JP2006281270A - Hand welding analyzer and hand welding torch-integrated type monitoring camera applicable to the analyzer - Google Patents

Hand welding analyzer and hand welding torch-integrated type monitoring camera applicable to the analyzer Download PDF

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JP2006281270A
JP2006281270A JP2005104443A JP2005104443A JP2006281270A JP 2006281270 A JP2006281270 A JP 2006281270A JP 2005104443 A JP2005104443 A JP 2005104443A JP 2005104443 A JP2005104443 A JP 2005104443A JP 2006281270 A JP2006281270 A JP 2006281270A
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manual welding
image
welding
welding torch
analyzer
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JP2005104443A
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Japanese (ja)
Inventor
Satoru Asai
Katsumi Kubo
Masatake Sakuma
Ryusuke Tsuboi
克巳 久保
正剛 佐久間
竜介 坪井
知 浅井
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Toshiba Corp
株式会社東芝
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a hand welding analyzer that images the behavior of a TIG hand welding operation and that evaluates welding skill based on the feature amount extracted from the image, and also to provide a hand welding torch integrated type monitoring camera that is applicable to the analyzer. <P>SOLUTION: The hand welding analyzer analyzes and processes the image information around a molten pool during the welding that is imaged by the monitoring camera installed in the periphery of the target hand welding operation. The analyzer is equipped with a hand welder integrated type image pickup unit 1 that integrally connects the monitoring camera 2 with the hand welding torch 3, an image data recorder 8 that processes and records the digital signals of the image from the image pickup unit, a data processor 9 that processes the recorded image information as data, and a display device 10 that displays the information so processed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an improved manual welding torch-integrated surveillance camera applied to a manual welding work analysis apparatus and a manual welding work analysis apparatus.

  In the recent welding technology field, for example, TIG welding field, while the automation of welding construction is progressing, it is still highly dependent on the skill and ability of skilled welders for the parts that are difficult to automate. It has become.

  In addition, as the knowledge information becomes more sophisticated and complicated with the automation of welding construction, even for inexperienced welders or skilled welders, various kinds of behavior during welding construction are image-processed and image-processed knowledge information It is necessary to construct a welder support system that feeds back and improves the skill level.

  Under such circumstances, for example, with a conventional TIG manual welding work analyzer, the work time of the welder is measured, and the work points that should be managed to acquire skills by managing the time are clarified. Most of them measured efficiency.

  In order to improve the efficiency of welding work, Patent Document 1 is proposed in which a welded part is imaged with a camera and a technique for controlling welding line copying and welding conditions based on this knowledge information is fed back to the welder. Yes.

  Further, Patent Document 2 has been proposed in which the state of a weld pool is grasped based on a video signal of a welded portion, operation information necessary for welding is given, and displayed on a monitor screen.

Further, Patent Document 3 has been proposed which realizes a welding torch with a built-in visual sensor capable of detecting a situation of a welded portion, correcting a welding locus and welding conditions, and constructing a high-quality welded portion.
Japanese Patent No. 3322549 JP 2002-205166 A JP 2003-164971 A

  The analysis of the welding machine related to the welding technology during the construction is progressing with the development of automation of the welding machine, but the behavior analysis of the skilled welder when performing the manual welding is hardly advanced. In combination with the further promotion of automation of welding construction, in order to support the succession of skilled skills related to welding technology from the side, we analyze the behavior of skilled welders with a higher resolution than before, and improve them Therefore, it is necessary to construct a support system that enables even an inexperienced welder to easily understand and acquire complicated welding techniques, including feedback to the skilled welder himself.

  In general, in behavior analysis during welding by a skilled welder, a method of simultaneously detecting the three-dimensional position of a sensor previously mounted on the body surface using a medium such as magnetism or ultrasonic waves is known. .

  However, even if such a medium is used, it is difficult to perform a skill analysis of a skilled welder who sells the dexterity of the hand.

  Further, the above-disclosed patent document shows a configuration suitable for feature extraction specializing in automatic control applications of a welding machine in monitoring of welding work, and in manual welding, a welding machine operated by a skilled welder. The analysis of the amount controlled by the above, specifically, the feed amount of the filler rod in TIG manual welding has not been investigated.

  In addition, for example, in the case of MAG welding, the above-disclosed patent document discloses that even if the wire feed amount is monitored by the drive unit of the automatic wire feed mechanism, the wire feed amount corresponding to the change in the wire protrusion amount during the welding operation is monitored. The time variation of the salary is not measured.

