CN117871539B - Laser welding quality detection system and method based on optical coherence tomography - Google Patents
Laser welding quality detection system and method based on optical coherence tomography Download PDFInfo
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Abstract
The embodiment of the invention discloses a laser welding quality detection system and method based on optical coherence tomography. The system is applied to laser welding equipment and comprises a laser interference imaging system, a beam splitting module and an image processing module, wherein the laser interference imaging system emits a detection laser beam; the beam splitting module splits the detection laser beam into a first sample light, a second sample light and a third sample light, and the laser interference imaging system receives reflected light beams formed on the surface of the sample to be welded by the first sample light, the second sample light and the third sample light after beam combination and forms interference images; the image processing module performs phase analysis on interference images of the laser interference imaging system to respectively obtain a pre-welding image, a welding image and a post-welding image. The invention can monitor the quality before, during and after welding in real time and nondestructively without time division, is beneficial to finding and correcting potential problems in time, is beneficial to avoiding defects and improving production efficiency and ensures the reliability of the final product.
Description
Technical Field
The embodiment of the invention relates to the technical field of laser welding detection, in particular to a laser welding quality detection system and method based on optical coherence tomography.
Background
The laser welding is a high-precision welding method, and the process flow comprises the following steps: 1) The workpieces to be welded are prepared, their surfaces are ensured to be clean, and correct positioning and clamping are performed according to design requirements. 2) Setting laser welding equipment, including adjusting parameters such as laser power, focal length, laser beam diameter and the like. The setting of these parameters will vary depending on the material and design requirements of the workpiece. 3) And an accurate positioning system is used for ensuring that a laser welding spot is accurately aligned with a welding line so as to ensure the welding precision and quality. 4) Laser preheating is often performed prior to the actual welding. This helps to increase the temperature of the weld zone, reduce thermal distortion, and improve weld quality. 5) By aiming the laser beam at the weld, the laser energy is converted to heat energy, which melts the surface of the workpiece. Laser welding can be divided into two main types, conventional laser welding and laser deep-melt welding, with the specific process parameters depending on the type of welding and the workpiece material. 6) After the welding is completed, the weld zone begins to cool. Care is taken in controlling the temperature gradient during cooling to prevent cracking and deformation.
In the whole process flow of laser welding, each step has an important influence on the final welding quality, potential problems are found and corrected in time, and the method is beneficial to avoiding defects and improving production efficiency. However, most of the current welding quality detection is pre-welding detection or post-welding detection, and the current welding quality detection does not have the capability of in-welding detection, so that real-time online comprehensive detection cannot be realized.
Disclosure of Invention
The invention provides a laser welding quality detection system and method based on optical coherence tomography, which are used for monitoring the quality before, during and after welding in real time without time division, are beneficial to timely finding and correcting potential problems, are beneficial to avoiding defects and improving production efficiency, and ensure the reliability of a final product.
In a first aspect, an embodiment of the present invention provides a laser welding quality detection system based on optical coherence tomography, which is applied to a laser welding device, where the laser welding device is configured to emit a welding laser beam to perform laser welding on a sample to be welded in a relatively moving state;
The detection system includes:
the laser interference imaging system is used for emitting detection laser beams;
The beam splitting module is used for splitting the detection laser beam to form first sample light, second sample light and third sample light, phase differences exist between the first sample light, the second sample light and the third sample light, and the first sample light, the second sample light and the third sample light sequentially irradiate a pre-welding position, a mid-welding position and a post-welding position of the surface of the sample to be welded in the moving direction of the sample to be welded and form reflected light beams; the beam splitting module is further configured to combine reflected light beams of the first sample light, the second sample light, and the third sample light;
The laser interference imaging system is also used for receiving the reflected light beams formed by the first sample light, the second sample light and the third sample light after beam combination on the surface of the sample to be welded and forming interference images;
And the image processing module is used for acquiring the interference image of the laser interference imaging system, and carrying out phase analysis on the interference image of the laser interference imaging system to respectively acquire a pre-welding image, a welding image and a post-welding image.
Optionally, the beam splitting module includes a first coupler, and an output end of the first coupler is optically connected to the first optical fiber, the second optical fiber and the third optical fiber respectively;
the first optical fiber is used for transmitting the first sample light, the second optical fiber is used for transmitting the second sample light, and the third optical fiber is used for transmitting the third sample light.
Optionally, the beam splitting module further includes an optical angle adjusting frame, and output ends of the first optical fiber, the second optical fiber and the third optical fiber are respectively fixed on the optical angle adjusting frame, so that the output ends of the first optical fiber, the second optical fiber and the third optical fiber are respectively aligned with the pre-welding position, the mid-welding position and the post-welding position of the surface of the sample to be welded.
Optionally, the difference Δl in length between the first optical fiber, the second optical fiber, and the third optical fiber satisfies: delta L is more than or equal to C/F; wherein F is the laser pulse frequency of the detection laser beam, and C is the light speed.
Optionally, the laser interference imaging system includes:
A broadband light source for emitting an original laser beam;
the broadband light source is optically connected with the second coupler, and the second coupler is used for splitting the original laser beam into a reference beam and a sample beam;
A reference arm for transmitting the reference beam and feeding back a reflected beam of the reference beam to the second coupler;
the sample arm is in optical connection with the beam splitting module and is used for transmitting the sample beam as the detection laser beam to the beam splitting module and feeding back the reflected beams formed by the combined first sample beam, the second sample beam and the third sample beam on the surface of the sample to be welded to the second coupler so as to enable the reflected beams of the reference beam and the reflected beams of the combined first sample beam, the second sample beam and the third sample beam to interfere;
And the spectrum detector is optically connected with the second coupler and is used for detecting interference light formed by the reflected light beams of the reference light beam and the reflected light beams of the first sample light, the second sample light and the third sample light after beam combination to obtain the interference image.
