CN203418212U - Automatic welding line tracing control system based on magnetic control electric arc and laser vision sensing - Google Patents
Automatic welding line tracing control system based on magnetic control electric arc and laser vision sensing Download PDFInfo
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- CN203418212U CN203418212U CN201320422081.5U CN201320422081U CN203418212U CN 203418212 U CN203418212 U CN 203418212U CN 201320422081 U CN201320422081 U CN 201320422081U CN 203418212 U CN203418212 U CN 203418212U
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Abstract
Description
Technical field
The utility model relates to a kind of welding control method and system, particularly a kind of control system for automatic welding.
Background technology
During automatic welding, be processing and the rigging error of real-Time Compensation because of workpiece, and because sweating heat is out of shape the variation of caused position while welding and size, must adopt suitable welding seam tracking method.
In conventional weld seam tracking sensor, arc sensor real-time is best, wherein magnetic control arc sensor because of machinery-free vibrations and wearing and tearing and the little performance of volume outstanding; Laser vision sensor obtaining information amount is large, and weld joint tracking is effective.But single sensor is difficult to overcome the impact that in welding process, various uncertain factor butt welded seam deviation informations extract, and the possibility of weld joint tracking failure is larger.Multiple different sensor is organically combined, and is the effective way that solves weld joint tracking under complex environment, is also the inexorable trend of Automation of Welding development.
At present, many senses information mix together technology is obtaining larger development aspect military affairs utilization, but in the weld joint tracking of automatic welding system, studies less.For the data fusion based on magnetic control arc and vision sensor, study, foundation be take magnetic control arc sensor as main body, laser vision sensor carries out the fusion criterion of the prediction of deviation, at employing double-sensing, estimate on the basis of checking the fusion method of calibrating and realize soldering joint automatic tracking, for the application of many senses information mix together technology in welding robot weld joint tracking provides theoretical reference.
Summary of the invention
The purpose of this utility model is to provide a kind of fast response time, good stability, fault-tolerance is high, tracking accuracy is high, the practical soldering joint automatic tracking control system based on magnetic control arc and laser-vision sensing.A kind of weld seam deviation recognition system based on magnetic control arc and laser-vision sensing has been proposed, for the data fusion based on magnetic control arc and vision sensor, study, foundation be take magnetic control arc sensor as main body, laser vision sensor carries out the fusion criterion of the prediction of deviation, adopting on the basis of the methods such as the pretreatment of piecewise interpolation data, discreet value validity check, seam track prediction, adaptive weighted fusion, form effective data fusion scheme, realized spatial complex track weld seam from motion tracking.This system can effectively be avoided the limitation of single-sensor, improves weld joint tracking precision and System Error-tolerance Property, and algorithm simply and is easily realized, and for many senses information mix together technology realizes complicated seam track at welding robot, in motion tracking, applies theoretical foundation is provided.
The utility model solves the technical scheme that its technical problem adopts: the utility model provides a kind of soldering joint automatic tracking control system based on magnetic control arc and laser-vision sensing, it comprises welding gun 1, the source of welding current 2, wire-feed motor 3, executing agency, image collecting device 6, Hall element 7, controller 8, driver 9, magnetic control arc sensor 10 and laser vision sensor 11, the source of welding current 2 the two poles of the earth connect respectively wire-feed motor 3 and Hall element 7, Hall element 7 is connected with controller 8, wire-feed motor 3 is connected with the welding gun 1 being arranged in executing agency, magnetic control arc sensor 10 is set on welding gun 1, laser vision sensor 11 is set on magnetic control arc sensor 10, laser vision sensor 11 is connected with controller 8 by image collecting device 6, controller 8 connects executing agency by driver 9.
Described executing agency comprises the stepper motor on welding tractor 4, cross balladeur train 5 and cross balladeur train 5; Cross balladeur train 5 comprises that height regulates balladeur train 13 to regulate the left and right adjusting balladeur train 12 on balladeur train 13 with being arranged on just, and welding gun 1 is arranged on left and right adjusting balladeur train 12.
Described executing agency comprises each motor on welding robot 14 and welding robot 14, and welding gun 1 is arranged on welding robot 14, is specifically arranged on the end of welding robot 14 arms.
Described executing agency comprises each motor on special welding machine 15 and special welding machine 15; Special welding machine 15 comprises X-axis Level tune balladeur train 16 and Y-axis height adjusting slider 17, and Y-axis height adjusting slider 17 is arranged on X-axis Level tune balladeur train 16; Welding gun 1 is arranged on special welding machine 15, is specifically arranged on Y-axis height adjusting slider 17.
