JP3398657B2 - Welding sensor - Google Patents
Welding sensorInfo
- Publication number
- JP3398657B2 JP3398657B2 JP2000312268A JP2000312268A JP3398657B2 JP 3398657 B2 JP3398657 B2 JP 3398657B2 JP 2000312268 A JP2000312268 A JP 2000312268A JP 2000312268 A JP2000312268 A JP 2000312268A JP 3398657 B2 JP3398657 B2 JP 3398657B2
- Authority
- JP
- Japan
- Prior art keywords
- welding
- image
- light
- imaging
- welding wire
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
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- Length Measuring Devices By Optical Means (AREA)
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、溶接中の溶接状態
を測定する溶接用センサに関し、特にアーク溶接におい
て開先断面および溶接ワイヤ先端部と溶融池を撮像して
得られる２次元画像に基づいて３次元位置を推定して溶
接制御するために使用する溶接用センサに関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a welding sensor for measuring a welding state during welding, and in particular, based on a two-dimensional image obtained by imaging a groove cross section, a welding wire tip and a molten pool in arc welding. The present invention relates to a welding sensor used to estimate a three-dimensional position and control welding.
【０００２】[0002]
【従来の技術】従来から、溶接部を撮影してモニターし
たり画像解析して溶接制御する方法が開発されてきた。
たとえば、特開平８−２７６２７１には、溶接トーチの
斜め前方に設けた１台のカメラを用いて開先位置計測と
溶接ワイヤ先端の位置計測をし、これにより開先倣い溶
接する方法が開示されている。この方法は、溶接電流を
低下させてアーク光を弱めた時にレーザ光切断像を取得
して開先位置計測に用いることにより、溶接部の近くの
開先状態を把握して溶接倣いを行おうとするものであ
る。この方法では、溶接開始点における溶接ワイヤ先端
位置と溶接開始直後におけるアーク光画像の重心点位置
との差を初期設定値とし、撮像した溶接アーク光の重心
点位置を初期設定値で補正して溶接ワイヤの先端位置を
求めている。2. Description of the Related Art Conventionally, a method of controlling welding by photographing and monitoring a welded portion or analyzing an image has been developed.
For example, Japanese Unexamined Patent Publication No. 8-276271 discloses a method of measuring the groove position and the position of the tip of the welding wire by using one camera provided obliquely in front of the welding torch, and thereby performing the groove profile welding. ing. In this method, when the welding current is reduced and the arc light is weakened, a laser beam cutting image is acquired and used for measuring the groove position, so that the groove state near the welded part is grasped and the welding profile is attempted. To do. In this method, the difference between the position of the welding wire tip at the welding start point and the position of the center of gravity of the arc light image immediately after the start of welding is set as the initial setting value, and the position of the center of gravity of the captured welding arc light is corrected by the initial setting value. We are looking for the tip position of the welding wire.
【０００３】また、特開平１０−０９４８７２に、アー
ク溶接の近傍をテレビカメラで撮影し、得られる画像信
号を用いて自動溶接機を開先倣い制御する方法が開示さ
れている。この方法は、溶接ワイヤや開先が基準位置に
あるときの撮影画面についてウインドウを設定してお
き、現在の撮影画面中にこのウインドウと相関が強い部
分を検出して現在の溶接ワイヤと開先の相対位置を見出
すようにしたものである。照明光やアーク光が変化して
も正確に位置を検出することができ、良好な開先倣いを
行うことができるとされる。Further, Japanese Patent Application Laid-Open No. 10-094872 discloses a method of photographing the vicinity of arc welding with a television camera and using an image signal obtained to control the groove welding of an automatic welding machine. With this method, a window is set for the shooting screen when the welding wire or groove is at the reference position, and the part with a strong correlation with this window is detected in the current shooting screen to detect the current welding wire and groove. The relative position of is to be found. It is said that even if the illumination light or the arc light changes, the position can be accurately detected, and good groove copying can be performed.
【０００４】しかし、特開平８−２７６２７１に開示さ
れた方法では、溶接ワイヤの先端位置を初期設定値に基
づいて補正して求めるため、溶接中に条件変化があれば
位置が不正確になり、またアーク光画像の重心位置に基
づいて推定するため、溶接アーク光の状態に左右されて
正確な位置を確定することが困難である。また、特開平
１０−０９４８７２に開示された方法では、２次元画面
中に現れた相対的位置関係しか明らかにならないので、
現実の３次元空間における正確な位置を知ることができ
ない。さらに、上記従来技術には、溶融状態に基づいて
溶接条件を制御する技術的思想を示唆するものがない。However, in the method disclosed in Japanese Unexamined Patent Publication No. 8-276271, since the tip position of the welding wire is obtained by correcting it based on the initial set value, if the condition changes during welding, the position becomes inaccurate. Further, since the estimation is performed based on the position of the center of gravity of the arc light image, it is difficult to determine an accurate position depending on the state of the welding arc light. Further, since the method disclosed in Japanese Patent Laid-Open No. 10-094872 only reveals the relative positional relationship that appears in the two-dimensional screen,
It is not possible to know the exact position in the actual three-dimensional space. Furthermore, none of the above-mentioned conventional techniques suggests the technical idea of controlling the welding conditions based on the molten state.
