and the device of the embodiment of the disclosure can dynamically generate a plurality of codes in real time according to the surface shape of the workpiece and control the laser to project the line laser of the codes in a time-sharing manner, so that less light is projected during each projection, and reflection is less likely to be caused. And the images with corresponding reflection characteristics in the partial images are subjected to reflection elimination treatment by adopting different reflection elimination algorithms, so that the reflection elimination effect can be improved. The reflected light may also be moved out of view by adjusting the position and attitude of the movement of the laser and/or the first camera, thereby eliminating or reducing reflections.
The embodiment of the disclosure can dynamically adjust the pose and the laser coding according to the shape and the surface material of the workpiece, is suitable for the fine positioning reflection interference elimination of workpieces with various shapes and materials, and has higher adaptability and robustness.
An embodiment of the present disclosure also provides a non-transitory computer readable storage medium storing a computer program which, when executed by a processor, implements a local scanning method as described in any embodiment of the present disclosure and a method of eliminating workpiece reflection interference as described in any embodiment of the present disclosure.
In any one or more of the above-described exemplary embodiments of the present disclosure, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium, and executed by a hardware-based processing unit. The computer-readable medium may comprise a computer-readable storage medium corresponding to a tangible medium, such as a data storage medium, or a communication medium that facilitates transfer of a computer program from one place to another, such as according to a communication protocol. In this manner, a computer-readable medium may generally correspond to a non-transitory tangible computer-readable storage medium or a communication medium such as a signal or carrier wave. Data storage media may be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, code and/or data structures for implementing the techniques described in this disclosure. The computer program product may include a computer-readable medium.
By way of example, and not limitation, such computer-readable storage media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Moreover, any connection may also be termed a computer-readable medium, for example, if the instructions are transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital Subscriber Line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. It should be appreciated, however, that computer-readable storage media and data storage media do not include connection, carrier wave, signal, or other transitory (transient) media, but are instead directed to non-transitory tangible storage media. Disk and disc, as used herein, includes Compact Disc (CD), laser disc, optical disc, digital Versatile Disc (DVD), floppy disk or blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.
The instructions may be executed by one or more processors, such as one or more Digital Signal Processors (DSPs), general purpose microprocessors, application Specific Integrated Circuits (ASICs), field programmable logic arrays (FPGAs), or other equivalent integrated or discrete logic circuitry. Thus, the term "processor" as used herein may refer to any of the foregoing structure or any other structure suitable for implementation of the techniques described herein. Additionally, in some aspects, the functionality described herein may be provided within dedicated hardware and/or software modules configured for encoding and decoding, or incorporated in a combined codec. Also, the techniques may be fully implemented in one or more circuits or logic elements.
The technical solutions of the embodiments of the present disclosure may be implemented in a wide variety of at least two devices or apparatuses, including a wireless handset, an Integrated Circuit (IC), or a set of ICs (e.g., a chipset). Various components, modules, or units are described in this disclosure to emphasize functional aspects of devices configured to perform the described techniques, but do not necessarily require realization by different hardware units. Rather, as described above, the various units may be combined in a codec hardware unit or provided by a collection of interoperable hardware units (including one or more processors as described above) in combination with suitable software and/or firmware.
Claims (12)
1. A local scanning method, comprising:
determining a target area of the workpiece to be scanned based on the three-dimensional model of the workpiece; the target area to be scanned of the workpiece is a welding line area;
when the target area is locally scanned, controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, wherein light rays generated when the at least two coded line lasers are projected to the target area are different;
the at least two codes are generated according to the surface shape of the workpiece, each code of the at least two codes corresponds to at least one line segment, the at least two codes comprise at least one group of codes, and the line segments corresponding to all codes in the same group can be combined into a complete laser line;
Wherein, at least one line segment corresponding to one code refers to at least one line segment of a light line generated when the coded line laser is projected to the target area;
the at least two encodings are generated as follows: at a plurality of positions of the local scanning track, determining a curve or a curved surface generated by intersecting a laser projection plane generated by scanning at each position with the surface of the three-dimensional model through simulation, and generating at least one group of codes corresponding to the position according to the shape of the curve or the curved surface;
when the target area is locally scanned, the laser is controlled to project at least two coded line lasers to the target area in a time sharing way, and the method comprises the following steps: in the process of driving the laser to move along a local scanning track, controlling the laser to project the at least one group of codes corresponding to the position to the target area in a time-sharing manner at each position;
the generating at least one group of codes corresponding to the position according to the shape of the curve or the curved surface comprises the following steps:
Setting a plurality of value intervals, generating a code for at least one line segment formed by points of the curve, the slope values of which belong to the same value interval, so that the code corresponds to the at least one line segment, and all the generated codes are coded into a group; or alternatively
Generating at least one line segment of an interval at the curve position according to the inflection point when the curve comprises one or more inflection points, regenerating a first code corresponding to the at least one line segment, and coding the first code and the complement of the first code into a group, wherein the complement of the first code corresponds to other line segments except the at least one line segment on the curve; or alternatively
Setting a plurality of value intervals, generating a code for at least one line segment corresponding to a point of the gradient value belonging to the same value interval on the curved surface, so that the code corresponds to the at least one line segment, and all the generated codes are coded into a group.
2. The local scanning method as claimed in claim 1, wherein:
At least one group of codes comprises a first code and a second code which are complementary codes, and at least one line segment corresponding to the first code and at least one line segment corresponding to the second code can be combined into the complete laser line.