The beneficial effects of the utility model are: for single sensor, be difficult to meet the problem of the requirement that between real-time empty, weld joint tracking precision and accurate mass are controlled, proposed the seam tracking system that a kind of magnetic control arc sensor is combined with vision sensor.This system is given full play to vision sensor and the dual measurement of magnetic control arc sensor, the comprehensive advantage of checking mutually.By the self adaptation of these two kinds of different measuring precision sensor observed quantity weights is dynamically adjusted, select optimum deviation fetch strategy, can have a huge impact the effect of system keeps track and precision, make weld seam deviation that system extracts more close to the real displacement at welding gun phase butt welded seam center, realize high-precision weld seam deviation information extraction; Weld joint tracking precision and stability to the larger seam track of degree of crook and weld seams shaped zigzag line knuckle place have greatly been improved, actual welding engineer testing has been verified the validity of this algorithm, tracking effect is better than single-sensor seam tracking system, stability is higher, practical, there is important actual application value, can be widely used in welding robot or in motion tracking special plane system.
Accompanying drawing explanation
Fig. 1 is operation principle schematic diagram of the present utility model;
Fig. 2 is structural representation of the present utility model;
Fig. 3 is the course of work schematic diagram that double-sensing is estimated the fusion method of check calibration;
Fig. 4 is the structural representation of the utility model embodiment 7;
Fig. 5 is the structural representation of the utility model embodiment 8.
In figure: 1-welding gun, the 2-source of welding current, 3-wire-feed motor, 4-welding tractor, 5-cross balladeur train, 6-image collecting device, 7-Hall element, 8-controller, 9-driver, 10-magnetic control arc sensor, 11-laser vision sensor, 12-left and right adjusting balladeur train, 13-just regulates balladeur train, 14-welding robot, 15-special welding machine, 16-X axle Level tune balladeur train, 17-Y axle height adjusting slider.
The specific embodiment
Below in conjunction with drawings and Examples, the utility model is described in further details.
Embodiment 1, the utility model adopts the automatic weld tracking control method based on magnetic control arc and laser-vision sensing, in welding process, magnetic control arc sensor 10 is controlled welding arc scanning groove, Hall element 7 is by the welding current signal detecting circuit signal processing after filtering, by interfering signal filtering and by useful signal, extract and amplify and carry out software processing and computing afterwards, trying to achieve the deviation information that welding gun 1 departs from weld seam center; Laser vision sensor 11 tilts to be incident upon on seam groove by laser, by image collecting device 6, gather the laser stripe image that comprises characteristics of weld seam, through adaptive threshold, cut apart and the steps such as medium filtering, refinement and slope calculations, obtain the departure at welding gun 1 butt welded seam center.These two kinds of weld seam deviation information input to tracking system central controller 8 in the lump, the fusion method that adopts double-sensing to estimate check calibration is carried out information processing, deviation information after merging is as the weld seam deviation regulated quantity of executing agency, by executing agency, carrying out weld seam deviation regulates, realize soldering joint automatic tracking, complete automatic welding.In order to realize the soldering joint automatic tracking based on magnetic control arc sensing and laser-vision sensing, the weld seam deviation information that need to first obtain each sensor is carried out effective integration, system by the weld seam deviation information conveyance after merging to system central controller, by controller, send instruction again and carry out real-time online correction to driver drives executing agency, complete weld seam from motion tracking.Consult Fig. 1 to Fig. 3.
Embodiment 2, and the fusion method that the utility model employing double-sensing is estimated check calibration is to Fusion.In the research of hybrid multisensor data fusion algorithm, due to sensor confidential interval and precision different, conventionally need to rule of thumb to each sensor, be weighted, its weights directly affect measurement, be subject to the impact of Nonlinear perturbations in actual welding environment, performance is very unstable.For this problem, propose a kind of double-sensing and estimated the fusion method of check calibration, the main points that double-sensing is estimated the fusion method of check calibration are: in welding process, by preposition laser vision sensor butt welded seam center, undertaken estimating early stage, obtain the discreet value of weld seam lateral deviation, magnetic control arc sensor extracts welding gun phase butt welded seam central cross offset deviation as measured value, after data pretreatment, by setting threshold value, discreet value is carried out to validity check, the effectively degree of crook of discreet value by prediction seam track and whether broken line flex point, according to predicting the outcome, divide two kinds of situations to carry out data fusion, when seam track curvature is less than the set threshold value of system, the adaptive optimal Weighted Fusion criterion of employing based on total mean square deviation minimum processed laser vision sensor discreet value and magnetic control arc sensor measured value, after fusion, carry out EKF, by filtered weld seam deviation fusion value, effective discreet value is proofreaied and correct, obtain weld seam deviation information more accurately, when seam track curvature is greater than the set threshold value of system, the weld seam deviation measured value of the magnetic control arc sensor of usining output is as system weld seam deviation fusion value, invalid discreet value abandons, the warm value of weld seam deviation of the upper periodic sampling of system output.Consult Fig. 1 to Fig. 5, all the other are with embodiment 1.