Optionally, the laser welding device comprises a first optical filter and a reflecting galvanometer; the welding laser beam is reflected by the first optical filter and the reflecting vibrating mirror in sequence and irradiates the surface of the sample to be welded;
The sample arm comprises a collimating mirror, a second optical filter and a reflecting mirror;
the sample light beam is sequentially transmitted by the collimating mirror and the second optical filter, reflected by the reflecting mirror, transmitted by the first optical filter and reflected by the reflecting vibrating mirror, and is incident into the first coupler.
In a second aspect, an embodiment of the present invention further provides a method for detecting quality of laser welding based on optical coherence tomography, which is applied to the system for detecting quality of laser welding based on optical coherence tomography according to any one of the first aspect, where the method includes:
acquiring an interference image of the laser interference imaging system;
And carrying out phase analysis on the interference image of the laser interference imaging system to respectively obtain a pre-welding image, a welding image and a post-welding image.
Optionally, phase resolving is performed on the interference image of the laser interference imaging system to obtain a pre-weld image, a mid-weld image and a post-weld image, respectively, including:
Drawing gray scale graphs at different positions in the moving direction of the sample to be welded by using the interference image;
performing Fourier transform on the gray scale graph, and converting the gray scale graph from a time domain curve into a frequency domain curve;
searching frequency main peaks corresponding to the pre-welding position, the mid-welding position and the post-welding position of the sample to be welded in a frequency domain curve;
extracting main phases corresponding to the frequency main peaks of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively;
performing equal-phase interpolation processing on the sample to be welded near the main phases of the pre-welding position, the mid-welding position and the post-welding position respectively to obtain near-phase information of the sample to be welded near the pre-welding position, the mid-welding position and the post-welding position respectively;
Calculating single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the near phase information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively;
Calculating to obtain cross-section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position which are respectively different in the direction perpendicular to the movement direction of the sample to be welded;
and calculating to obtain three-dimensional depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position in the whole welding process according to the section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position at different moments in the moving process.
Optionally, after calculating to obtain the cross-sectional depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position, which are respectively different in the direction perpendicular to the movement direction of the sample to be welded, the method further comprises:
fitting to obtain a melting depth curve of the sample to be welded in the welding process according to the section depth image of the position of the sample to be welded in the welding process;
The melt depth curve is marked with melt depth evaluation.
Optionally, after calculating single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the near phase information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position, before calculating and obtaining cross-section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position, which are different in a direction perpendicular to the movement direction of the sample to be welded, respectively, the method further comprises:
and normalizing the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively.
According to the technical scheme, the laser interference imaging system, the beam splitting module and the image processing module are arranged in the detection system, detection laser beams of the laser interference imaging system are split into three sample lights with different phases by the beam splitting module and are irradiated to the positions before, during and after welding of the sample to be welded, the laser interference imaging system is used for forming interference images of the combined light reflected by the three sample lights, and the image processing module is used for carrying out phase analysis on the interference images to obtain images of the positions before, during and after welding of the sample to be welded. Wherein, the cleaning and the preparation work of the welding surface can be ensured through the pre-welding image so as to eliminate pollutants and ensure the quality of a welding area; parameters and internal melting states in the welding process can be obtained through the images in the welding process, the welding quality is monitored in real time, potential problems are found and corrected in time, the parameters can be adjusted in real time, and the consistency and the efficiency of welding are improved; the welded weld joint can be subjected to quality detection through the welded image, and the quality detection comprises detection defects, cracks, holes and the like, so that subsequent treatment, such as welding slag removal, surface polishing and the like, can be conveniently performed, and the appearance and functional requirements of a final product are met. The embodiment of the invention solves the problems that most of the existing welding quality detection is pre-welding detection or post-welding detection, has no capability of in-welding detection and cannot realize real-time on-line comprehensive detection, can monitor the quality before welding, during welding and after welding in a non-destructive manner in real time without time intervals, is beneficial to timely finding and correcting potential problems, is beneficial to avoiding defects and improving production efficiency, and ensures the reliability of a final product.
Drawings
FIG. 1 is a schematic structural diagram of a laser welding quality detection system based on optical coherence tomography according to an embodiment of the present invention;
Fig. 2 is a schematic structural view of a laser welding apparatus according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of a beam splitting module according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of an optical interference imaging system according to an embodiment of the present invention;
FIG. 5 is a flow chart of a laser welding quality detection method based on optical coherence tomography according to an embodiment of the present invention;
fig. 6 is a flowchart of another laser welding quality detection method based on optical coherence tomography according to an embodiment of the present invention.
Detailed Description
The invention is described in further detail below with reference to the drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting thereof. It should be further noted that, for convenience of description, only some, but not all of the structures related to the present invention are shown in the drawings.
