CN207508491U - Automatic following device of welding seam based on line array CCD - Google Patents
Automatic following device of welding seam based on line array CCD Download PDFInfo
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- CN207508491U CN207508491U CN201721635387.3U CN201721635387U CN207508491U CN 207508491 U CN207508491 U CN 207508491U CN 201721635387 U CN201721635387 U CN 201721635387U CN 207508491 U CN207508491 U CN 207508491U
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Abstract
The utility model is related to a kind of automatic following device of welding seam based on line array CCD, which solve the existing THE WELD SEAM TRACKING TECHNOLOGYs based on video detection processing to control lag, centering accuracy is low, position error is bigger, can not rapidly rectify a deviation head the technical issues of, including line array CCD module, master controller, servo-driver, linkage mechanism, walking mechanism, welding flux box and head；Linkage mechanism includes rack, workbench, head mounting bracket, lead screw pair, servo motor, servo motor is connect with rack, the lateral surface of the output axis connection of lead screw pair and servo motor, the nut connection on the medial surface and lead screw pair of workbench, head mounting bracket and workbench connects；Rack is fixedly connected in walking mechanism；Head is connected on head mounting bracket, and welding flux box is connected on head mounting bracket, and line array CCD module is connected on welding flux box；The utility model is widely used in other welding technology fields such as submerged-arc welding.
Description
Technical field
The utility model is related to submerged arc welding technique field, in particular to a kind of weld seam based on line array CCD automatically with
Track device.
Background technology
It is well known that submerged-arc welding has, high degree of automation, production efficiency are high, appearance of weld is good, without arc light radiation etc.
Advantage.High-tech industry production is higher and higher to the quality requirement of thick plates, before submerged-arc welding is made to have increasingly wide application
Scape.
During ubmerged-arc welding operation, the welding torch of submerged-arc welding should be corresponding with position while welding always, but since welding tractor is led
, often there is the phenomenon that head and welding seam bias, seriously in rail and position while welding offset, electric arc reasons such as invisible under welding flux layer
Affect welding quality.In order to ensure that head is directed at Weld pipe mill, the position of necessary certification adjustment head before weldering.In weld job
In the process, it is also desirable to take measures to ensure head alignment Weld pipe mill, so as to improve welding productivity and weldquality.
At present, THE WELD SEAM TRACKING TECHNOLOGY is to ensure the effective means of head alignment Weld pipe mill.So-called weld joint tracking, refer to
Welding torch is controlled device, and welding torch, as regulated variable, passes through the biographies such as machinery, video, laser relative to the deviation of Weld pipe mill position
Sensed quantity means, control welding torch make its in entire welding process always with weld seam counterpart.Tracking based on video detection processing
Technology is using more and more, such as Patent No. 201410820791.2, entitled " weld seam detection based on video analysis with
The Chinese invention patent of track method " discloses the welding seam tracking method using pid algorithm, however, the THE WELD SEAM TRACKING TECHNOLOGY exists
Following technical problem：
(1) control lag, centering accuracy is low, and position error is bigger；
(2) during the movement of adjustment head, the displacement accuracy of measurement of head is low；
(3) can not rapidly rectify a deviation head；
(4) cause final welding quality low.
Invention content
The utility model is exactly to control lag, centering to solve the existing THE WELD SEAM TRACKING TECHNOLOGY handled based on video detection
Accuracy is low, and position error is bigger, can not rapidly rectify a deviation head the technical issues of, provide a kind of control process without stagnant
Afterwards, centering accuracy is high, and position error is small, the automatic following device of welding seam based on line array CCD that can quickly rectify a deviation.
The technical solution of the utility model is, including line array CCD module, master controller, servo-driver, linkage mechanism,
Walking mechanism, welding flux box and head；
Linkage mechanism includes rack, electric machine support, workbench, head mounting bracket, upper rail component, lower guideway component, silk
Thick stick is secondary, servo motor and shaft coupling, electric machine support are connect with rack, and servo motor is connect with electric machine support；Rack includes support
The upper end of beam, pedestal, upper mounting rail, lower mounting rail, left head installing plate and leading screw support base installing plate, lower mounting rail and supporting beam
Connection, upper mounting rail and lower mounting rail are arranged in parallel, the left end vertical connection of left head installing plate and lower mounting rail, leading screw support base
The right end vertical connection of installing plate and lower mounting rail；The left end of upper mounting rail and left head installing plate vertical connection, upper mounting rail
Right end and leading screw support base installing plate vertical connection；
Upper rail component is connect with upper mounting rail, and lower guideway component is connect with lower mounting rail；Upper rail component and lower guideway
Component is respectively equipped with sliding block；
It is connected with leading screw support base on leading screw support base installing plate, the left end of lead screw pair passes through shaft coupling and servo motor
Axis connection is exported, the right end of lead screw pair is connect with leading screw support base；
The medial surface of workbench is vertically connected with nut seat, and the nut in lead screw pair is connect with nut seat, upper rail component
It is connect respectively with the medial surface of workbench with the sliding block on lower guideway component；The lateral surface of head mounting bracket and workbench connects；
Pedestal is fixedly connected in walking mechanism；Head is connected on head mounting bracket, and welding flux box is connected to head installation
On frame, line array CCD module is connected on welding flux box；
Line array CCD module is electrically connected with master controller, and the output terminal of master controller and the input terminal of servo-driver connect,
The output terminal of servo-driver is connect with servo motor.