【０００５】[0005]
【発明が解決しようとする課題】そこで、本発明が解決
しようとする課題は、アーク溶接中の溶接ワイヤ先端位
置、溶融池など溶接部位の３次元位置をより正確に推定
し、開先との正確な位置関係を把握する溶接用センサを
提供し、また、開先線に適正に倣ってアーク溶接を行
い、また溶融池の状態を把握して溶接条件の調整を行う
ために利用できる溶接用センサを提供することである。Therefore, the problem to be solved by the present invention is to more accurately estimate the three-dimensional position of the welding wire tip position and the weld pool such as the molten pool during arc welding, and Welding sensors that can be used to provide a welding sensor that accurately grasps the positional relationship, perform arc welding properly following the groove line, and grasp the state of the weld pool to adjust welding conditions It is to provide a sensor.
【０００６】[0006]
【課題を解決するための手段】上記課題を解決するた
め、本発明の溶接用センサは、溶接トーチに対して溶接
の進行方向前方にレーザ投光器と撮像機構、この撮像機
構に加えて画像処理機構を含む撮像装置、さらに演算装
置を備え、レーザ投光器を用いて溶接進行方向前方の溶
接部に光切断像を形成し、撮像装置により溶接トーチか
ら延出した溶接ワイヤと溶融池とを含む溶接部および溶
接部の前に位置する光切断像が１つの画面に写し込まれ
た画像をリアルタイムで取得し、演算装置が溶接トーチ
とレーザ光の空間位置情報および取得した画像の情報を
用いて光切断像と溶接ワイヤの空間位置を求めることを
特徴とする。In order to solve the above-mentioned problems, the welding sensor of the present invention comprises a laser projector and an image pickup mechanism in front of the welding torch in the welding advancing direction, and an image processing mechanism in addition to this image pickup mechanism. An image pickup device including an imaging device and a computing device, a laser floodlight is used to form a light-section image in a welding part in the front direction of welding, and a welding part including a welding wire and a molten pool extended from a welding torch by the imaging device. And an image in which a light-section image in front of the welded part is displayed on one screen is acquired in real time, and the arithmetic unit uses the welding torch and the spatial position information of the laser light and the information of the acquired image to perform the light-section. The feature is that the spatial position of the image and the welding wire is obtained.
【０００７】本発明の溶接用センサによれば、撮像装置
により取得した画像情報に溶接トーチやレーザ光の実際
の位置情報を加味して溶接ワイヤ先端位置や開先位置を
推定するため、それぞれの位置を３次元位置情報として
正確に把握することができる。従って、従来技術より精
度の高い開先倣い制御を行うことができる。また、溶融
池の正確な位置と形状を把握することができるので、溶
接ワイヤの位置制御ばかりでなく、溶接条件の調整に用
いることも可能である。さらに、溶接部の手前における
開先の状態をモニターすることができるため、溶接条件
の変更にある程度の時間が必要な場合にも十分調整が可
能である。According to the welding sensor of the present invention, the tip position and the groove position of the welding wire are estimated by adding the actual position information of the welding torch and laser light to the image information acquired by the image pickup device. The position can be accurately grasped as three-dimensional position information. Therefore, it is possible to perform groove tracking control with higher accuracy than in the conventional technique. Further, since the accurate position and shape of the molten pool can be grasped, it can be used not only for controlling the position of the welding wire but also for adjusting welding conditions. Further, since it is possible to monitor the state of the groove in front of the welded portion, it is possible to make sufficient adjustment even when it takes some time to change the welding conditions.