The terminology used in the embodiments of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. It should be noted that, the terms "upper", "lower", "left", "right", and the like in the embodiments of the present invention are described in terms of the angles shown in the drawings, and should not be construed as limiting the embodiments of the present invention. In addition, in the context, it will also be understood that when an element is referred to as being formed "on" or "under" another element, it can be directly formed "on" or "under" the other element or be indirectly formed "on" or "under" the other element through intervening elements. The terms "first," "second," and the like, are used for descriptive purposes only and not for any order, quantity, or importance, but rather are used to distinguish between different components. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
The term "comprising" and variants thereof as used herein is intended to be open ended, i.e., including, but not limited to. The term "based on" is based at least in part on. The term "one embodiment" means "at least one embodiment".
It should be noted that the terms "first," "second," and the like herein are merely used for distinguishing between corresponding contents and not for defining a sequential or interdependent relationship.
It should be noted that references to "one", "a plurality" and "a plurality" in this disclosure are intended to be illustrative rather than limiting, and those skilled in the art will appreciate that "one or more" is intended to be construed as "one or more" unless the context clearly indicates otherwise.
Fig. 1 is a schematic structural diagram of a laser welding quality detection system based on optical coherence tomography according to an embodiment of the present invention, and fig. 2 is a schematic structural diagram of a laser welding apparatus according to an embodiment of the present invention, and referring to fig. 1 and 2, the detection system 100 is applied to a laser welding apparatus 200, where the laser welding apparatus 200 is configured to emit a welding laser beam to perform laser welding on a sample 300 to be welded in a relatively moving state.
The detection system 100 includes: a laser interference imaging system 110 for emitting a detection laser beam; the beam splitting module 120 is configured to split the detection laser beam to form a first sample light 11, a second sample light 12, and a third sample light 13, where a phase difference exists between each of the first sample light 11, the second sample light 12, and the third sample light 13, and the first sample light 11, the second sample light 12, and the third sample light 13 sequentially irradiate a pre-welding position a, a mid-welding position b, and a post-welding position c of the surface of the sample 300 to be welded in a moving direction of the sample 300 to be welded and form a reflected beam; the beam splitting module 120 is further configured to combine the reflected light beams of the first sample light 11, the second sample light 12, and the third sample light 13; the laser interference imaging system 110 is further configured to receive reflected light beams formed by the combined first sample light 11, second sample light 12, and third sample light 13 on the surface of the sample 300 to be welded, and form interference images; the image processing module 130 is configured to obtain an interference image of the laser interference imaging system 110, and perform phase analysis on the interference image of the laser interference imaging system 110 to obtain a pre-weld image, an in-weld image, and a post-weld image, respectively.
The laser interference imaging system 110 essentially refers to an Optical Coherence Tomography (OCT) system, whose core principle is based on a low coherence interference principle of light, and obtains backscattered light of a sample, and through demodulation and processing of interference signals, a two-dimensional tomographic or three-dimensional stereo structure image of the sample is obtained by reconstruction. OCT is a high resolution optical imaging technique that can be used to observe internal structures and features of materials, suitable for non-contact, real-time and high resolution imaging. The essence of the invention is that a spectral domain optical coherence tomography (SD-OCT) system is applied to laser welding quality detection, and in the laser welding quality monitoring of the invention, the OCT system, namely the laser interference imaging system 110, is integrated with the laser welding equipment 200, so that real-time welding quality monitoring can be realized, and problems can be found in time and measures can be taken. The OCT can penetrate through the molten state of the welding line in the welding process and acquire high-resolution images, so that the problems of defects, air holes, cracks and the like in the welding line can be detected. And analyzing the bonding condition of the welding interface, and detecting whether poor bonding or interface separation exists.
Spectral domain OCT systems typically use a light source to generate laser light, which may be visible or near infrared light, depending on the desired depth penetration and sample 300 characteristics to be welded, and wherein a portion of the light is split into sample light by a beam splitter and another portion is used as reference light. The sample light is guided to the welding area through the collimator and the short-wave pass filter, so that the laser can irradiate the surface of the welding line of interest. The sample light interacts with the weld surface to produce reflected and scattered light signals that contain information about the internal structure of the weld area. The reflected and scattered light signal is returned to the SD-OCT system, and the sample light and the reference light meet again, forming an interference image. The features of this interference image are caused by the optical path differences inside the sample 300 to be welded, providing depth information about the structure of the welded area. The overall process allows the system to scan and acquire high resolution cross-sectional images of the weld area in real time, thereby facilitating assessment of weld quality, detection of potential defects, and providing real-time monitoring of the welding process.
Based on the principle of detecting the internal structure of the sample 300 to be welded by optical coherence tomography, the beam splitting module 120 is further provided in the embodiment of the present invention, and is mainly used for splitting the sample light output by the OCT system into three sample lights with different phases, and respectively irradiating the sample light to be welded 300 at the position before, during and after the welding, that is, as shown in the figure, the first sample light 11 irradiates the position a before the welding, the second sample light 12 irradiates the position b after the welding, and the third sample light 13 irradiates the position after the welding, so that the image information of different welding positions of the sample 300 to be welded can be obtained by the reflected light of the first sample light 11, the second sample light 12 and the third sample light 13.