Preferably, master controller is STC15W4K microcontrollers, and light is equipped between STC15W4K microcontrollers and servo-driver
Coupling, the 1st pin of STC15W4K microcontrollers and servo-driverPort connects, and the 2nd of STC15W4K microcontrollers draws
Foot and servo-driverPort connects, and the enable port of servo-driver and the collector of optocoupler connect, optocoupler
Emitter is grounded, and the anode of optocoupler meets power supply VCC by resistance, and the cathode of optocoupler connects with the 5th pin of STC15W4K microcontrollers
It connects；STC15W4K microcontrollers use P-pulse scheme control servo-driver；
According to the direction of travel of walking mechanism, the camera lens in line array CCD module is located at the front of head, head and linear array
CCD module alignments, the position of head correspond to the center of line array CCD module.
The utility model also provides a kind of automatic following device of welding seam based on line array CCD, including line array CCD module, surpasses
Sound wave range sensor, master controller, servo-driver, linkage mechanism, walking mechanism, welding flux box, the second servo-driver and
Head；
Linkage mechanism includes rack, electric machine support, workbench, head mounting bracket, upper rail component, lower guideway component, water
Square to lead screw pair, horizontal direction servo motor, shaft coupling, vertical direction servo motor, vertical direction lead screw pair, left rail group
Part and right guide assembly, electric machine support are connect with rack, and horizontal direction servo motor is connect with electric machine support；Rack includes support
Beam, pedestal, upper mounting rail, lower mounting rail, left head installing plate and leading screw support base installing plate, upper mounting rail, lower mounting rail, left head
Installing plate and leading screw support base installing plate are joined together to form rectangular frame, and vertical direction servo motor is watched by vertical direction
Motor mount is taken to be fixedly connected with supporting beam；The upper end of vertical direction lead screw pair connects with the output shaft of vertical direction servo motor
It connects, lower end is connect by leading screw support base with pedestal, and left rail component and right guide assembly are connected to vertical direction servo
Between motor mount and pedestal, left rail component is equipped with third sliding block, and right guide assembly is equipped with Four-slider；Upper installation
Beam, lower mounting rail, left head installing plate and the inside of rectangular frame of leading screw support base installing plate composition and vertical direction lead screw pair
On nut connection, third sliding block and Four-slider are connect with the inside of the rectangular frame；
Upper rail component is connect with upper mounting rail, and lower guideway component is connect with lower mounting rail；Upper rail component and lower guideway
Component is respectively equipped with sliding block；
Leading screw support base is connected on leading screw support base installing plate, the left end of horizontal direction lead screw pair passes through shaft coupling and water
Square to servo motor output axis connection, the right end of horizontal direction lead screw pair supports with the leading screw on leading screw support base installing plate
Seat connection；
The medial surface of workbench is vertically connected with nut seat, and the nut in horizontal direction lead screw pair is connect with nut seat, on
Sliding block on guide assembly and lower guideway component is connect respectively with the medial surface of workbench；The outside of head mounting bracket and workbench
Face connects；
Pedestal is fixedly connected in walking mechanism；Head is connected on head mounting bracket, and welding flux box is connected to head installation
On frame, line array CCD module and ultrasonic distance sensor are connected on welding flux box；
Line array CCD module, ultrasonic distance sensor are electrically connected respectively with master controller, the output terminal of master controller and two
The output terminal of the input terminal connection of a servo-driver, horizontal direction servo motor and servo-driver connects, and vertical direction is watched
The output terminal that motor is taken with the second servo-driver is connect.
Preferably, master controller is STC15W4K microcontrollers, and light is equipped between STC15W4K microcontrollers and servo-driver
Coupling, the 1st pin of STC15W4K microcontrollers and servo-driverPort connects, and the 2nd of STC15W4K microcontrollers draws
Foot and servo-driverPort connects, and the enable port of servo-driver and the collector of optocoupler connect, optocoupler
Emitter is grounded, and the anode of optocoupler meets power supply VCC by resistance, and the cathode of optocoupler connects with the 5th pin of STC15W4K microcontrollers
It connects；STC15W4K microcontrollers use P-pulse scheme control servo-driver；
According to the direction of travel of walking mechanism, the camera lens in line array CCD module is located at the front of head, head and linear array
CCD module alignments, the position of head correspond to the center of line array CCD module；
According to the direction of travel of walking mechanism, ultrasonic distance sensor is located at the front of head.