【０００８】なお、本発明における撮像装置は、画面中
の光切断像領域と溶接部分領域に対応して異なる透過特
性を有するフィルタを備えてもよい。溶接部分における
発光は、溶接ワイヤ先端付近のアーク光とアークを囲む
溶融池の熱放射光であり、遠赤外領域の光が多く含まれ
る。一方、光切断像を形成するレーザ光の波長は適当に
選択することができる。そこで、レーザ光として、アー
クの周囲に広がる溶融池が大量に発する遠赤外領域の光
より短いレーザ光を選択し、撮像機構において光切断像
を写し込む入射光線が通過する部分にレーザ光の波長領
域を透過するバンドパスフィルタを置くと、撮像機構に
より取得する溶接画像中の光切断像の部分がより鮮明に
現れるようになる。The image pickup apparatus according to the present invention may be provided with a filter having different transmission characteristics corresponding to the light section image area and the welded area in the screen. The light emission at the welded portion is the arc light near the tip of the welding wire and the thermal radiation light of the molten pool surrounding the arc, and includes much light in the far infrared region. On the other hand, the wavelength of the laser light that forms the light section image can be appropriately selected. Therefore, as the laser beam, select a laser beam that is shorter than the light in the far-infrared region that a large amount of molten pool spreading around the arc emits, and the laser beam is transmitted to the portion through which the incident light beam that captures the light-cut image in the imaging mechanism passes. If a band-pass filter that transmits the wavelength region is placed, the portion of the light section image in the welding image acquired by the imaging mechanism will appear more clearly.
【０００９】レーザ光源として、たとえば６８０ｎｍか
ら８３０ｎｍの波長範囲のレーザ光を発生するレーザダ
イオードを利用することができる。特にアーク光の波長
が７００ｎｍ付近の成分を多く含むことから、７８０ｎ
ｍから８３０ｎｍの波長範囲内のレーザダイオードを利
用することが好ましい。なお、溶融池を写し込む位置に
は遠赤外線以外をカットする遠赤外パスフィルタを設け
ることが好ましい。また、減光フィルタを設けてもよ
い。このように簡単な光学要素を用いて画像信号を変成
することにより、画像処理機構の処理アルゴリズムを効
果的に単純化することができる。As the laser light source, for example, a laser diode which emits laser light in the wavelength range of 680 nm to 830 nm can be used. Especially since the wavelength of the arc light contains many components near 700 nm,
It is preferred to utilize laser diodes in the wavelength range from m to 830 nm. A far-infrared pass filter that cuts off other than far-infrared rays is preferably provided at the position where the molten pool is imaged. Further, a neutral density filter may be provided. By transforming the image signal using such simple optical elements, the processing algorithm of the image processing mechanism can be effectively simplified.
【００１０】また、本発明の溶接用センサは、撮像機構
で取得した画像に基づいて撮像画面中の溶接ワイヤの先
端位置および光切断像の特徴点それぞれの２次元座標値
を求め、２次元座標値それぞれと撮像装置の光学中心を
結ぶ各直線を算出し、溶接ワイヤ先端位置と結ぶ直線と
溶接トーチの軸が含まれる面の交点を用いて溶接ワイヤ
先端の３次元位置を算出することにより溶接位置と溶融
池位置を推定し、光切断像の特徴点と光学中心を結ぶ直
線とレーザ光走査面との交点を用いて特徴点の３次元位
置を算出することにより開先位置を推定するようにする
ことができる。Further, the welding sensor of the present invention obtains the two-dimensional coordinate values of the tip position of the welding wire and the characteristic points of the light-section image on the image pickup screen based on the image acquired by the image pickup mechanism. Welding by calculating each straight line connecting each value and the optical center of the imaging device, and calculating the three-dimensional position of the welding wire tip using the intersection of the line connecting the welding wire tip position and the surface including the axis of the welding torch Position and weld pool position are estimated, and the groove position is estimated by calculating the three-dimensional position of the feature point using the intersection of the straight line connecting the feature point of the light section image and the optical center and the laser light scanning surface. Can be
【００１１】特に、撮像画面中の２次元位置Ｍ（ｍ1，
ｍ2）と空間における３次元位置Ｒ（ｒ1，ｒ2，ｒ3）が
αを媒介変数として６点以上の既知点の撮像結果に基づ
いて算出されたカメラパラメータＣ（ｃij（ただしｉ＝
１〜３，ｊ＝１〜４））により関連付けられていること
を利用して溶接ワイヤ先端あるいは光切断像特徴点と撮
像装置の主点を結ぶ直線を算出する場合は、数学的裏付
けを持ってより正確にそれぞれの３次元位置を求めるこ
とができる。In particular, the two-dimensional position M (m 1 ,
m 2) and the three-dimensional position in space R (r 1, r 2, r 3) are camera parameters are calculated based on the imaging of the known point of six or more as a parametric result α C (c ij (where i =
1 to 3, j = 1 to 4)) are used to calculate the straight line connecting the welding wire tip or the optical cutting image feature point and the principal point of the image pickup device, there is mathematical support. It is possible to obtain each three-dimensional position more accurately.
【００１２】本発明の溶接用センサによれば、アーク溶
接中の溶接部位と開先特徴点の３次元位置をより正確に
推定し、また溶接位置前方の開先状態を把握できるの
で、開先線に適正に倣ったアーク溶接制御、また溶融池
の状態に基づいた溶接条件調整を行うことができる。According to the welding sensor of the present invention, it is possible to more accurately estimate the three-dimensional positions of the welding site and the groove feature point during arc welding, and to grasp the groove state in front of the welding position. It is possible to perform arc welding control properly following the line and adjust welding conditions based on the state of the molten pool.