Still further, based on the pre-welding, during-welding and post-welding image information of the sample 300 to be welded, the embodiment of the invention further provides an image processing module 130, which is mainly used for performing phase analysis on the interference image fed back by the OCT system, so as to obtain the pre-welding, during-welding and post-welding image information of the sample 300 to be welded. Specifically, since the first sample light 11, the second sample light 12 and the third sample light 13 have phase differences between two, that is, the phases are different, in the image processing module 130, interference images formed by light rays of three phases can be separated according to the phase difference, the image corresponding to the phase of the first sample light 11 is an image of the position before welding of the sample 300 to be welded, the image corresponding to the phase of the second sample light 12 is an image of the position during welding of the sample 300 to be welded, and the image corresponding to the phase of the third sample light 13 is an image of the position during welding of the sample 300 to be welded. And according to the images of the front, middle and rear positions of the sample 300 to be welded, the whole welding process detection of the sample 300 to be welded can be realized. Wherein, using the first sample light 11, the weld before welding may be image captured and analyzed to identify potential defects, non-uniformities, or other problems, while acquiring detailed surface shape information, including shape and size of the weld; the second sample light 12 can be used for acquiring a real-time melting state in the laser welding process, and judging the current welding state and defect condition in real time; using the third sample light 13, the pattern of the welded seam surface can be observed in order to detect the flatness and quality of the welded seam.
According to the technical scheme, the laser interference imaging system, the beam splitting module and the image processing module are arranged in the detection system, detection laser beams of the laser interference imaging system are split into three sample lights with different phases by the beam splitting module and are irradiated to the positions before, during and after welding of the sample to be welded, the laser interference imaging system is used for forming interference images of the combined light reflected by the three sample lights, and the image processing module is used for carrying out phase analysis on the interference images to obtain images of the positions before, during and after welding of the sample to be welded. Wherein, the cleaning and the preparation work of the welding surface can be ensured through the pre-welding image so as to eliminate pollutants and ensure the quality of a welding area; parameters and internal melting states in the welding process can be obtained through the images in the welding process, the welding quality is monitored in real time, potential problems are found and corrected in time, the parameters can be adjusted in real time, and the consistency and the efficiency of welding are improved; the welded weld joint can be subjected to quality detection through the welded image, and the quality detection comprises detection defects, cracks, holes and the like, so that subsequent treatment, such as welding slag removal, surface polishing and the like, can be conveniently performed, and the appearance and functional requirements of a final product are met. The embodiment of the invention solves the problems that most of the existing welding quality detection is pre-welding detection or post-welding detection, has no capability of in-welding detection and cannot realize real-time on-line comprehensive detection, can monitor the quality before welding, during welding and after welding in a non-destructive manner in real time without time intervals, is beneficial to timely finding and correcting potential problems, is beneficial to avoiding defects and improving production efficiency, and ensures the reliability of a final product.
Fig. 3 is a schematic structural diagram of a beam splitting module according to an embodiment of the present invention, referring to fig. 1 to fig. 3, the beam splitting module 120 includes a first coupler 121, and an output end of the first coupler 121 is optically connected to a first optical fiber 1221, a second optical fiber 1222, and a third optical fiber 1223, respectively; the first optical fiber 1221 is used to transmit the first sample light 11, the second optical fiber 1222 is used to transmit the second sample light 12, and the third optical fiber 1223 is used to transmit the third sample light 13.
In the embodiment of the present invention, the length difference Δl between the first optical fiber 1221, the second optical fiber 1222, and the third optical fiber 1223 may be set to satisfy: delta L is more than or equal to C/F; wherein F is the laser pulse frequency of the detection laser beam, and C is the light speed.
At this time, the length difference of the three optical fibers is greater than the wavelength of the laser pulse, so that a phase difference greater than or equal to one wavelength can be generated when the sample light is output by the three optical fibers, thereby ensuring that the three sample lights have a larger phase difference, and facilitating the phase analysis of the image processing module 130.
Continuing with fig. 3, further, the beam splitting module 120 further includes an optical angle adjusting frame 123, and output ends of the first optical fiber 1221, the second optical fiber 1222, and the third optical fiber 1223 are respectively fixed on the optical angle adjusting frame 123, so that the output ends of the first optical fiber 1221, the second optical fiber 1222, and the third optical fiber 1223 are aligned with a pre-soldering position, a mid-soldering position, and a post-soldering position of the surface of the sample 300 to be soldered, respectively.
Fig. 4 is a schematic structural diagram of an optical interference imaging system according to an embodiment of the present invention, and referring to fig. 1 to 4, a laser interference imaging system 110 includes: a broadband light source 111 for emitting an original laser beam; a second coupler 112, the broadband light source 111 being optically connected to the second coupler 112, the second coupler 112 being for splitting the original laser beam into a reference beam and a sample beam; a reference arm 113 for transmitting a reference beam and feeding back a reflected beam of the reference beam to the second coupler 112; a sample arm 114 optically connected to the beam splitting module 120, for transmitting the sample beam as a detection laser beam to the beam splitting module 120, and feeding back reflected beams of the combined first, second and third sample lights 11, 12 and 13 formed on the surface of the sample 300 to be welded to the second coupler 112, so that the reflected beams of the reference beam interfere with the reflected beams of the combined first, second and third sample lights 11, 12 and 13; and a spectrum detector 115 optically connected to the second coupler 112 for detecting interference light formed by the reflected light beam of the reference beam and the reflected light beams of the combined first, second and third sample lights 11, 12 and 13 to obtain an interference image.
It should be added that, as shown in fig. 4, the laser interference imaging system 110 further includes an isolator 116, where the broadband light source 111 is optically connected to the second coupler 112 through the isolator 116, and the isolator 116 is used to avoid the light beam returned by the reference arm 113 or the sample arm 114 from entering the broadband light source 111 and interfering with the broadband light source 111.