The beneficial effects of the utility model are：
(1) control process is without lag, and centering accuracy is high, position error very little；
(2) during adjustment head movement up and down, the displacement accuracy of measurement of head is high, and moving process is reliable and stable；
(3) it can rapidly rectify a deviation, make head quick centring weld seam；
(4) welding torch tracks weld seam always in the welding process, and welding quality greatly improved.
The utility model further feature by the description of detailed description below, is clearly stated that.
Description of the drawings
Fig. 1 is the front view of linkage mechanism；
Fig. 2 is the vertical view of linkage mechanism；
Fig. 3 is the side view after the section view of A-A directions in Fig. 1；
Fig. 4 is the front view of rack；
Fig. 5 is the vertical view of rack；
Fig. 6 is the left view of rack；
Fig. 7 is the view in B directions in Fig. 5；
Fig. 8 is the front view of left head；
Fig. 9 is the left view of left head；
Figure 10 is the front view of right end；
Figure 11 is the vertical view of right end；
Figure 12 is the left view of right end；
Figure 13 is electric machine support front view；
Figure 14 is the vertical view of electric machine support；
Figure 15 is the right view of electric machine support；
Figure 16 is the front view of workbench；
Figure 17 is the vertical view of workbench；
Figure 18 is the left view of workbench；
Figure 19 is the schematic diagram of the automatic following device of welding seam based on line array CCD；
Figure 20 is the circuit diagram of master controller；
Figure 21 is the circuit diagram of servo-driver；
Figure 22 is the flow chart of the automatic seam tracking method based on line array CCD；
Figure 23 is master controller intermediate range program flow diagram；
Figure 24 is the usage state diagram of the automatic following device of welding seam based on line array CCD；
Figure 25 is the vertical view of structure shown in Figure 24；
Figure 26 is the left view of structure shown in Figure 24；
Figure 27 is the structure diagram that the linkage mechanism of automatic following device of welding seam can move up and down；
Figure 28 is the sectional view in B-B directions in Figure 27；
Figure 29 is the vertical view of structure shown in Figure 27；
Figure 30 is vertical range between ultrasonic distance sensor and head and ultrasonic distance sensor and workpiece
Weld seam between vertical range schematic diagram；
Figure 31 is the flow chart that head is controlled to move up and down.
Symbol description in figure：
1. rack, 101. supporting beams, 102. pedestals, mounting rail on 103.；104. lower mounting rail, 105. left installing plates,
106. leading screw support base installing plate；2. left head, 3. head mounting brackets, 310. workbench connecting plates, 311. mounting holes, 320. heads
Connecting plate, 330. installing plates；4. electric machine support, 401. first connecting plates, 402. second connecting plates, 403. motor mounting plates；5.
Workbench, 501. right end mounting holes, 502. upper installing holes, 503. times mounting holes, 504. nut seats；505. rectangular channel；It is led on 6.
Rail assembly, 601. first sliding blocks, 602. second sliding blocks；7. lower guideway component, 701. third sliding blocks；8. lead screw pair, 9. servos electricity
Machine, 10. shaft couplings；20. line array CCD module, 30. master controllers, 40. servo-drivers, 50. heads, 60. walking mechanisms, 70.
Wire reel, 80. welding flux boxes, 81. discharge ports, 90. workpiece, 100. control cabinets；11. vertical direction servo motor, 11-1. Vertical Squares
To servo motor mounting base, 12. vertical direction lead screw pair, 13. left rail components, 14. right guide assemblies, 1401. Four-sliders；
15. ultrasonic distance sensor.
Specific embodiment
Referring to the drawings, the utility model is described in further detail with specific embodiment.
Embodiment 1
As shown in Figs. 1-3, linkage mechanism include rack 1, left head 2, head mounting bracket 3, electric machine support 4, workbench 5, on
Guide assembly 6, lower guideway component 7, lead screw pair 8, servo motor 9, shaft coupling 10, electric machine support 4 are connect with rack 1, servo electricity
Machine 9 is connect with electric machine support 4；Upper rail component 6, lower guideway component 7 are connect respectively with rack 1；The left end of lead screw pair 8 passes through connection
The output axis connection of axis device 10 and servo motor 9, the right end of lead screw pair 8 are connect by leading screw support base with the right end of rack 1；Work
The medial surface for making platform 5 is connect with the nut in lead screw pair 8, the sliding block on upper rail component 6, lower guideway component 7 respectively with work
The medial surface connection of platform 5；Head mounting bracket 3 is connect with the lateral surface of workbench 5；Left head 2 is connect with the left end of rack 1.