【００１３】[0013]
【発明の実施の形態】以下、本発明に係る溶接用センサ
の実施の形態を、図面を用い実施例に基づいて詳細に説
明する。図１は本実施例の部品配置を説明する構成図、
図２は取得される画像を説明する図面、図３は本実施例
の溶接用センサにより特徴点の３次元座標を求める手順
を説明する流れ図である。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a welding sensor according to the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a block diagram for explaining the arrangement of parts in this embodiment,
FIG. 2 is a drawing for explaining the acquired image, and FIG. 3 is a flow chart for explaining the procedure for obtaining the three-dimensional coordinates of the feature points by the welding sensor of this embodiment.
【００１４】本実施例は、図中右方向に進行する溶接方
向に対して溶接トーチ２１の前方から撮像する溶接用セ
ンサである。溶接用センサは、レーザ投光器１、撮像機
構３と画像処置機構５を備える撮像装置、および演算装
置７からなり、レーザ投光器１と撮像機構３は溶接トー
チに対して固定されている。溶接トーチ２１の中心軸に
沿って溶接ワイヤ２３が延出して先端と被溶接物の間に
溶接アークを形成し、被溶接物が局所的に溶けて溶融池
２５を形成する。This embodiment is a welding sensor for picking up an image from the front of the welding torch 21 with respect to the welding direction proceeding to the right in the figure. The welding sensor includes a laser projector 1, an image pickup device having an image pickup mechanism 3 and an image treatment mechanism 5, and an arithmetic unit 7. The laser projector 1 and the image pickup mechanism 3 are fixed to a welding torch. The welding wire 23 extends along the central axis of the welding torch 21 to form a welding arc between the tip and the object to be welded, and the object to be welded is locally melted to form the molten pool 25.
【００１５】レーザ投光器１は、開先１５に垂直な平面
１７内にレーザを走査して開先表面で反射させ、表面形
状を光切断像１９として得る装置で、溶接トーチ２１の
僅か前方を照射する。なお、光切断像を形成するレーザ
光はスリット光であってもよい。また、撮像機構３は、
ＣＣＤカメラやＩＴＶカメラなど、映像中の対象物位置
が撮像面１３に固定された２次元座標系により表現でき
るものを利用する。なお撮像機構３には光学系１１と撮
像面１３が組み込まれており、光学系１１により撮像面
１３に開先の光切断像１９と溶接ワイヤ２３と溶融池２
５を結像する。撮影対象物とその像は光学中心を通る直
線で結ぶことができる。The laser projector 1 is a device that scans a laser in a plane 17 perpendicular to the groove 15 and reflects it on the groove surface to obtain a surface profile as a light-section image 19. The laser projector 1 irradiates just before the welding torch 21. To do. The laser light forming the light-section image may be slit light. In addition, the imaging mechanism 3
A camera such as a CCD camera or an ITV camera that can represent the position of the object in the image by a two-dimensional coordinate system fixed on the image pickup surface 13 is used. An optical system 11 and an image pickup surface 13 are incorporated in the image pickup mechanism 3, and the optical system 11 causes the image pickup surface 13 to have a light-cut image 19 of a groove, a welding wire 23, and a molten pool 2.
Image 5 The object to be photographed and its image can be connected by a straight line passing through the optical center.
【００１６】なお、溶融池の部分は遠赤外領域の光を強
く放射するので、光切断像がこれらと区別しやすいよう
に光切断用レーザ光はより短波長の領域の光を使用す
る。そこで、画像信号として両者が簡単に区別でき、特
に光切断像が明確に撮影できるように、それぞれに適合
して光波長特性が異なる透過特性を有するフィルタ９を
備えるようにしてもよい。Since the portion of the molten pool strongly radiates light in the far infrared region, the laser light for light cutting uses light in a shorter wavelength region so that the light cutting image can be easily distinguished from these. Therefore, in order that the both can be easily distinguished as the image signal, and in particular, the light-section image can be clearly photographed, a filter 9 having a transmission characteristic different in light wavelength characteristic may be provided for each of them.