With continued reference to fig. 1-4, further, the laser welding apparatus 200 includes a first optical filter 210 and a reflective galvanometer 220; the welding laser beam is sequentially reflected by the first optical filter 210 and the reflecting galvanometer 220 and irradiates the surface of the sample 300 to be welded; sample arm 114 includes a collimating mirror 1141, a second filter 1142, and a reflecting mirror 1143; the sample beam is sequentially transmitted through the collimator 1141 and the second filter 1142, reflected by the mirror 1143, transmitted through the first filter 210, and reflected by the mirror 220, and is incident into the first coupler 121.
Wherein the first filter 210 and the second filter 1142 are each short pass filters that function to select short wavelength light that is transmitted through the system to optimize imaging and measurement of the weld area. The light source of the SD-OCT system may emit light at multiple wavelengths, and a short pass filter may be used to select a particular short wavelength light to pass through the system, thereby helping to match the optimal detection range of the system to the internal structure of the weld. Short pass filters can be used to exclude long wavelength light that does not provide depth information about the weld area, thereby optimizing depth imaging of the weld interior structure. In the weld area, there may be uncorrelated signals from other sources or environments, and short-pass filters may help suppress these uncorrelated signals, improving the signal-to-noise ratio and sharpness of the image. The reflecting galvanometer 220 is used for changing the propagation directions of the welding laser beam and the detecting laser beam, so that the scanning is realized on the surface of the sample 300 to be welded, namely, the sequential welding process is realized. In addition, a field lens 230 and a gas nozzle 240 are also provided in the laser welding apparatus 200. The function of the field lens 230 is to direct and focus the laser beam onto the weld area in order to achieve accurate imaging and measurement of the weld. The field lens 230 is capable of focusing the welding laser beam to form a small and sharp focal point at the welding area. This helps to increase the spatial resolution of the system, enabling a more accurate detection of the microstructure of the welded area. The field lens 230 is also used to guide the path of the detection laser beam to ensure that the detection laser is accurately irradiated to the weld surface so as to obtain depth information about the weld area. The field lens 230 can adjust the angle of the light path to adapt to different welding conditions and different weld shapes, thereby improving the applicability and flexibility of the system. The purpose of the gas nozzle 240 is that during laser welding, the weld area may be contaminated with smoke, gas or other particulate matter, affecting the optical imaging quality. The gas nozzle 240 may clean potential contaminants by providing a gas flow to the weld area, ensuring that the SD-OCT system obtains clear imaging. The gas nozzle 240 may also be used to provide cooling during high temperature laser welding to prevent overheating of the weld area. Thereby helping to protect the optical elements and ensure proper operation of the SD-OCT system. Some laser welding processes may involve gas assist, such as laser plasma arc welding (LASER PLASMA ARC WELDING, LPAW). The gas nozzle 240 may be used to direct a flow of assist gas to interact with the laser of the weld area while maintaining cleanliness of the weld area.
Based on the same inventive concept, the embodiment of the present invention further provides a method for detecting laser welding quality based on optical coherence tomography, and fig. 5 is a flowchart of a method for detecting laser welding quality based on optical coherence tomography according to the embodiment of the present invention, first, the method is applied to a system for detecting laser welding quality based on optical coherence tomography according to any embodiment of the present invention, and the method may be performed by an image processing module in a system for detecting laser welding quality based on optical coherence tomography, where the image processing module may be implemented by software and/or hardware. Referring to fig. 1 to 5, the detection method includes the steps of:
s110, acquiring an interference image of the laser interference imaging system.
The step is performed while the laser welding device performs laser welding and the laser welding quality detection system performs pre-welding, during-welding and post-welding detection. In the welding quality detection process of the laser welding quality detection system, a detection laser beam is emitted through the laser interference imaging system, the detection laser beam is split into first sample light, second sample light and third sample light by the beam splitting module, the first sample light, the second sample light and the third sample light are respectively irradiated to a pre-welding position a, a mid-welding position b and a post-welding position c of the surface of a sample to be welded to form reflected light beams, and the reflected light beams of the first sample light, the second sample light and the third sample light are combined by the beam splitting module; the laser interference imaging system receives the reflected light beams formed by the first sample light, the second sample light and the third sample light after beam combination on the surface of the sample to be welded, and forms interference images. Therefore, the interference image in the step is the interference image formed by the reflected light beams of the three sample light received by the laser interference imaging system and the reference light, and as described above, the interference image contains the image information of the pre-welding position a, the mid-welding position b and the post-welding position c of the sample to be welded acquired by the three sample light. The step of obtaining interference images of the laser interference imaging system is essentially a process of obtaining integrated image information of pre-welding image information, in-welding image information and post-welding image information in real time in the welding process.
S120, carrying out phase analysis on an interference image of the laser interference imaging system to respectively obtain a pre-welding image, a welding image and a post-welding image.
Also as described above, the interference image here is an interference image formed by reflected light after image information of the pre-weld position a, the in-weld position b, and the post-weld position c of the sample to be welded acquired by three sample lights, which have a phase difference between each other. Therefore, the step is essentially a process of analyzing the three sample lights with different phases by utilizing the characteristic that the three sample lights have phase differences, so that the image information of the three sample lights at the position a before, the position b during and the position c after the welding of the sample to be welded can be extracted, and the monitoring of each position of the sample to be welded before, during and after the welding in the welding process can be realized.