  Moreover, since the surface of the filler rod is generally glossy uniformly, it is difficult to identify the amount of the filler rod fed from the image even if image processing is performed.

  In addition, in the case of an automatic welder, a wire feeding mechanism is provided, so if the feeding amount of the feeding driving device is monitored, the feeding amount of the filler rod to the molten pool can be measured. However, in manual welding, it is usually difficult to provide a mechanism for measuring the feed amount of the filler rod at hand because the operation of feeding the filler rod held in the left hand while carrying the torch held in the right hand is performed.

  Under these circumstances, in order to transfer the welding skills of a skilled welder to an inexperienced welder, knowledge information related to manual welding such as the behavior of the skilled welder and the feeding amount of the filler rod is imaged and imaged. It was necessary to digitally analyze and visualize the welding technique.

  The present invention has been made in view of such circumstances. For example, in TIG manual welding work, the welding rod feeding behavior of an experienced welder is visualized and visualized, and an experienced instructor or an inexperienced welder can The construction behavior based on the skill or skill of the skilled welder can be easily grasped, and the feeding rod feeding speed and feeding amount over time from the visualized image, the feeding rod feeding behavior Manual welding torch integrated monitoring applied to manual welding work analysis equipment and manual welding work analysis equipment that can quantitatively analyze and evaluate changes in the shape, size, etc. of the molten pool that change with the behavior of the torch bar The purpose is to provide a camera.

  In order to achieve the above-mentioned object, the manual welding work analysis apparatus according to the present invention is characterized in that, as described in claim 1, the surroundings of the molten pool during welding work taken with a monitoring camera installed around the manual welding work target. In a manual welding work analysis device that analyzes and processes image information, a manual welding machine integrated imaging device that integrally connects a surveillance camera to a manual welding torch, and image data recording that processes and records digital signals from the imaging device The apparatus includes a device, a data processing device that processes the recorded image as data, and a display device that displays the processed information.

  Moreover, in order to achieve the above-mentioned object, the surveillance camera according to the present invention has a pass band in a band away from the peak wavelength of the welding arc light. An optical filter is provided.

  Further, in order to achieve the above-described object, the manual welding operation analysis apparatus according to the present invention is, as described in claim 3, the manual welding machine integrated imaging apparatus is based on an image captured by a surveillance camera. When analyzing the behavior of a manual welding torch during welding, the position of the open tip contour line is detected from the change in the contrast of the arc light reflection intensity at the open tip of the weld base metal in the image, and the manual welding detected from the image The target position of the manual welding torch is converted with the tip position of the torch, and the analysis data of the torch carrying rod of the manual welding torch is obtained.

  Moreover, in order to achieve the above-described object, the manual welding operation analysis apparatus according to the present invention is a TIG based on an image captured by a surveillance camera. When welding analysis is performed, the welding rod is marked at regular intervals, the position of the marked welding rod inserted into the molten pool, the distance between the electrode tip of the manual welding torch and the molten pool, the welding rod It is configured to acquire data on the amount of feed.

  Moreover, in order to achieve the above-mentioned object, the manual welding operation analysis apparatus according to the present invention is such that, as described in claim 5, the marks given to the filler rod at regular intervals are thin along the circumferential direction. It is characterized by a sharpened constricted line.

  Moreover, in order to achieve the above-described object, the manual welding work analysis apparatus according to the present invention is a TIG welding based on an image captured by a surveillance camera. In the analysis, the contour shape of the molten pool is obtained from the difference between the reflection of the arc light on the molten pool surface and the reflection on the groove surface.

  In addition, the manual welding torch integrated surveillance camera applied to the manual welding operation analysis apparatus according to the present invention is a surveillance camera installed around the object of manual welding operation in order to achieve the above object. In a manual welding work analysis device that analyzes and processes image information around the weld pool during welding that was photographed with a camera, a manual welding machine integrated imaging device that integrally connects a surveillance camera to a manual welding torch, and from this imaging device An image data recording device that processes and records digital signals of an image, a data processing device that processes information as a recorded image, and a display device that displays the processed information. Includes an axial position adjustment slide for moving the monitoring camera relative to the manual welding torch, and a camera elevation adjustment slide for adjusting the camera elevation angle. It includes those were.