As shown in figs. 4-7, rack 1 includes supporting beam 101, pedestal 102, upper mounting rail 103, lower mounting rail 104, left head peace
Loading board 105 and leading screw support base installing plate 106, pedestal 102 is connect with the lower end of supporting beam 101, lower mounting rail 104 and supporting beam
101 upper end connection, upper mounting rail 103 and the setting of lower 104 side by side parallel of mounting rail, left head installing plate 105 and lower mounting rail 104
Left end vertical connection, the right end vertical connection of leading screw support base installing plate 106 and lower mounting rail 104；A left side for upper mounting rail 103
End and left 105 vertical connection of head installing plate, right end and 106 vertical connection of leading screw support base installing plate of upper mounting rail 103.Upper peace
The left part of dress beam 103 is set there are two electric machine support mounting hole, and right part sets that there are four upper rail component mounting holes.Lower mounting rail 104
Left part set there are two electric machine support mounting hole, right part sets that there are four lower guideway component mounting holes.
Upper rail component 6 is mounted on upper mounting rail 103, and lower guideway component 7 is mounted on lower mounting rail 104.Upper rail
Component 6 is equipped with the first sliding block 601 and the second sliding block 602, and lower guideway component 7 is equipped with third sliding block 701 and Four-slider.
Leading screw support base is connected on leading screw support base installing plate 106.
As illustrated in figs. 13-15, electric machine support 4 includes the first connecting plate 401, the second connecting plate 402, motor mounting plate 403,
First connecting plate 401 and 403 vertical connection of motor mounting plate, the second connecting plate 402 and 403 vertical connection of motor mounting plate.The
One connecting plate 401 and the second connecting plate 402 are arranged side by side.Mounting hole there are two being set on first connecting plate 401, the second connecting plate
Mounting hole there are two being set on 402.Motor mounting plate 403 is equipped with circular hole, and circular hole is surrounded by four mounting holes.
Two mounting holes on first connecting plate 401 are matched with two electric machine support mounting holes of upper 103 left part of mounting rail,
It is connected with screw.Two electric machine support mounting holes of two mounting holes and lower 104 left part of mounting rail on the second connecting plate 402
Match, connected with screw.Mounting hole on the drive end bearing bracket of servo motor 9 and four mounting hole screws on motor mounting plate 403
Connection, the output shaft of servo motor 9 pass through the circular hole on motor mounting plate 403.
Lead screw pair 8 is equipped with nut, and right end and the leading screw support base on leading screw support base installing plate 106 of lead screw pair 8 connect
It connects.The output axis connection that the left end of lead screw pair 8 passes through shaft coupling 10 and servo motor 9.Lead screw pair 8 and upper rail component 6, under lead
Rail assembly 7 is arranged in parallel.
As shown in figs. 16-18, the lower right corner of workbench 5 is set there are four right end mounting hole 501, and the top of workbench 5 is equipped with
Eight upper installing holes 502, the lower part of workbench 5 are equipped with eight lower mounting holes 503, and centre position is hung down on the inside of the left part of workbench 5
It is direct-connected to be connected to nut seat 504；The right part medial surface of workbench 5 is equipped with rectangular channel 505.
Four mounting holes 502 of 5 upper left-hand of workbench are matched with the mounting hole on the first sliding block 601, are connected by screw
It connects.Four mounting holes 502 of 5 upper right of workbench are matched with the mounting hole on the second sliding block 602, are connected by screw.Work
Four mounting holes 503 for making 5 lower left side of platform are matched with the mounting hole on third sliding block 701, are connected by screw.Workbench 5
Four mounting holes 503 on the right side of lower part are matched with the mounting hole on Four-slider, are connected by screw.
Nut seat 504 is connect with the nut in lead screw pair 8.
As shown in figs. 10-12, head mounting bracket 3 includes workbench connecting plate 310 and head connecting plate 320, head connection
Plate 320 and 310 vertical connection of workbench connecting plate, set that there are four mounting holes 311 on workbench connecting plate 310.Head connecting plate
Installing plate 330 is connected on 320.
Four mounting holes 311 on workbench connecting plate 310 are matched with four right end mounting holes 501 on workbench 5, are led to
Cross screw connection.
As Figure 8-9, left head 2 includes cylindrical portion 201 and connecting plate 202, and cylindrical portion 201 is connect with connecting plate 202.Even
It is set on fishplate bar 202 there are four mounting hole, which matches with four mounting holes on left head installing plate 105, uses screw
Connection.Servo-driver and master controller and respective lines can be installed in cylindrical portion 201.
Head is mounted on the head connecting plate 320 of head mounting bracket 3, and servo motor 9 drives lead screw pair 8 to rotate, so as to
Workbench 5 and head mounting bracket 3 is driven to move, head mounting bracket 3 drives head movement, in this way, linkage mechanism adjustment head moves
When dynamic, the displacement accuracy of measurement of head is high, and head moving process is reliable and stable.
As shown in figure 19, the automatic following device of welding seam based on line array CCD include line array CCD module 20, master controller 30,
Servo-driver 40, head 50 and aforementioned linkage mechanism and welding flux box and the power supply unit of each module.Line array CCD mould
Block 20 is used to acquire the image of weld seam as image collecting device；On the one hand master controller 30 controls line array CCD module 20 to work,
On the other hand the real offset that calculation processing calculates head and weld seam is carried out to the picture signal that line array CCD module 20 is sent,
So as to send drive signal to servo-driver 40, servo-driver 40 sends out pulse drive signal to servo motor 9 again, makes to watch
It takes the action of motor 9 and drives the movement alignment Weld pipe mill of head 50.