According to the technical scheme, the interference image of the laser interference imaging system is firstly obtained, then the phase analysis is carried out on the interference image of the laser interference imaging system, and a pre-welding image, a mid-welding image and a post-welding image are respectively obtained, wherein the cleaning and the preparation work of the welding surface can be ensured through the pre-welding image so as to eliminate pollutants and ensure the quality of a welding area; parameters and internal melting states in the welding process can be obtained through the images in the welding process, the welding quality is monitored in real time, potential problems are found and corrected in time, the parameters can be adjusted in real time, and the consistency and the efficiency of welding are improved; the welded weld joint can be subjected to quality detection through the welded image, and the quality detection comprises detection defects, cracks, holes and the like, so that subsequent treatment, such as welding slag removal, surface polishing and the like, can be conveniently performed, and the appearance and functional requirements of a final product are met. The embodiment of the invention solves the problems that most of the existing welding quality detection is pre-welding detection or post-welding detection, has no capability of in-welding detection and cannot realize real-time on-line comprehensive detection, can monitor the quality before welding, during welding and after welding in a non-destructive manner in real time without time intervals, is beneficial to timely finding and correcting potential problems, is beneficial to avoiding defects and improving production efficiency, and ensures the reliability of a final product.
Fig. 6 is a flowchart of another laser welding quality detection method based on optical coherence tomography according to an embodiment of the present invention, which is refined based on the previous embodiment. In this embodiment, for step S120 of the foregoing embodiment, performing phase analysis on an interference image of a laser interference imaging system to obtain a pre-weld image, an in-weld image, and a post-weld image, respectively, and specifically refining the method includes the following steps:
drawing gray scale graphs at different positions in the moving direction of a sample to be welded by utilizing the interference image;
Carrying out Fourier transform on the gray scale graph, and converting the gray scale graph from a time domain curve into a frequency domain curve;
searching frequency main peaks corresponding to the position before welding, the position during welding and the position after welding of the sample to be welded in the frequency domain curve;
extracting main phases corresponding to frequency main peaks of a sample to be welded at a pre-welding position, a mid-welding position and a post-welding position respectively;
Performing equal-phase interpolation processing on the sample to be welded near the main phases of the pre-welding position, the mid-welding position and the post-welding position respectively to obtain near-phase information of the sample to be welded near the pre-welding position, the mid-welding position and the post-welding position respectively;
Calculating single-point depth image information of the sample to be welded at the pre-welding position, the in-welding position and the post-welding position according to the near phase information of the sample to be welded at the pre-welding position, the in-welding position and the post-welding position respectively;
calculating to obtain cross-section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to single-point depth image information of the sample to be welded at different pre-welding positions, mid-welding positions and post-welding positions in the direction perpendicular to the movement direction of the sample to be welded;
And calculating to obtain three-dimensional depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position in the whole welding process according to the cross-sectional depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position at different moments in the moving process.
For details not yet described in detail in this embodiment, please refer to the previous embodiment.
As shown in fig. 6, the method for detecting the quality of laser welding based on optical coherence tomography provided in this embodiment includes the following steps:
S210, acquiring an interference image of a laser interference imaging system;
S220, drawing gray scale graphs at different positions in the moving direction of the sample to be welded by utilizing the interference image;
This step is a process of converting the interference image into gradation information for representation. It should be noted that, in the process of moving the sample to be welded relative to the laser welding device, the position in welding changes in real time, and meanwhile, the laser welding quality detection system of the embodiment of the invention monitors the positions before, during and after welding at the current moment to obtain interference images. Therefore, this step is a process of drawing a corresponding gray scale graph for the interference image acquired at each time.
In addition, since the laser interference imaging system is affected by noise such as environmental noise and temperature noise, a noise signal is present in the generated interference image, and therefore, the interference image needs to be subjected to denoising before the step S220, so as to avoid interference of quality monitoring by the environment, temperature, and the like.
S230, carrying out Fourier transform on the gray scale graph, and converting the gray scale graph from a time domain curve into a frequency domain curve;
S240, searching frequency main peaks corresponding to the pre-welding position, the mid-welding position and the post-welding position of the sample to be welded in the frequency domain curve;
the above steps S230 and S240 are a process of converting the time domain image into the frequency domain for analysis. Because the sample to be welded can be in different states at the position before welding, the position after welding and the position after welding, the reflected light of three beams of sample light at the three positions can be obviously different, the interference information can be different, and certain difference can be generated in the frequency domain. The two steps are the process of respectively determining the corresponding image information of the pre-welding position, the mid-welding position and the post-welding position on the frequency domain curve.
S250, extracting main phases corresponding to frequency main peaks of a sample to be welded at a pre-welding position, a welding position and a post-welding position respectively;
S260, performing equal-phase interpolation processing on the sample to be welded near the main phases of the pre-welding position, the mid-welding position and the post-welding position respectively to obtain near-phase information of the sample to be welded near the pre-welding position, the mid-welding position and the post-welding position respectively;
S270, calculating single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the near phase information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively;
Based on the step S240, the image information corresponding to the position before, during and after welding can be distinguished and obtained, and the steps S250 to S270 are the process of converting the three frequency domain information into the phase information and increasing the richness of the phase information to restore the image information of the three positions by using the sufficient phase information. Specifically, in step S250, the frequency information corresponding to the pre-welding, the during-welding and the post-welding is converted into the phase information, in step S260, the phase information corresponding to the pre-welding, the during-welding and the post-welding is used as a basis, the detailed phase information is filled in, in step S270, the detailed phase information corresponding to the pre-welding, the during-welding and the post-welding is converted into the image, and because of the characteristics of laser interference imaging, the image using the phase conversion is substantially the image at the corresponding positions and at different depths, namely the single-point depth image.