【００１７】フィルタ９を備える場合は、撮像機構３の
映像出力をモニタで観察すると、図２のモニタ画面２９
に示すように、フィルタ９の遠赤外光を透過する遠赤外
パスフィルタ３１の部分には溶接アークと溶融池２５に
対応する部分が、照射するレーザ光の波長領域を透過す
るバンドパスフィルタ３３の部分には光切断像１９が観
察されるように割り付けるようにする。このようなフィ
ルタはそれぞれの特性を有するものを別々に配置し位置
調整して使用してもよいし、それぞれを上下に接合した
１枚の分割フィルタを境界位置が溶融池と必要な開先部
分の光切断像の間に来るように調整して使用してもよ
い。また、このフィルタ９は光学系１１と撮像面１３の
間に設置してもよい。なお、それぞれ特性の異なるフィ
ルタを配したカメラを２台設け、これらカメラの取得し
た画像を合成して用いてもよい。また、溶融池の部分に
対応するフィルタは、単なる減光フィルタでもよく、あ
るいは遠赤外パスフィルタと減光フィルタを併用しても
よい。さらに、カメラの絞り機構を活用すれば、フィル
タが無くても良い。When the image output of the image pickup mechanism 3 is observed on the monitor when the filter 9 is provided, the monitor screen 29 shown in FIG.
As shown in FIG. 7, the portion of the far infrared pass filter 31 of the filter 9 that transmits the far infrared light is a band pass filter in which the portion corresponding to the welding arc and the molten pool 25 transmits the wavelength region of the laser light to be irradiated. The portion 33 is arranged so that the light section image 19 can be observed. Such filters may be used by arranging filters with their respective characteristics separately and adjusting their positions. Alternatively, one divided filter in which each filter is joined vertically is used as the boundary position where the boundary is the molten pool and the required groove part. You may adjust and use so that it may come between the light section images. The filter 9 may be installed between the optical system 11 and the image pickup surface 13. It is also possible to provide two cameras each having a filter having a different characteristic and synthesize images obtained by these cameras. Further, the filter corresponding to the molten pool portion may be a simple neutral density filter, or may be a combination of a far infrared pass filter and a neutral density filter. Further, if the diaphragm mechanism of the camera is utilized, the filter may be omitted.
【００１８】モニタ画面２９中には、輝度の高いアーク
光や溶融池２５の映像と、短波長色の光切断像が共に明
瞭に現れている。なお、バンドパスフィルタ３３の輪郭
を光切断像の形状に合わせた凹みを持たせて、その凹み
部分に溶融池が侵入できるようにすると、溶融池と開先
光切断像の間の距離が極めて小さい場合にも、両者いず
れも明瞭な映像として１枚の画面に映し込むことができ
る。In the monitor screen 29, both the arc light with high brightness and the image of the molten pool 25 and the light section image of the short wavelength color are clearly shown. If the contour of the bandpass filter 33 has a dent adapted to the shape of the light section image so that the molten pool can enter the dent, the distance between the molten pool and the groove light section image becomes extremely large. Even if they are small, both of them can be projected on one screen as clear images.
【００１９】画像処理装置５は、撮像面１３に結像した
画像に基づく映像信号を入力して所定のアルゴリズムに
従って解析し、溶接ワイヤ先端や開先接合線など映像中
の特徴点を抽出して画面中の２次元位置として特定す
る。このような特徴点の抽出は既に一般的になっている
各種技術を活用すればよい。The image processing device 5 inputs a video signal based on the image formed on the image pickup surface 13 and analyzes it according to a predetermined algorithm to extract characteristic points in the video such as a welding wire tip and a groove joining line. It is specified as a two-dimensional position on the screen. Extraction of such feature points may be performed by utilizing various techniques that are already popular.
【００２０】演算装置７は、画像処理装置５から解析結
果を入力して撮像面に投影された溶接ワイヤ２３の先端
位置や開先の光切断像における特徴点などの２次元位置
と光学中心を結ぶ直線の方程式を求める。さらに、これ
ら直線の方程式と、予め求めてある溶接ワイヤ２３の軸
が含まれる面２７やレーザ照射面１７との交点として溶
接ワイヤ先端や特徴点の３次元座標値、すなわち実態と
しての空間位置座標を求める。物体座標系は任意に定め
ることができるが、自動溶接装置などを用いる場合は、
溶接ロボットを含む溶接台車の軌道に平行なＺ軸を持つ
座標系や、アクチュエータの軸を基準にした座標系を設
定することが好ましい。The arithmetic unit 7 inputs the analysis result from the image processing unit 5 and determines the two-dimensional position and the optical center of the tip position of the welding wire 23 projected on the image pickup surface or the feature point in the light section image of the groove. Find the equation of the connecting straight line. Furthermore, the three-dimensional coordinate values of the tip of the welding wire or the characteristic points, that is, the actual spatial position coordinates, as the intersections of these straight line equations and the surface 27 including the axis of the welding wire 23 and the laser irradiation surface 17 which have been obtained in advance. Ask for. The object coordinate system can be set arbitrarily, but when using an automatic welding device,
It is preferable to set a coordinate system having a Z axis parallel to the trajectory of the welding carriage including the welding robot or a coordinate system based on the axis of the actuator.