  The manual welding torch integrated monitoring camera applied to the manual welding operation analysis device and the manual welding analysis device according to the present invention images the behavior of the welder's hand during the construction work of manual welding, and the behavior from the captured image. Based on this data information, quantification of individual differences among multiple skilled welders, differences in movement with inexperienced welders, behavior in the process of specific individuals acquiring welding skills It is possible to easily realize analysis and consideration of skills for welding that has not been sufficiently analyzed and evaluated so far.

  In particular, since it is possible to extract and analyze and evaluate features that were previously difficult to evaluate, such as automatic evaluation of the feed amount of the filler rod in manual welding, many correction processes have been required manually. The processing procedure that had been used will be automated, so that analysis experience under various and diverse conditions and the analysis and comparison of work by many welders will be greatly streamlined.

  In addition, by making information on manual welding skills into data, it becomes possible to analyze and evaluate the essence of the skills in more detail than before, so it is possible to develop more advanced automatic welding technology using a different approach. It is possible to further contribute to the expansion of the application range of welding equipment by formulating an efficient training program and using data in the welding field where aging and labor shortages are a concern.

  Embodiments of a manual welding torch integrated surveillance camera applied to a manual welding work analysis apparatus and a manual welding work analysis apparatus according to the present invention will be described below with reference to the drawings and reference numerals attached to the drawings.

  FIG. 1 is a conceptual diagram showing an embodiment of a manual welding operation analysis apparatus according to the present invention.

  The manual welding operation analysis apparatus according to the present embodiment holds, for example, a hand welder-integrated imaging apparatus 1 that connects a CCD camera (CCD: charge coupled device) 2 to a manual welding torch 3 with a right hand, On the basis of the power supply device 6 provided to the manual welding torch 3 of the manual welding torch integrated imaging device 1 of the welder 5 holding the rod 4 with the left hand while controlling the current, and the current supplied from the power supply device 6 When the welding rod 4 is melted by arc heat from the manual welding torch 3 and welded to the welding base material 7, the CCD camera 2 images changes in the welding torch 3, the welding rod 4, or the molten pool, An image data recording device 8 that processes and records digital signals obtained by continuously converting captured images into frames, a data processing device 9 that processes the recorded images as data, and a display that displays the processed information. It is constituted by a device 10.

  As shown in FIG. 2, the manual welding machine-integrated imaging apparatus 1 includes an axial position adjustment slide unit that moves a CCD camera 2 connected to the manual welding torch 3 in the axial direction toward the electrode 11 of the manual welding torch 3. 12 and a camera elevation angle adjustment slide portion that can freely adjust the elevation angle of the CCD camera 2 so that the electrode 11 and the molten pool generated during welding are within the angle of view. 13, an axial position fixing screw portion 14 for setting the camera elevation angle adjustment slide portion 13 after moving in the axial direction, a camera elevation angle position fixing screw portion 15 for setting the position after the elevation angle adjustment of the CCD camera 2, and the CCD camera 2. Is set on the camera elevation angle adjusting slide unit 13 and the image captured by the CCD camera 2 is converted into a digital signal and sent to the image data recording device. And a cable 16.

  When imaging the electrode 11 or the like, the CCD camera 2 is set at a position where the extension of the axis intersects the electrode 11 of the manual welding torch 3 within the range of 5 mm to 20 mm.

  The CCD camera 2 includes a camera lens 17 that forms an image satisfactorily, and an optical filter 18 that restricts the intensity of light incident on the CCD surface and the frequency band of the camera lens 17.

  The optical filter 18 is provided in the CCD camera 2 by selecting an attenuation rate and a wavelength band as necessary according to the feature quantity to be analyzed.

  The optical filter 18 also has a pass band in a band far from the peak wavelength of the welding arc light, specifically, a wavelength band of 850 nm or more, or a narrow band with a half-value width of about 10 nm at 1064 nm. Applied.

  The optical filter 18 includes a wavelength-dependent neutralizing filter having partially different transmittance distributions, and a narrow band whose transmission wavelength is set in the infrared region and in a band away from the peak wavelength of the welding light. A clearer image is captured by combining the filter.

  Although the cable 16 is explicitly illustrated, in practice, the cable 16 is wired to the manual welding torch 3 at a position that does not hinder the field of view for monitoring the movement and construction state of the welding rod of the welder 5.