Embodiment 3, and the utility model is realized soldering joint automatic tracking in conjunction with magnetic control arc sensor and laser vision sensor.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
Embodiment 4, and the utility model adopts the weld seam deviation real-time detection method based on seam track prediction, can improve weld joint tracking precision.In order to solve, seam track is complicated, degree of crook is large, and the problem of place, especially large broken line angle weld joint tracking difficulty, has proposed the weld seam deviation real-time detection method based on seam track prediction.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
The main points that weld seam deviation based on seam track prediction detects are in real time: by preposition laser sensor, extract seam track feature, the situation of change of judgement seam track, in seam track curvature, large and broken line flex point place, obtains more accurate weld seam deviation by the good magnetic control arc sensor of real-time performance and measures as the correction of system actuator; And less and non-flex point, extreme point in the situation that, adopt the method for laser sensor and magnetic control arc sensing data Weighted Fusion to obtain weld seam deviation in seam track curvature.
By laser vision sensor, obtain future range the position coordinates of interior all sampled points , through curve, can obtain seam track ? the approximate function of section , by function expression calculates all flex points and extreme point in section, and calculate the curvature of the seam track of all sampled points place prediction .
According to this seam track, predict the outcome, minute two kinds of situations are carried out data fusion, and fusion criterion can be summarized as follows:
1,, in conjunction with welding procedure, establish fusion criterion boundary value , when time, or welding torch position is positioned at flex point, extreme point place, lower because adopting laser vision to follow the tracks of weld seam precision, even cannot realize tracking, therefore adopt the weld seam deviation measured value of magnetic control arc sensor output as system weld seam deviation fusion value;
2, when time, and the non-flex point of welding torch position, extreme point place, adopt Weighted Fusion criterion to process dual sensor observation, after the valuation filtering of double-sensing data, export weld seam deviation fusion value.
Embodiment 5, the utility model also provides a kind of soldering joint automatic tracking control system based on magnetic control arc and laser-vision sensing, it comprises welding gun 1, the source of welding current 2, wire-feed motor 3, executing agency, image collecting device 6, Hall element 7, controller 8, driver 9, magnetic control arc sensor 10 and laser vision sensor 11, the source of welding current 2 the two poles of the earth connect respectively wire-feed motor 3 and Hall element 7, Hall element 7 is connected with controller 8, wire-feed motor 3 is connected with the welding gun 1 being arranged in executing agency, magnetic control arc sensor 10 is set on welding gun 1, laser vision sensor 11 is set on magnetic control arc sensor 10, laser vision sensor 11 is connected with controller 8 by image collecting device 6, controller 8 connects executing agency by driver 9.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
Embodiment 6, and described executing agency comprises the stepper motor on welding tractor 4, cross balladeur train 5 and cross balladeur train 5; Cross balladeur train 5 comprises that height regulates balladeur train 13 to regulate the left and right adjusting balladeur train 12 on balladeur train 13 with being arranged on just, and welding gun 1 is arranged on left and right adjusting balladeur train 12.Deviation information after merging, as the weld seam deviation regulated quantity of executing agency, is carried out weld seam deviation by cross balladeur train 5 and is regulated, and realizes soldering joint automatic tracking, completes automatic welding.Wherein, for the weld seam deviation in left and right adjusting balladeur train 12 directions, the data fusion method of estimating check calibration according to double-sensing by seam tracking system controller 8 is controlled driver 9 and is driven the adjusting of rectifying a deviation of stepper motor on left and right adjusting balladeur train 12; For the weld seam deviation of welding gun 1 central axis direction, by seam tracking system controller 8, according to the height displacement Deviation Control driver 9 of magnetic control arc sensor 10 output, drive height to regulate the adjusting of rectifying a deviation of stepper motor on balladeur train 13.It is all orthogonal that left and right adjusting balladeur train 12 and height regulate balladeur train 13 when the welding tracking to weld seam together with every, and therefore also have another name called it " cross balladeur train ".The adjusting of whole system executing agency is by controller 8, to send instruction to control driver 9, thus Driving Stepping Motor and control that the motor of welding tractor 4 walkings worked in coordination with, and its collaborative work mode is by realizing the software programming of controller 8.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