【００２１】撮像座標と光学中心を結ぶ直線は、同次座
標系を用いた線形化手法に基づいて導出されたカメラパ
ラメータを使って行う座標変換法により求める。上記座
標変換法は、本願出願人が出願した特願平１１−１６６
６９６号に詳細に説明されているので、ここでは簡単に
説明する。撮像機構における光学的関係から、焦点距離
ｆの光学系により空間中のある測定点Ｐ（ｘ，ｙ，ｚ）
を結像面に投影した点Ｐ’（ｘc，ｙc，ｚc）は、下式
（１）で与えられる。なお、光学軸をＺ軸とした。A straight line connecting the image pickup coordinates and the optical center is obtained by a coordinate conversion method using camera parameters derived based on a linearization method using a homogeneous coordinate system. The coordinate conversion method is described in Japanese Patent Application No. 11-166 filed by the applicant of the present application.
Since it is described in detail in No. 696, a brief description will be given here. Due to the optical relationship in the imaging mechanism, a certain measurement point P (x, y, z) in space is obtained by the optical system with the focal length f.
A point P ′ (x c , y c , z c ) obtained by projecting the image on the image plane is given by the following equation (1). The optical axis is the Z axis.
【数２】
ここで、ｚc＝０である。また、α＝ｆ／（ｆ＋ｚ）と
なる。[Equation 2] Here, z c = 0. Further, α = f / (f + z).
【００２２】さらに、媒介変数Ｗhを加えて３次元の点
（ｘ，ｙ，ｚ）を４次元の点（ｘh，ｙh，ｚh，ｗh）で
表し同次座標系を用いて線形化すると、座標変換は下式
（２）の行列演算で記述することができる。ここで、ｘ
＝ｘh／ｗh，ｙ＝ｙh／ｗh，ｚ＝ｚh／ｗhである。ま
た、（ｘ，ｙ，ｚ，１）は同次座標系表現における物体
点Ｐの座標、（ｘch，ｙch，ｚch，ｗch）は撮像面上の
投影点Ｐ’の座標である。Furthermore, parametric W h were added 3-dimensional point with (x, y, z) of the four-dimensional point (x h, y h, z h, w h) the homogeneous coordinate system expressed in When linearized, the coordinate transformation can be described by the matrix operation of the following equation (2). Where x
= X h / w h, y = y h / w h, it is z = z h / w h. Further, (x, y, z, 1) is the coordinate of the object point P in the homogeneous coordinate system representation, and (x ch , y ch , z ch , w ch ) is the coordinate of the projection point P ′ on the imaging surface. .
【数３】 [Equation 3]
【００２３】ロボットやアクチュエータなどの移動軌道
と関連付けられた物体座標系と撮像座標系を関係付ける
座標変換Ｔは、同次座標系表現では回転と平行移動を含
めて下式（３）で表される。The coordinate transformation T relating the object coordinate system associated with the moving trajectory of the robot or actuator to the image pickup coordinate system is expressed by the following equation (3) including rotation and translation in the homogeneous coordinate system expression. It
【数４】 [Equation 4]
【００２４】したがって、物体座標系での点Ｐから撮像
座標系での点Ｐ’への変換は下式（４）で表すことがで
きる。Therefore, the conversion from the point P in the object coordinate system to the point P'in the image pickup coordinate system can be expressed by the following equation (4).
【数５】 [Equation 5]
【００２５】撮像座標系における撮像面では常にｚch＝
０なので、撮像面における像の２次元位置Ｍ（ｍ1，
ｍ2）と空間における３次元位置Ｒ（ｒ1，ｒ2，ｒ3）の
変換を表わす下式（５）が得られる。なお、αは媒介変
数に相当する。On the image pickup plane in the image pickup coordinate system, z ch =
Since it is 0, the two-dimensional position M (m 1 , m 1 ,
m 2 ) and the following equation (5) representing the transformation of the three-dimensional position R (r 1 , r 2 , r 3 ) in space are obtained. Note that α corresponds to a parameter.