  The CCD camera 2 is installed in a direction that is the direction of manual welding as viewed from the manual welding torch 3, and the insertion position of the filler rod 4, the preceding distance of the molten pool, the electrode 11, the groove line of the welded portion, and the like. Is set to a position within the camera field of view.

  An example of the image of the welding execution state imaged with the CCD camera 2 set in such a position is shown in FIG.

  FIG. 3 shows, as an example, an image of groove cap welding of the first layer by TIG manual welding. The molten pool 20 and the electrode 11 at the peripheral position, the electrode tip 11a, the arc light 21, and the molten pool 20 are shown. The outline 4a of the filler bar 4 inserted in the projection is projected.

  Further, the groove edge line 22 located on both sides of the molten pool 20 is visually confirmed by the reflection of the arc light 21 with respect to the groove surface.

  Based on such an image, analysis of the manual welding construction work of the welder 5 and processing of feature extraction are performed.

  FIG. 4 is an example of information processed in the data processing apparatus 9 shown in FIG. 1, which is an extraction of a rod behavior called weaving of the manual welding torch 3, that is, a view from the groove center line of the welding base material 7. This is an algorithm for extracting the movement of the tip position of the manual welding torch.

  The algorithm according to the present embodiment includes an image extraction step (step 1), a straight edge component detection step (step 2), a groove edge line intersection point coordinate calculation step (step 3), and a groove centerline calculation step (step 4). , An image distance calculation step between the groove center line and the electrode tip (step 5), an actual size value conversion step (step 6) for converting an actual size value from the image, and a manual welding torch rod behavior evaluation step (step 7) It is configured.

  First, in the present embodiment, in the image extraction step (step 1), image extraction is performed for one frame of the peripheral image in the molten pool 20 continuously recorded in the data processing device 9 described above.

When the image around the weld pool 20 is extracted, in the linear edge component detection step (step 2), the CCD camera 2 is obtained in advance in the field of view of the CCD camera 2 with respect to fixing the installation position on the manual welding torch 3. Hand welding torch electrode tip coordinate (x 0 , y 0 ) and CCD camera 2 visual field midpoint (x c , y c ) (CCD camera optical axis line and manual welding torch center axis A vertical line Iv with respect to a straight line connecting the extended lines is set, and a line profile (luminance distribution) on the set vertical line Iv is obtained.

  On the other hand, it is considered that a straight line extending from the CCD camera visual field midpoint to the outer periphery of the visual field sequentially passes through the arc light 21, the molten pool 20, the groove processing surface (the reflected light of the arc light), and the surface of the welding base material 7. That is, it is expected that the profiles are in the order of “bright (light source)”, “dark”, “bright”, “dark”.

  At this time, the brightness is drastically reduced at the open tip corresponding to the boundary from the groove surface to the surface of the weld base material 7.

  For such a sharp reduction in luminance, the following analysis and processing are performed in the groove edge line intersection point coordinate calculation step (step 43).

First, the coordinates are obtained from the coordinates when the luminance is reduced and the coordinate points (x L , y L ), (x R , y R ) where the luminance gradient is negative and the absolute value of the gradient is maximum.

  In such a process, the coordinates of the luminance change are obtained even for a straight line parallel to the above-described normal line Iv, and the obtained coordinates are connected with straight lines in the left and right fields of view of the electrode 11 of the manual welding torch 3, and the open end edge is obtained. Two line segments corresponding to are detected.

Next, based on the X and Y coordinates of the CCD camera field of view, the intersection of the two detected line segments (the point at infinity in the CCD camera field of view) is obtained. Further, in the groove center line calculation step (step 44), the groove center line passes through the infinity point, so that the midpoint {(x L + x R ) / 2, a straight line connecting points corresponding to (y L + y R ) / 2}} is detected. The detected straight line is treated as a weld line (center line of the groove) on the image.

In the image distance calculation step (step 45) between the groove center line and the electrode tip, a distance D between the detected center line and the electrode tip is calculated.

  When the distance D is obtained in this way, in the actual size value conversion step (step 46) from the image, conversion from the image to the actual size value is performed. That is, a conversion factor F to an actual size value is calculated on the basis of the number of pixels of an object whose dimensions obtained on the image are known, for example, the thickness of the electrode, and this conversion factor F is used as the distance D between the center line and the electrode tip. By multiplying, the actual size value M is obtained from the following equation.