Embodiment 7, and described executing agency comprises each motor on welding robot 14 and welding robot 14, and welding gun 1 is arranged on welding robot 14, is specifically arranged on the end of welding robot 14 arms.Deviation information after merging is as the weld seam deviation regulated quantity of executing agency, and welding robot 14 is carried out weld seam deviation and regulated, and realizes soldering joint automatic tracking, completes automatic welding.Wherein, the adjusting of whole system executing agency is by controller 8, to send instruction to control driver 9, thus Driving Stepping Motor and control that each motor of welding robot 14 worked in coordination with, and its collaborative work mode is by realizing the software programming of controller 8.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
Embodiment 8, and described executing agency comprises each motor on special welding machine 15 and special welding machine 15; Special welding machine 15 comprises X-axis Level tune balladeur train 16 and Y-axis height adjusting slider 17, and Y-axis height adjusting slider 17 is arranged on X-axis Level tune balladeur train 16; Welding gun 1 is arranged on special welding machine 15, is specifically arranged on Y-axis height adjusting slider 17.Deviation information after merging is as the weld seam deviation regulated quantity of executing agency, and the X-axis Level tune balladeur train 16 of special welding machine 15 is carried out weld seam deviation with Y-axis height adjusting slider 17 and regulated, and realizes soldering joint automatic tracking, completes automatic welding.Wherein, for the weld seam deviation in X-axis Level tune balladeur train 16 directions, the data fusion method of estimating check calibration according to double-sensing by seam tracking system controller 8 is controlled driver 9 and is driven the adjusting of rectifying a deviation of stepper motor on X-axis Level tune balladeur train 16; For the weld seam deviation of Y-axis height adjusting slider 17 central axis directions, by seam tracking system controller 8, according to the height displacement Deviation Control driver 9 of magnetic control arc sensor output, drive the adjusting of rectifying a deviation of stepper motor on Y-axis height adjusting slider 17.The adjusting of whole system executing agency is by controller 8, to send instruction to control driver 9, thus Driving Stepping Motor and control that the motor of special welding machine 15 walkings worked in coordination with, and its collaborative work mode is by realizing the software programming of controller 8.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
Embodiment 9, controller of the present utility model can be by single-chip microcomputer, DSP, PLC, ARM, FPGA, the replacement such as industrial computer or computer, laser vision sensor can be by laser structure optical sensor, laser scanning sensor or initiatively light vision sensor replace, be intended to real-time performance, the magnetic control arc sensor that anti-arc light jamming performance is superior and highly sensitive, the laser vision sensor that obtaining information amount is large organically combines, by the fusion method that adopts double-sensing to estimate check calibration, magnetic control arc sensor and laser vision sensor data are merged, obtain accurate weld seam deviation information, for soldering joint automatic tracking, and be widely used in welding robot or in motion tracking special plane system, overcome the impact that in welding process, various uncertain factor butt welded seam deviation informations extract, reduce and follow the tracks of failed possibility, fundamentally improve overall system performance.Consult Fig. 1 to Fig. 5, all the other same above-described embodiments.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103341685A (en) * | 2013-07-17 | 2013-10-09 | 湘潭大学 | Weld joint automatic tracking control method and system based on magnetic controlling arcs and laser vision sensing |
| CN104808582A (en) * | 2015-04-27 | 2015-07-29 | 广东工业大学 | Embedded digital controller based on FPGA and control method of embedded digital controller |
| CN105149733A (en) * | 2015-09-17 | 2015-12-16 | 湘潭大学 | Method and device for controlling vertical welding process of applying synchronizing pulse compound magnetic field |
| CN105935830A (en) * | 2016-06-14 | 2016-09-14 | 惠州市铠屹精密机械有限公司 | Intelligent welding system and welding method thereof |
-
2013
- 2013-07-17 CN CN201320422081.5U patent/CN203418212U/en not_active IP Right Cessation
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103341685A (en) * | 2013-07-17 | 2013-10-09 | 湘潭大学 | Weld joint automatic tracking control method and system based on magnetic controlling arcs and laser vision sensing |
| CN103341685B (en) * | 2013-07-17 | 2016-08-17 | 湘潭大学 | A kind of automatic weld tracking control method based on magnetic control arc and laser-vision sensing and system |
| CN104808582A (en) * | 2015-04-27 | 2015-07-29 | 广东工业大学 | Embedded digital controller based on FPGA and control method of embedded digital controller |
| CN105149733A (en) * | 2015-09-17 | 2015-12-16 | 湘潭大学 | Method and device for controlling vertical welding process of applying synchronizing pulse compound magnetic field |
| CN105935830A (en) * | 2016-06-14 | 2016-09-14 | 惠州市铠屹精密机械有限公司 | Intelligent welding system and welding method thereof |
| CN105935830B (en) * | 2016-06-14 | 2018-06-26 | 惠州市铠屹精密机械有限公司 | A kind of Intelligent welding system and its welding method |
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