As shown in figure 20, master controller 30 uses STC15W4K microcontrollers, and the microcontroller is with operating voltage is wide, the speed of service
Soon, reliability is high, low in energy consumption is good at；Clock source can select external crystal or be internally integrated high-precision R_C clocks；Built-in reset
Circuit；With 8 road 10-bit high speed Precision A/D conversion ports.
Operating voltage when STC15W4K microcontrollers work is 5V, and using internal R_C clocks, clock setting is
22.1184MHz；10bitADC precision；Flash uses 40KB.
Line array CCD module 20 includes image pick-up card and CCD camera, and CCD camera is connect with image pick-up card, image
Capture card is equipped with interface.Being sensed based on CCD for Wuhu Lan Zhou Electronic Science and Technology Co., Ltd.s production can be used in line array CCD module 20
Device TSL1401CL modules acquire product for one dimensional image.TSL1401CL modules are by the photodiode battle array of one 128 × 1
Row, relevant charge amplifier circuit, the pixel data holding unit and interface circuit composition of an inside, it is provided together
Shi Jicheng is originated and all pixels of dwell time.Interface circuit is equipped with serial input terminal SI and clock end CLK and simulation regards
Frequency signal output end AO.SI is connected to the 17th pin of STC15W4K microcontrollers, and CLK is connected to the 19th of STC15W4K microcontrollers
Pin, analog video signal output terminals A O ends are connected to the 9th pin (ADC interface) of STC15W4K microcontrollers.STC15W4K is mono-
Piece machine controls TSL1401CL modules by SI, CLK.
As shown in figure 21, the SD20- that servo-driver 40 is produced using Eura Drives Electric Co., Ltd.
G751T2M1F0D7B3N type products, servo motor 9 use SMSA-401S32BDM1 type products.SD20-
L1, L3 port of G751T2M1F0D7B3N model servo-drivers are connect with contactor KM1, and QF breakers connect with contactor KM1
It connects, AC single phase 220V plant-grid connection QF breakers, manual power switch is connect with contactor KM1.SD20-
Three-phase alternating current output terminal U, V, W and servo motor connection of G751T2M1F0D7B3N model servo-drivers.STC15W4K monolithics
1st pin of machine and SD20-G751T2M1F0D7B3N model servo-driversPort (the 15th port) connects,
2nd pin of STC15W4K microcontrollers and SD20-G751T2M1F0D7B3N model servo-driversPort the (the 27th
Port) connection.SD20-G751T2M1F0D7B3N model servo-drivers enablePort and the current collection of optocoupler U1
Pole connects, the emitter of optocoupler U1 ground connection, and the anode of optocoupler U1 meets power supply VCC by resistance R1, the cathode of optocoupler U1 with
The 5th pin connection of STC15W4K microcontrollers.
STC15W4K microcontrollers use P-pulse scheme control servo-driver, use Signal wire sends P-pulse control servo motor rotation, (forward or reverse)；Using externalWithButton realizes emergent stopping and ann reset function；Use the F-INH and R- for being installed on mechanical tracks
INH limit switches realize plumb joint mechanical part move forward and backward in limit mechanical position；Use FORWARD and BACK buttons
Realization manually adjusts plumb joint mechanical device and moves forward and backward action.
The power module powered to the peripheral circuit of STC15W4K microcontrollers, line array CCD module and servo-driver uses
LM2596 series switch power supply chips, DC15V (3A) inputs, output VCC (5V), tri- tunnel of PWR (+5V) and 12V.
As shown in figs 24-26, the pedestal of linkage mechanism 102 is fixedly mounted in walking mechanism 60, head 50 is mounted on
On head mounting bracket 3, welding flux box 80 is mounted on head mounting bracket 3, and the discharge port 81 of welding flux box 80 is located at the end of head 50
Place.Line array CCD module 20 is mounted on welding flux box 80, and line array CCD module 20 is located at the front position of head 50 (with reference to 25 He of figure
26, arrow represents the direction of travel of walking mechanism 60, and the camera lens of line array CCD module 20 is located at the front of head 50).Wire reel 70
In the supporting beam 101 of linkage mechanism, the welding wire on wire reel 70 is guided on head 50；Control cabinet 100 is arranged on linkage
Beside mechanism, master controller 30, servo-driver 40 are placed in control cabinet 100.
Workpiece 90 to be welded is located at the lower section of head 50.The scan line and workpiece of Shot Detection in line array CCD module 20
90 bead direction is vertical.
Head 50 is aligned with line array CCD module 20, and the position of head 50 corresponds to the center of line array CCD module 20.
Automatic seam tracking method based on line array CCD includes the following steps：
Step 1, system initialization.