[Equation 2]
M = F × D
A series of continuous processes according to the above-described steps are calculated for each frame, and time-series data corresponding to the imaged time, for example, a certain time interval Δt is obtained. Based on this time-series data, the horizontal axis represents time, the vertical axis represents the actual size value M, and the result is plotted. The manual welding torch rod movement evaluation process (step 47).

  As described above, in the present embodiment, the torch handling rod is imaged by the manual welding machine integrated imaging device, the analysis is performed based on the image of the imaged manual welding torch handling rod, and the torch handling rod is evaluated by processing. Therefore, after confirming the behavior of the welder himself / herself, it can be used as data information for further advancement of the welding technology, and can contribute to the succession of the welding technology as educational material for inexperienced welders.

  In evaluating a manual work torch carrying rod, in order to perform the feature extraction and conversion process of the manual welding torch carrying rod easily and at high speed, some assumptions may be taken in consideration of shooting conditions. As this assumption, the requirement that “the CCD camera is in the vicinity of the groove center line axis and the same conversion coefficient is used in the actual size conversion of the left and right groove lines due to a large deviation” may be adopted.

  In addition, in order to perform highly accurate analysis and evaluation including measurement of welding speed in consideration of correction due to the inclination of the CCD camera position by acquiring a more local conversion factor, a constant (known) is provided on the base material groove surface. Marks such as straight lines and dots may be provided at intervals, and the actual dimensions may be converted from the intervals between the marks and the size (number of pixels) on the image.

  FIG. 5 is a flowchart for performing analysis processing of the feed amount of the filler rod in TIG manual welding.

  The filler bar 4 is marked in advance in order to evaluate the feeding amount at regular intervals. For this marking, for example, a constricted wire cut finely along the circumferential direction of the filler rod is used. When the constriction line is used as a marking, the reflectivity of the arc light 21 changes locally at the corner of the constriction line of the filler bar 4 in the welding rod ruled mark position coordinate detection step (step 1). A high melting rod 4 is imaged and detected.

  An image when welding is performed using the filler rod 4 with such marking is shown in FIG. In FIG. 6, the electrode tip (manual welding torch tip) and the filler rod axial line P are visualized by using the above-mentioned markings.

  Further, in FIG. 6, the detection of the tip position of the filler bar is performed by determining whether or not the filler bar is inserted in the molten pool. That is, in the state where the filler bar is not inserted, the extension of one groove side surface of the molten pool shape contour at the open tip draws a gentle curve, leading to the contour of the opposite groove side surface, Alternatively, the arc light is superimposed so that the brightness is high and the boundary is unclear. However, when the groove has a gap, the shape contour of the molten pool has a characteristic that a part of the shape contour line of the molten pool at the open tip becomes a sharp shape, the brightness of the contour is low, and the boundary is unclear. is there.

  On the other hand, when the molten rod is not inserted, the shape contour of the molten pool changes, the molten pool contour of the molten rod insertion portion contacts the rod of the molten rod, and the molten pool shape contour at the open tip Is not loose near the insertion part. For this reason, the molten pool locally rises at the contact portion between the molten pool and the filler rod, the sharpness of the contour is increased, and the brightness of the contour line is increased.

  Using such an event, in the welding rod tip position coordinate detection step (step 2), determination of success or failure of insertion of the welding rod into the molten pool and detection of the position of the welding rod tip are performed.

  In the line profile (luminance distribution) processing step (step 3), the line profile (luminance distribution) of the filler rod axial line P including the electrode tip position is obtained from the image shown in FIG.

In addition, in the image around the molten pool shown in FIG. 6, a region with high luminance due to the reflected light from the three ruled markings N 1 , N 2 , and N 3 is recognized on the surface of the filler bar. FIG. 7 shows the luminance distribution obtained from the tip of the manual welding torch to the position of the ruled markings N 1 , N 2 , N 3 along the filler rod axial line P shown in FIG. With the feeding of the filler rod, the filler rod is consumed as time passes, and the ruled markings N 1 , N 2 , N 3 appear at the farthest place in the image and move sequentially toward the molten pool, Finally, it overlaps with the position of the tip of the filler rod and disappears in the molten pool.

At this time, for each image, a distance Dw between the obtained melt bar tip position coordinates and the position coordinates of the ruled markings N 1 , N 2 , and N 3 is obtained, and is the same as the above-described manual welding torch rod. In addition, time series data is obtained. The obtained time series data is shown in FIG.