【数６】 [Equation 6]
【００２６】この係数行列は位置、姿勢、画角などカメ
ラに関するデータを全て含みカメラの視線を表現するも
ので、この係数を一般にカメラパラメータと呼ぶ。特定
点の撮像面上の２次元座標とその物体座標系上の３次元
座標を上式（５）に適用することにより両者を結ぶ直線
で交わる２枚の平面の方程式が得られる。カメラパラメ
ータの各係数は、レンズの焦点距離やカメラの位置や姿
勢の実測値から求めることもできるが、形状や位置が既
知の基準となる物体を利用し、これを撮像装置で計測し
た結果を用いてキャリブレーションすることが実用的で
ある。This coefficient matrix expresses the line of sight of the camera including all data relating to the camera such as position, orientation and angle of view, and this coefficient is generally called a camera parameter. By applying the two-dimensional coordinates of the specific point on the imaging surface and the three-dimensional coordinates of the object coordinate system thereof to the above equation (5), an equation of two planes intersecting with a straight line connecting the two can be obtained. Although each coefficient of the camera parameter can be obtained from the measured value of the focal length of the lens and the position and orientation of the camera, an object that is a reference whose shape and position are known is used, and the result measured by the imaging device is used. It is practical to use and calibrate.
【００２７】物体座標系上の基準点（ｒ1，ｒ2，ｒ3）
と撮像面上の対応する位置（ｍ1，ｍ 2）を１組与えれ
ば、２個の方程式が得られる。カメラパラメータは１２
個の要素を有するので、互いに独立した６個以上の基準
点を用いてカメラパラメータの係数を求めることができ
る。このようにして求めたカメラパラメータにより、撮
像面上の映像の位置に基づいて溶接ワイヤ先端や開先上
の特徴点などを見通す視線の式が求められる。Reference point (r1, R2, R3)
And the corresponding position (m1, M 2) Give me a pair
For example, two equations are obtained. The camera parameter is 12
Since it has 4 elements, 6 or more standards independent of each other
You can use the points to find the coefficients of the camera parameters.
It With the camera parameters obtained in this way,
Based on the position of the image on the image plane, on the welding wire tip or groove
A line-of-sight expression that looks through the feature points of is required.
【００２８】また、溶接ワイヤ２３は溶接トーチ２１の
軸に沿って真っ直ぐに突出する場合が多く、上記の視線
が溶接トーチの軸を含む面２７に当たる点が溶接ワイヤ
先端位置である可能性が高い。溶接トーチ軸を含む面２
７を物体座標系上に形状方程式として表しておけば、視
線との交点は数学的に算出することができ、溶接ワイヤ
２３先端位置の３次元座標は容易に求めることができ
る。また、溶接ワイヤ先端の周囲に広がる溶融池２５の
位置も同時に求まることになる。In many cases, the welding wire 23 projects straight along the axis of the welding torch 21, and the point where the above line of sight hits the surface 27 including the axis of the welding torch is likely to be the welding wire tip position. . Surface 2 including welding torch axis
If 7 is represented as a shape equation on the object coordinate system, the intersection with the line of sight can be calculated mathematically, and the three-dimensional coordinates of the tip position of the welding wire 23 can be easily obtained. Further, the position of the molten pool 25 spreading around the tip of the welding wire is also obtained at the same time.
【００２９】さらに、開先の光切断像１９は、レーザ投
光器１から面状に照射されるレーザ光により形成される
から、レーザ光走査面１７を表す形状方程式を求めてお
いて、開先上の特徴点を見通す視線の方程式との交点を
算出することにより、特徴点の３次元座標は容易に求め
ることができる。Furthermore, since the light-cut image 19 of the groove is formed by the laser light emitted from the laser projector 1 in a plane shape, the shape equation representing the laser light scanning surface 17 is obtained and the groove top is obtained. The three-dimensional coordinates of the feature point can be easily obtained by calculating the intersection with the equation of the line of sight that sees through the feature point.
【００３０】本実施例の溶接用センサを用いて、撮像面
２１内に写し込まれた溶接トーチ、溶接ワイヤ、溶融
池、開先などの３次元位置を、図３に示す手順により求
めて、開先倣い制御や溶接条件調整など溶接制御に使用
することができる。Using the welding sensor of this embodiment, the three-dimensional positions of the welding torch, welding wire, weld pool, groove, etc., which are imaged in the image pickup surface 21, are obtained by the procedure shown in FIG. It can be used for welding control such as groove profile control and welding condition adjustment.
【００３１】すなわち、
溶接ロボットなどを搭載する溶接台車が走行する際に
利用する３次元の物体座標系を定める（Ｓ１）。
溶接ワイヤが含まれる平面、レーザ光走査面、溶接ト
ーチ筐体の特定表面など、画面に含まれる物体の形状を
その物体座標系上で表現する形状方程式を確定する（Ｓ
２）。
溶接部位の撮像面における２次元撮像座標系と３次元
物体座標系との変換パラメータ、すなわちカメラパラメ
ータを算定する（Ｓ３）。That is, a three-dimensional object coordinate system used when a welding carriage equipped with a welding robot or the like travels is determined (S1). A shape equation expressing the shape of the object included in the screen on the object coordinate system, such as the plane including the welding wire, the laser light scanning surface, the specific surface of the welding torch housing, is determined (S
2). A conversion parameter between the two-dimensional imaging coordinate system and the three-dimensional object coordinate system on the imaging surface of the welding site, that is, a camera parameter is calculated (S3).