Step 2, by linkage mechanism adjustment head 50 to mechanical origin, make the weld seam centering of head 50 and workpiece 90, this
The weld seam three of model machine head 50, linear CCD sensor TSL1401CL modules and workpiece 90 centering simultaneously, linear CCD sensor
The scan line of Shot Detection in TSL1401CL modules is vertical with the bead direction of workpiece 90；Linear CCD sensor
TSL1401CL modules have 128 pixels in itself, define the 64th pixel as linear CCD sensor TSL1401CL modules
Center.
Step 3, start walking mechanism 60 to advance to the progress weld job of workpiece 90 according to the arrow direction in Figure 25.
Step 4, the linear CCD sensor TSL1401CL modules for being installed on 50 front of head are continuously detected comprising weld seam
Uniline image information exports the analog electrical signal of often 128 pixels of row, send to the ADC ports of STC15W4K microcontrollers.
Step 5, the ADC module of STC15W4K microcontrollers is converted to weld seam analog electrical signal the number of 128 pixels
Signal.
Step 6, the serial number of the pixel of STC15W4K microcontrollers setting linear CCD sensor TSL1401CL module centers
Baseline threshold centered on 64.STC15W4K microcontrollers are averaging after each pixel data is added with front and rear adjacent pixel data
Value, then 128 to calculating average values arrange from big to small, are minimized, the corresponding pixel of this minimum value is exactly weld seam
Central point, corresponding serial number are just Nmid.The calculation formula of average value is：X1=(n1+n2)/2, X2=(n1+n2+n3)/3, X3=
(n2+n3+n4)/3, and so on, X127=(n126+n127+n128)/3, X128=(n127+n128)/2, n1,n2,…,n127,n128Table
Show the 1st pixel data, the 2nd pixel data ... ..., the 127th pixel data, the 128th pixel data.
If deviateing weld seam in head walking, the serial number of Weld pipe mill pixel will not be with linear CCD sensor
The 64th pixel serial number of center of TSL1401CL modules is consistent.It is consequently possible to calculate the difference of two serial numbers is as weld excursion
Value, calculates controlled quentity controlled variable, detailed process is further according to weld excursion value：Judge whether Nmid is more than threshold value 64, if it is, logical
It crosses formula (Nmid-64) * a/b and calculates pulse number of the output to servo-driver, enter step 7；Otherwise pass through formula (64-
Nmid) * a/b calculate pulse number of the output to servo-driver, jump to step 8.A/b is represented in pulse number calculation formula
Servo-driver electronic gear proportion.
After the quantity of pulse determines servo motor rotation, distance that head moves left and right.
Step 7, the 2nd pin output high level of STC15W4K microcontrollers, the 1st pin of STC15W4K microcontrollers send arteries and veins
Punching string is to servo-driver, and servo-driver is according to the instruction of STC15W4K microcontrollers, and control servo motor rotates forward, so as to drive
Airplane Nose Right displacement and weld seam centering；
Step 8, the 2nd pin output low level of STC15W4K microcontrollers, the 1st pin of STC15W4K microcontrollers send arteries and veins
Punching string is to servo-driver, and servo-driver is according to the instruction of STC15W4K microcontrollers, control servo motor reversion, so as to drive
Nose Left displacement and weld seam centering.
In this way, the welding torch that head 50 generates tracks weld seam always in the welding process, ensure the quality of welding.This was controlled
Cheng Zhong, the displacement accuracy of measurement of head is high, and centering accuracy is high.
In abovementioned steps 2, mechanical origin is that the 64th pixel is only illustrated, it should be noted that line array CCD module is in itself
Pixel be N if, center reference threshold value is exactly N/2.
Similarly, the mechanical origin in previous example can be the 65th pixel, and center reference threshold value is 65, then, it can be with
It obtains, if the pixel of line array CCD module in itself is M, center reference threshold value is exactly M/2+1.
Embodiment 2
In order to which head 50 is made to adjust position in vertical direction, carried out on the basis of previous embodiment 1 further
It improves, makes 106 groups of upper mounting rail 103, lower mounting rail 104, left head installing plate 105 and leading screw support base installing plate in rack 1
Into rectangular frame be slidably connected with supporting beam 101.Concrete structure as can be seen in figures from 27 to 29, by vertical direction servo motor 11,
Vertical direction lead screw pair 12, left rail component 13 and right guide assembly 14 are realized.
Vertical direction servo motor 11 is fixedly connected by vertical direction servo motor mounting base 11-1 with supporting beam 101,
The upper end of vertical direction lead screw pair 12 and the output axis connection of vertical direction servo motor 11, the lower end of vertical direction lead screw pair 12
It is connect by leading screw support base with pedestal 102, left rail component 13 and right guide assembly 14 are connected to vertical direction servo
Between motor mount 11-1 and pedestal 102, left rail component 13 is equipped with third sliding block, and right guide assembly 14 is equipped with the 4th
Sliding block 1401.The rectangle that upper mounting rail 103, lower mounting rail 104, left head installing plate 105 and leading screw support base installing plate 106 form
The inside of frame is connect with the nut in vertical direction lead screw pair 12, third sliding block and Four-slider 1401 and the rectangular frame
Inside connection.The input terminal of vertical direction servo motor 11 is connected with the output terminal of corresponding second servo-driver.