  In FIG. 8, a sawtooth-like farthest ruled mark detection position sudden change portion appears in the plotted data. This is because the welding rod is consumed as the manual welding progresses and the relative position of the ruled line changes. This is because new ruled markings appear sequentially from the edge of the video field of view.

  In order to evaluate the feeding amount of the filler bar, after converting the sawtooth plot into a linear plot corresponding to the actual feeding state of the filler rod, the length of the filler rod or its diameter is taken into consideration. A process of converting into the feed volume of the filler bar is required.

For this reason, in the feed amount integration processing step (step 4), the change amount of the adjacent image of the obtained distance Dw is obtained in the sawtooth plot described above, and this magnitude is attached to the filler rod on the image. A pixel amount I corresponding to the interval between the ruled markings N 1 , N 2 , and N 3 is obtained, and a value obtained by subtracting the pixel amount I from the distance Dw is calculated as the integrated distance Dwc.

  Since the number of subtracting the pixel amount I every time the detected ruled mark changes, the cumulative distance Dwc finally becomes a negative value, but the processing of all image frames to be analyzed is completed. At that time, the restart is taken as the origin, the slope is converted into positive and negative, and the process is performed again.

  The processing result obtained in the feed amount integration processing step (step 4) is shown in FIG.

  After the feed amount integration processing step (step 4) is completed, the consumed filler rod is converted to the actual size in the actual size conversion processing step (step 54).

  The feed rod feed speed is evaluated in the ruled line displacement fitting process (step 6) by dividing the entire data into the whole or part of the above-mentioned conversion data to the actual size of the melt rod and performing approximate calculation by straight line fitting. From the above, the inclination is obtained, and finally, the feeding amount and feeding speed of the filler rod are evaluated in the feeding rod feeding amount and speed evaluation step (step 7).

  As described above, in the present embodiment, the line profile (luminance distribution) of the filler rod is imaged by the manual welding machine integrated imaging device, and the image is analyzed and processed based on the imaged image of the line profile of the filler rod. Since it is configured to evaluate the feeding amount and speed of the filler rod, it can be used as data information for further leap of welding technology after confirming the behavior of welding itself, and training of inexperienced welders It can contribute to the succession of welding technology as data.

  FIG. 10 is a flowchart for performing the analysis process of the molten pool shape.

  The algorithm for analyzing and processing the molten pool shape according to the present embodiment includes a molten pool side surface contour detecting step (step 1), a superimposed portion contour estimating step (step 2), a molten pool area evaluating step (step 3), an actual size converting step ( Step 4) is provided.

  First, in the molten pool side surface contour detection step (step 1), the arc light reflectance on the molten pool surface is low and the reflectance on the groove surface is high. After obtaining the (luminance distribution) and tracing the luminance change from the tip of the electrode, an elliptical fit is applied to the obtained set of coordinate points, and a rough outline of the molten pool is detected.

  Further, in the molten pool side surface contour detection step (step 1), the contour of the side surface portion where the molten pool contacts the groove surface is detected based on the feeding position of the filler rod and the position of the electrode obtained in advance.

  The line profile on the line segment from the electrode tip position to the groove surface is “bright”, “dark”, “bright”, “bright” along the arc light, molten pool surface, bead surface, and groove side surface. In order, the outline of the molten pool is detected by threshold processing of the line profile change to “dark” and “light”.

  Based on the detected contour coordinate points, ellipse approximation is performed (overlapping portion contour detection step, step 2), and the area of the ellipse is obtained in the molten pool area evaluation step (step 3).

  When the area of the ellipse is obtained in the molten pool area evaluation step (step 3), the molten pool area on the image is converted to the actual size in the actual size conversion step (step 4) based on the obtained area of the ellipse. After conversion to the actual size, an evaluation of the molten pool area can be obtained without using information on the location hidden behind the electrodes and the filler rod.

  As described above, in the present embodiment, the line profile of the molten pool is imaged by the manual welder-integrated imaging device, and the shape of the molten pool is analyzed and processed based on the captured image of the molten pool line profile. Therefore, after confirming the behavior of the welder himself / herself, it can be used as data information for further progress of the welding technique, and can contribute to the succession of the welding technique as educational material for inexperienced welders.