3. The local scanning method as claimed in claim 1, wherein:
The local scan trajectory is generated by: generating the welding seam area according to the joint of the plates in the three-dimensional model, generating initial local scanning positions and postures of all scanning points according to the welding seam area and the welding gun model, and combining the local scanning positions and postures of all the scanning points into the local scanning track in sequence.
4. The local scanning method as claimed in claim 1, wherein:
the generating at least one line segment of the interval at the curve position according to the inflection point comprises:
Generating a line segment at one inflection point position, wherein the line segment comprises the inflection point and has a preset length; or alternatively
Generating a plurality of line segments at the inflection point positions respectively, wherein each line segment comprises a corresponding inflection point and has a preset length; or alternatively
Generating a line segment between two adjacent inflection points, wherein two ends of the line segment are a preset length away from the corresponding inflection point; or alternatively
In generating a segment covering two adjacent inflection points, both ends of the segment are spaced from the corresponding inflection points by a predetermined length.
5. A local scanning device comprising a memory and a processor, wherein the memory holds a computer program which, when executed by the processor, is capable of implementing the local scanning method according to any one of claims 1 to 4.
6. A method of eliminating workpiece reflection interference, comprising:
Acquiring a three-dimensional model of a workpiece;
according to the local scanning method of any one of claims 1 to 4, controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, and controlling a first camera to shoot the target area when each coded line laser is projected by the laser, so as to acquire a plurality of local images;
And processing the plurality of partial images through a reflection elimination algorithm, and synthesizing the processed plurality of partial images with the three-dimensional model to obtain the enhanced three-dimensional model of the workpiece.
7. The method according to claim 6, wherein:
Before the controlling laser time-sharing projects at least two coded line lasers towards the target area, the method further comprises:
Acquiring the positions and the postures of the laser and the first camera during local scanning and the surface shape information of the three-dimensional model, and performing simulation of the local scanning based on the acquired information;
Under the condition that the reflected light generated by the projected light of the laser on the surface of the workpiece can enter the visual field range of the first camera through simulation, the position and/or the posture of the laser and/or the first camera are adjusted so that the reflected light in the visual field range is reduced or eliminated;
And if the adjustment is successful, updating the positions and the attitudes of the laser and the first camera in the local scanning to the adjusted positions and attitudes.
8. The method according to claim 7, wherein:
the method further comprises the steps of: judging whether the workpiece generates reflected light in a local scanning process according to configuration information or according to the material and/or texture information of the workpiece; in the case that reflected light is generated, simulation of the local scan is performed based on the acquired information.
9. The method of claim 6, wherein the step of providing the first layer comprises,
The processing the plurality of partial images by the reflection elimination algorithm comprises the following steps:
processing partial images corresponding to different codes in the same group by adopting different reflection elimination algorithms; wherein, a local image corresponding to the code refers to one or more local images shot by the first camera when the coded line laser is projected.
10. An apparatus for eliminating workpiece reflective interference comprising a memory and a processor, wherein the memory stores a computer program, and wherein the processor is capable of implementing a method for eliminating workpiece reflective interference as claimed in any one of claims 6 to 9 when executing the computer program.
11. An automated welding system, comprising:
A robot with a mechanical arm;
The first camera and the laser are arranged on the mechanical arm, and the mechanical arm is arranged to drive the first camera and the laser to move so as to perform local scanning;
an image processing and control device electrically connected to the robot, the first camera and the laser and configured to perform the local scanning method according to any one of claims 1 to 4, wherein the target area is a weld area on the workpiece.
12. The automated welding system of claim 11, wherein the welding machine comprises a welding machine,
The automated welding system further comprises: a 3D camera or a plurality of 2D cameras arranged to scan the workpiece to generate a three-dimensional model of the workpiece;
the image processing and controlling device is further configured to perform:
Acquiring a three-dimensional model of a workpiece;
controlling a laser to project at least two coded line lasers to the target area in a time-sharing manner, and controlling a first camera to shoot the target area when the laser projects each coded line laser to acquire a plurality of partial images;
processing the plurality of partial images through a reflection elimination algorithm, and synthesizing the processed plurality of partial images and the three-dimensional model to obtain an enhanced three-dimensional model of the workpiece;
Before the control laser projects at least two coded line lasers to the target area in a time-sharing manner, the image processing and control device further performs:
Acquiring the positions and the postures of the laser and the first camera during local scanning and the surface shape information of the three-dimensional model, and performing simulation of the local scanning based on the acquired information;
Under the condition that the reflected light generated by the projected light of the laser on the surface of the workpiece can enter the visual field range of the first camera through simulation, the position and/or the posture of the laser and/or the first camera are adjusted so that the reflected light in the visual field range is reduced or eliminated;
If the adjustment is successful, updating the positions and the postures of the laser and the first camera in local scanning to the adjusted positions and postures;
The image processing and controlling device further performs: judging whether the workpiece generates reflected light in a local scanning process according to configuration information or according to the material and/or texture information of the workpiece; under the condition that reflected light can be generated, simulation of the local scanning is performed based on the acquired information;
The processing the plurality of partial images by the reflection elimination algorithm comprises the following steps:
processing partial images corresponding to different codes in the same group by adopting different reflection elimination algorithms; wherein, a local image corresponding to the code refers to one or more local images shot by the first camera when the coded line laser is projected.
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