Therefore, when vertical direction servo motor 11 drives upper mounting rail 103, lower mounting rail 104, left 105 and of head installing plate
When the rectangular frame that leading screw support base installing plate 106 forms moves up and down, workbench 5 moves up and down therewith, so as to drive head
50 move up and down.Ultrasonic distance sensor 15 is mounted on welding flux box 80, faces the weld seam of workpiece 90.According to walking mechanism
Direction of travel, ultrasonic distance sensor 15 is located at the front of head.The signal output end of ultrasonic distance sensor 15 with
STC15W4K microcontrollers connect.
Based on 50 structure moving up and down of head is made, the process that head 50 vertically moves up and down is controlled to be：
Step (1), ultrasonic distance sensor 15 in real time detection workpiece 90 weld seam and ultrasonic distance sensor 15 it
Between distance H.
Step (2), STC15W4K microcontrollers receive the range data H that ultrasonic distance sensor is sent.
Step (3), the distance that STC15W4K microcontrollers define head 50 to ultrasonic distance sensor 15 are L,
STC15W4K singlechip microcomputers head 50 arrives the distance h, h=H-L of the weld seam of workpiece 90.
Step (4), STC15W4K microcontrollers set head 50 to the reference range threshold value of the weld seam of workpiece 90 as Q.
Step (5), STC15W4K microcontrollers judge whether h is more than Q, if it is, being calculated by formula (h-Q) * e/f defeated
Go out to the pulse number of the second servo-driver, enter step (6)；Otherwise output is calculated to second by formula (Q-h) * e/f
The pulse number of servo-driver jumps to step (7).E/f represents the second servo-driver electricity in pulse number calculation formula
Sub- gear ratio.
After the quantity of pulse determines the rotation of the second servo motor, distance that head moves up and down.
Step (6), STC15W4K microcontrollers send train of pulse to the second servo-driver, the second servo-driver according to
The instruction of STC15W4K microcontrollers, control vertical direction servo motor 11 rotates forward, so as to drive head 50 to bottom offset；
Step (7), STC15W4K microcontrollers send train of pulse to the second servo-driver, the second servo-driver according to
The instruction of STC15W4K microcontrollers, control vertical direction servo motor 11 inverts, so as to which head 50 be driven to move up.
The above is not intended to limit the utility model only to the preferred embodiment of the utility model, for this
For the technical staff in field, various modifications and changes may be made to the present invention.
Claims (4)
1. a kind of automatic following device of welding seam based on line array CCD, which is characterized in that including line array CCD module, master controller,
Servo-driver, linkage mechanism, walking mechanism, welding flux box and head；
The linkage mechanism includes rack, electric machine support, workbench, head mounting bracket, upper rail component, lower guideway component, silk
Thick stick is secondary, servo motor and shaft coupling, the electric machine support are connect with rack, and the servo motor is connect with electric machine support；It is described
Rack includes supporting beam, pedestal, upper mounting rail, lower mounting rail, left head installing plate and leading screw support base installing plate, the lower installation
The upper end of beam and supporting beam connects, and the upper mounting rail and lower mounting rail are arranged in parallel, the left head installing plate and lower mounting rail
Left end vertical connection, the right end vertical connection of the leading screw support base installing plate and lower mounting rail；A left side for the upper mounting rail
End and left head installing plate vertical connection, right end and the leading screw support base installing plate vertical connection of the upper mounting rail；
The upper rail component is connect with upper mounting rail, and lower guideway component is connect with lower mounting rail；The upper rail component is under
Guide assembly is respectively equipped with sliding block；
Leading screw support base is connected on the leading screw support base installing plate, the left end of the lead screw pair passes through shaft coupling and servo electricity
The output axis connection of machine, the right end of the lead screw pair are connect with leading screw support base；
The medial surface of the workbench is vertically connected with nut seat, and the nut in the lead screw pair is connect with nut seat, it is described on
Sliding block on guide assembly and lower guideway component is connect respectively with the medial surface of workbench；The head mounting bracket and workbench
Lateral surface connects；
The pedestal is fixedly connected in walking mechanism；The head is connected on head mounting bracket, and welding flux box is connected to head
On mounting bracket, the line array CCD module is connected on welding flux box；
The line array CCD module is electrically connected with master controller, the output terminal of the master controller and the input terminal of servo-driver
Connection, the output terminal of servo-driver are connect with servo motor.