The conceptual diagram which shows embodiment of the manual welding operation | movement analyzer which concerns on this invention. The conceptual diagram which shows the manual welding integrated imaging device applied to the manual welding operation | movement analyzer based on this invention. The image figure which shows the periphery of the molten pool imaged with the manual welding integrated imaging device applied to the manual welding operation | movement analyzer which concerns on this invention. The flowchart which shows the analysis process of the manual welding torch bar in the manual welding operation | movement analyzer which concerns on this invention. The flowchart which shows the feed amount analysis process of the filler rod in the manual welding operation | movement analyzer which concerns on this invention. The image figure which shows the line profile of the manual welding torch front-end | tip part and a filler rod in the manual welding operation | work analyzer which concerns on this invention. The diagram which shows the pixel brightness | luminance of the imaged filler bar in the manual welding operation | movement analyzer based on this invention. The diagram which shows after the actual size conversion of the distance between the tip of a filler bar and ruled-line markings in the manual welding operation analysis apparatus according to the present invention. FIG. 3 is a diagram showing a cumulative feed amount of the filler rod in the manual welding operation analyzer according to the present invention. The flowchart which shows the analysis process of the shape of a molten pool in the manual welding operation | movement analyzer which concerns on this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manual welding machine integrated imaging device 2 CCD camera 3 Manual welding torch 4 Filler rod 4a Outline 5 Welder 6 Power supply device 7 Welding base material 8 Image data recording device 9 Data processing device 10 Display device 11 Electrode 11a Electrode tip 12 Axial position adjustment slide part 13 Camera elevation angle adjustment slide part 14 Axial position fixing screw part 15 Camera elevation angle position fixing screw part 16 Cable 17 Camera lens 18 Optical filter 19 Camera position fixing part 20 Weld pool 21 Arc light 22 Groove edge line

Claims (7)

  1. In a manual welding work analysis device that analyzes and processes image information around the weld pool being welded, taken with a surveillance camera installed around the target of the manual welding work, a hand welder integrated type that connects the surveillance camera to the manual welding torch. An imaging device, an image data recording device that processes and records a digital signal of an image from the imaging device, a data processing device that processes the recorded image as data, and a display device that displays the processed information A manual welding operation analyzer characterized by that.
  2. 2. The manual welding operation analyzer according to claim 1, wherein the monitoring camera includes an optical filter having a pass band in a band away from the peak wavelength of the welding arc light.
  3. When analyzing the behavior of a manual welding torch during welding based on an image captured by a surveillance camera, the manual welding machine integrated imaging device is capable of measuring the contrast of the arc light reflection intensity at the open tip of the weld base metal in the image. The configuration is such that the position of the open tip contour line is detected from the change, the target position of the manual welding torch is converted from the tip position of the manual welding torch detected from the image, and the analysis data of the torch carrying rod of the manual welding torch is acquired. The manual welding operation analysis apparatus according to claim 1, wherein:
  4. When the TIG welding analysis is performed based on the image captured by the surveillance camera, the manual welder integrated imaging device marks the filler rod at regular intervals and inserts the marked filler rod into the molten pool 2. The manual welding operation analysis apparatus according to claim 1, wherein data of position, distance between the tip of the electrode of the manual welding torch and the molten pool, and feed amount of the filler rod are acquired.
  5. 5. The manual welding operation analysis apparatus according to claim 4, wherein the marks attached to the filler rod at regular intervals are constricted lines that are finely cut along the circumferential direction.
  6. When the TIG welding analysis is performed based on the image captured by the monitoring camera, the manual welding integrated imaging device acquires the contour shape of the molten pool from the difference between the reflection of the arc light on the surface of the molten pool and the reflection on the groove surface. The manual welding operation analysis apparatus according to claim 1, which is configured.
  7. In a manual welding work analysis device that analyzes and processes image information around the weld pool being welded, taken with a surveillance camera installed around the target of the manual welding work, a hand welder integrated type that connects the surveillance camera to the manual welding torch. An imaging device, an image data recording device that processes and records a digital signal of an image from the imaging device, a data processing device that processes the recorded image as data, and a display device that displays the processed information On the other hand, the hand welder integrated imaging device includes an axial position adjustment slide unit that moves the monitoring camera relative to the manual welding torch, and a camera elevation angle adjustment slide unit that adjusts the camera elevation angle. Surveillance camera integrated with a manual welding torch applied to a manual welding operation analyzer.
JP2005104443A 2005-03-31 2005-03-31 Hand welding analyzer and hand welding torch-integrated type monitoring camera applicable to the analyzer Pending JP2006281270A (en)

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