It should be noted that, this step S270 is essentially to perform an a-Scan one-dimensional scanning mode, i.e. to measure the intensity of the reflected signal along a single direction, i.e. the depth direction, which is used to provide depth distribution information about the internal structure of the sample. By analyzing the returned light signals, properties of the tissue, such as density, reflectivity, etc., can be determined. A-Scan can be used to detect the location and quality of weld penetration. By measuring the intensity and depth distribution of the reflected signal, the presence of the weld and its location and shape in the weld material can be determined.
S280, calculating to obtain cross-section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to single-point depth image information of the sample to be welded at different pre-welding positions, mid-welding positions and post-welding positions in the direction perpendicular to the movement direction of the sample to be welded;
S290, calculating to obtain three-dimensional depth images of the sample to be welded at the position before welding, the position during welding and the position after welding in the whole welding process according to the section depth images of the sample to be welded at the position before welding, the position during welding and the position after welding at different moments in the moving process.
The steps S280 and S290 are the process of splicing the point information of the three positions before, during and after welding to form the face information and then to form the stereoscopic information. Through the two steps, three-dimensional monitoring images of all positions in the welding process can be obtained.
It should also be noted that, in the step S280, the B-Scan two-dimensional scanning mode is essentially performed, and the intensity of the reflected signal is measured along two directions, namely, the depth direction and the horizontal direction perpendicular to the movement of the sample to be welded, so as to generate a cross-sectional image similar to medical ultrasound, which is effective in providing more comprehensive and more visual tissue structure information, and by arranging a plurality of a-scans along the lateral positions, a B-Scan image can be formed, so as to display the cross-sectional structures of the sample at different depths. In the step S290, a C-Scan three-dimensional scanning mode is essentially performed, and the B-Scan scanning is performed on the two directions, i.e. the depth direction and the horizontal direction perpendicular to the movement of the sample to be welded, at different positions along the movement direction of the sample to be welded, so as to obtain a three-dimensional image of the sample surface, which is used to provide the overall structural information of the sample surface. The C-Scan image may show the shape, texture and any protrusions or depressions of the sample surface, which is useful for detecting surface lesions or evaluating the surface characteristics of the sample.
It should be further added that, after the depth image information of each point in the position before, during and after welding is obtained in step S270, natural differences exist in the image information of different depths due to the attenuation problem of the laser in the sample to be welded. Based on this, in the above embodiment, after step S270, before step S280, the following steps may be added: and S271, normalizing single-point depth image information of the sample to be welded at the position before welding, the position during welding and the position after welding respectively. The single-point depth image information with different depths can have a unified reference standard, and when the sectional view is formed by stitching in step S280, the melting state can be reflected by the contrast of the different depth images, so as to obtain the melting depth.
On the basis of the above embodiment, since the cross-sectional depth images of the sample to be welded at the positions before, during and after welding, that is, the cross-sectional views of the positions, can be obtained in step S280, in this embodiment of the present invention, the following steps may be added after step S280:
S281, fitting to obtain a fusion depth curve of the sample to be welded in the welding process according to the section depth image of the position of the sample to be welded in the welding process;
S282, marking the melt depth evaluation condition in the melt depth curve.
The two steps are used for analyzing the molten state of the welding position, and the molten depth of the welding position can be obtained by using the sectional image of the welding position. Because the image during welding can be acquired in real time during the welding process, the step S281 is essentially to collect the melting depth during the welding at each position during the welding process, and obtain the melting depth curves at different positions, so that the user can conveniently know the actual melting state of each position during the welding process. The fitting in step S281 may be performed by Halcon fitting. Based on the molten state of each location during the welding process, step 282 is essentially a process of automatically marking the melt depth evaluation. Those skilled in the art can know that the depth of melting during welding is an important index parameter of welding quality, so that the evaluation of the depth of melting can be understood as the evaluation of welding quality, that is, the real-time automatic evaluation of the state during welding can be realized through steps S281 and S282, so that a user can find and correct the problems existing during welding in time, and the parameters can be adjusted in time, thereby ensuring the quality of welding.
Note that the above is only a preferred embodiment of the present invention and the technical principle applied. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, and that various obvious changes, rearrangements, combinations, and substitutions can be made by those skilled in the art without departing from the scope of the invention. Therefore, while the invention has been described in connection with the above embodiments, the invention is not limited to the embodiments, but may be embodied in many other equivalent forms without departing from the spirit or scope of the invention, which is set forth in the following claims.