2. the automatic following device of welding seam according to claim 1 based on line array CCD, it is characterised in that：
The master controller is STC15W4K microcontrollers, and optocoupler is equipped between STC15W4K microcontrollers and servo-driver,
1st pin of STC15W4K microcontrollers and servo-driverPort connect, the 2nd pin of STC15W4K microcontrollers with
Servo-driverPort connects, and the enable port of servo-driver and the collector of optocoupler connect, the transmitting of optocoupler
Pole is grounded, and the anode of optocoupler meets power supply VCC by resistance, and the cathode of optocoupler is connect with the 5th pin of STC15W4K microcontrollers；
STC15W4K microcontrollers use P-pulse scheme control servo-driver；
According to the direction of travel of walking mechanism, the camera lens in line array CCD module is located at the front of head, head and line array CCD mould
Block is aligned, and the position of head corresponds to the center of line array CCD module.
3. a kind of automatic following device of welding seam based on line array CCD, which is characterized in that including line array CCD module, ultrasonic distance
Sensor, master controller, servo-driver, linkage mechanism, walking mechanism, welding flux box, the second servo-driver and head；
The linkage mechanism includes rack, electric machine support, workbench, head mounting bracket, upper rail component, lower guideway component, water
Square to lead screw pair, horizontal direction servo motor, shaft coupling, vertical direction servo motor, vertical direction lead screw pair, left rail group
Part and right guide assembly, the electric machine support are connect with rack, and the horizontal direction servo motor is connect with electric machine support；It is described
Rack includes supporting beam, pedestal, upper mounting rail, lower mounting rail, left head installing plate and leading screw support base installing plate, the upper installation
Beam, lower mounting rail, left head installing plate and leading screw support base installing plate are joined together to form rectangular frame, vertical direction servo electricity
Machine is fixedly connected by vertical direction servo motor mounting base with supporting beam；It is watched with vertical direction the upper end of vertical direction lead screw pair
The output axis connection of motor is taken, lower end is connect by leading screw support base with pedestal, and left rail component and right guide assembly connect respectively
It is connected between vertical direction servo motor mounting base and pedestal, left rail component is equipped with third sliding block, is set on right guide assembly
There is Four-slider；The inside for the rectangular frame that upper mounting rail, lower mounting rail, left head installing plate and leading screw support base installing plate form
It is connect with the nut in vertical direction lead screw pair, third sliding block and Four-slider are connect with the inside of the rectangular frame；
The upper rail component is connect with upper mounting rail, and lower guideway component is connect with lower mounting rail；The upper rail component is under
Guide assembly is respectively equipped with sliding block；
Leading screw support base is connected on the leading screw support base installing plate, the left end of the horizontal direction lead screw pair passes through shaft coupling
With the output axis connection of horizontal direction servo motor, the right end of the horizontal direction lead screw pair on leading screw support base installing plate
Leading screw support base connects；
The medial surface of the workbench is vertically connected with nut seat, and the nut in the horizontal direction lead screw pair connects with nut seat
It connects, the sliding block on the upper rail component and lower guideway component is connect respectively with the medial surface of workbench；The head mounting bracket
It is connect with the lateral surface of workbench；
The pedestal is fixedly connected in walking mechanism；The head is connected on head mounting bracket, and welding flux box is connected to head
On mounting bracket, the line array CCD module and ultrasonic distance sensor are connected on welding flux box；
The line array CCD module, ultrasonic distance sensor are electrically connected respectively with master controller, the output terminal of the master controller
It is connect with the input terminal of two servo-drivers, the output terminal connection of horizontal direction servo motor and servo-driver, Vertical Square
It is connect to servo motor with the output terminal of the second servo-driver.
4. the automatic following device of welding seam according to claim 3 based on line array CCD, it is characterised in that：
The master controller is STC15W4K microcontrollers, and optocoupler is equipped between STC15W4K microcontrollers and servo-driver,
1st pin of STC15W4K microcontrollers and servo-driverPort connect, the 2nd pin of STC15W4K microcontrollers with
Servo-driverPort connects, and the enable port of servo-driver and the collector of optocoupler connect, the transmitting of optocoupler
Pole is grounded, and the anode of optocoupler meets power supply VCC by resistance, and the cathode of optocoupler is connect with the 5th pin of STC15W4K microcontrollers；
STC15W4K microcontrollers use P-pulse scheme control servo-driver；
According to the direction of travel of walking mechanism, the camera lens in line array CCD module is located at the front of head, head and line array CCD mould
Block is aligned, and the position of head corresponds to the center of line array CCD module；
According to the direction of travel of walking mechanism, ultrasonic distance sensor is located at the front of head.
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| CN201721635387.3U CN207508491U (en) | 2017-11-29 | 2017-11-29 | Automatic following device of welding seam based on line array CCD |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107738023A (en) * | 2017-11-29 | 2018-02-27 | 威海职业学院 | Automatic following device of welding seam and method based on line array CCD |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107738023A (en) * | 2017-11-29 | 2018-02-27 | 威海职业学院 | Automatic following device of welding seam and method based on line array CCD |
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