Claims (8)
1. The laser welding quality detection system based on the optical coherence tomography is characterized by being applied to laser welding equipment, wherein the laser welding equipment is used for emitting a welding laser beam so as to perform laser welding on a sample to be welded in a relative moving state;
The detection system includes:
the laser interference imaging system is used for emitting detection laser beams;
The beam splitting module is used for splitting the detection laser beam to form first sample light, second sample light and third sample light, phase differences exist between the first sample light, the second sample light and the third sample light, and the first sample light, the second sample light and the third sample light sequentially irradiate a pre-welding position, a mid-welding position and a post-welding position of the surface of the sample to be welded in the moving direction of the sample to be welded and form reflected light beams; the beam splitting module is further configured to combine reflected light beams of the first sample light, the second sample light, and the third sample light;
The laser interference imaging system is also used for receiving the reflected light beams formed by the first sample light, the second sample light and the third sample light after beam combination on the surface of the sample to be welded and forming interference images;
The image processing module is used for acquiring the interference image of the laser interference imaging system, and carrying out phase analysis on the interference image of the laser interference imaging system to respectively acquire a pre-welding image, a welding image and a post-welding image;
the beam splitting module comprises a first coupler, and the output end of the first coupler is respectively and optically connected with a first optical fiber, a second optical fiber and a third optical fiber;
The first optical fiber is used for transmitting the first sample light, the second optical fiber is used for transmitting the second sample light, and the third optical fiber is used for transmitting the third sample light;
The laser interference imaging system includes:
A broadband light source for emitting an original laser beam;
the broadband light source is optically connected with the second coupler, and the second coupler is used for splitting the original laser beam into a reference beam and a sample beam;
A reference arm for transmitting the reference beam and feeding back a reflected beam of the reference beam to the second coupler;
the sample arm is in optical connection with the beam splitting module and is used for transmitting the sample beam as the detection laser beam to the beam splitting module and feeding back the reflected beams formed by the combined first sample beam, the second sample beam and the third sample beam on the surface of the sample to be welded to the second coupler so as to enable the reflected beams of the reference beam and the reflected beams of the combined first sample beam, the second sample beam and the third sample beam to interfere;
And the spectrum detector is optically connected with the second coupler and is used for detecting interference light formed by the reflected light beams of the reference light beam and the reflected light beams of the first sample light, the second sample light and the third sample light after beam combination to obtain the interference image.
2. The inspection system of claim 1, wherein the beam splitting module further comprises an optical angle adjustment frame, and wherein the output ends of the first optical fiber, the second optical fiber, and the third optical fiber are respectively fixed to the optical angle adjustment frame such that the output ends of the first optical fiber, the second optical fiber, and the third optical fiber are respectively aligned with the pre-weld position, the mid-weld position, and the post-weld position of the surface of the sample to be welded.
3. The detection system of claim 1, wherein a difference Δl in length between the first optical fiber, the second optical fiber, and the third optical fiber satisfies: delta L is more than or equal to C/F; wherein F is the laser pulse frequency of the detection laser beam, and C is the light speed.
4. The detection system of claim 1, wherein the laser welding apparatus comprises a first optical filter and a reflective galvanometer; the welding laser beam is reflected by the first optical filter and the reflecting vibrating mirror in sequence and irradiates the surface of the sample to be welded;
The sample arm comprises a collimating mirror, a second optical filter and a reflecting mirror;
the sample light beam is sequentially transmitted by the collimating mirror and the second optical filter, reflected by the reflecting mirror, transmitted by the first optical filter and reflected by the reflecting vibrating mirror, and is incident into the first coupler.
5. A method for detecting quality of laser welding based on optical coherence tomography, which is applied to the system for detecting quality of laser welding based on optical coherence tomography according to any one of claims 1 to 4, the method comprising:
acquiring an interference image of the laser interference imaging system;
And carrying out phase analysis on the interference image of the laser interference imaging system to respectively obtain a pre-welding image, a welding image and a post-welding image.
6. The method according to claim 5, wherein phase resolving the interference image of the laser interference imaging system to obtain a pre-weld image, an in-weld image, and a post-weld image, respectively, comprises:
Drawing gray scale graphs at different positions in the moving direction of the sample to be welded by using the interference image;
performing Fourier transform on the gray scale graph, and converting the gray scale graph from a time domain curve into a frequency domain curve;
searching frequency main peaks corresponding to the pre-welding position, the mid-welding position and the post-welding position of the sample to be welded in a frequency domain curve;
extracting main phases corresponding to the frequency main peaks of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively;
performing equal-phase interpolation processing on the sample to be welded near the main phases of the pre-welding position, the mid-welding position and the post-welding position respectively to obtain near-phase information of the sample to be welded near the pre-welding position, the mid-welding position and the post-welding position respectively;
Calculating single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the near phase information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively;
Calculating to obtain cross-section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position according to the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position which are respectively different in the direction perpendicular to the movement direction of the sample to be welded;
and calculating to obtain three-dimensional depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position in the whole welding process according to the section depth images of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position at different moments in the moving process.
7. The inspection method according to claim 6, wherein after calculating the cross-sectional depth images of the sample to be welded at the pre-weld position, the mid-weld position, and the post-weld position, respectively, based on the single-point depth image information of the sample to be welded at the pre-weld position, the mid-weld position, and the post-weld position, respectively, which are different in the direction perpendicular to the movement of the sample to be welded, further comprises:
fitting to obtain a melting depth curve of the sample to be welded in the welding process according to the section depth image of the position of the sample to be welded in the welding process;
The melt depth curve is marked with melt depth evaluation.
8. The inspection method according to claim 6, wherein after calculating single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position, and the post-welding position, respectively, based on the near-phase information of the sample to be welded at the pre-welding position, the mid-welding position, and the post-welding position, respectively, before calculating cross-sectional depth images of the sample to be welded at the pre-welding position, the mid-welding position, and the post-welding position, respectively, based on the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position, and the post-welding position, respectively, which are different in a direction perpendicular to a movement of the sample to be welded, respectively, further comprising:
and normalizing the single-point depth image information of the sample to be welded at the pre-welding position, the mid-welding position and the post-welding position respectively.
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