【００３２】このような準備を行った上で溶接中の溶接
部位を溶接進行方向前方から撮影して、
撮像用カメラで取得した画像中で溶接トーチ、溶接ワ
イヤ、開先などの特徴点を抽出し、その特徴点の２次元
撮像座標系上の座標を求める（Ｓ４）。
特徴点の撮像座標値にカメラパラメータを作用させ
て、光学中心とその特徴点を結ぶ直線の方程式を求める
（Ｓ５）。
各特徴点について、それが含まれる面の形状方程式と
視線方程式の交点として対象点の３次元物体座標系上の
座標値を算出する（Ｓ６）。After making such preparations, the welding site during welding is photographed from the front in the welding advancing direction, and characteristic points such as the welding torch, welding wire, and groove are extracted from the image acquired by the imaging camera. Then, the coordinates of the feature point on the two-dimensional imaging coordinate system are obtained (S4). A camera parameter is applied to the image-capturing coordinate value of the characteristic point to obtain an equation of a straight line connecting the optical center and the characteristic point (S5). For each feature point, the coordinate value of the target point on the three-dimensional object coordinate system is calculated as the intersection of the shape equation and the line-of-sight equation of the surface in which it is included (S6).
【００３３】本実施例の溶接用センサは、上記手順によ
り、溶接中の溶接ワイヤ２３先端と開先１９の位置を正
確に推定して３次元座標値として出力することができ
る。この出力情報を自動溶接装置で利用することによ
り、従来のように溶接トーチの位置で代用して倣い制御
するのではなく、溶接ワイヤの先端位置と開先位置を物
体座標系上に正確に指定して溶接位置制御することがで
きる。また、本実施例の溶接用センサは、開先の光切断
像を溶接進行方向手前に形成して、両者を１枚の撮像面
内に撮影するので、溶接位置が観察された開先に到達す
る前に必要な動作を行うことができる。The welding sensor of the present embodiment can accurately estimate the positions of the tip of the welding wire 23 and the groove 19 during welding by the above procedure and output them as three-dimensional coordinate values. By using this output information in an automatic welding device, the tip position and groove position of the welding wire can be specified accurately on the object coordinate system, instead of using the position of the welding torch as a substitute for copy control as in the past. Then, the welding position can be controlled. Further, the welding sensor of the present embodiment forms the optical cutting image of the groove in front of the welding advancing direction and photographs both of them in the single imaging plane, so that the welding position reaches the observed groove. You can take the necessary actions before you do so.
【００３４】なお、溶接ワイヤの突き出し長が変化した
ときでも精密な開先倣い溶接制御を行うことができる。
また、巻き癖などの影響で溶接ワイヤが曲がり、実際の
溶接ワイヤが溶接トーチの軸からずれた場合にも、溶接
トーチ軸が属する平面の上に位置するときの溶接ワイヤ
と実際の溶接ワイヤの見かけのワイヤ径の差に基づいて
位置ずれ量を算出して、正しい溶接ワイヤ先端位置を推
定することができる。また、溶接用センサで測定された
実際の開先幅が予定されたウィービング幅と異なる場合
には、溶接ワイヤがその位置に到達する前にウィービン
グ幅を調整することができる。Even when the protrusion length of the welding wire changes, precise groove-following welding control can be performed.
In addition, even if the welding wire bends due to the influence of curl and the actual welding wire deviates from the axis of the welding torch, the welding wire and the actual welding wire when positioned on the plane to which the welding torch axis belongs It is possible to estimate the correct welding wire tip position by calculating the positional deviation amount based on the apparent difference in wire diameter. Also, if the actual groove width measured by the welding sensor is different from the expected weaving width, the weaving width can be adjusted before the welding wire reaches that position.
【００３５】なお、溶融池の大きさや輝度により溶融状
態を推定することができるが、本実施例の溶接用センサ
では、１枚のモニタ画面中に溶融池とその溶接進行方向
手前における開先の光切断像が一緒に写っているため、
溶融池が観察した開先位置まで到達する時刻を見計らっ
て溶接条件を調整することができる。たとえば、溶接ワ
イヤと光切断像との間を３０ｍｍとすれば、溶接速度が
１０ｍｍ／ｓのときには溶接条件の調整に３秒間の余裕
がある。Although the molten state can be estimated by the size and brightness of the molten pool, the welding sensor of this embodiment displays the molten pool and the groove in front of the welding advancing direction in one monitor screen. Since the light section image is shown together,
The welding conditions can be adjusted by observing the time when the molten pool reaches the observed groove position. For example, if the distance between the welding wire and the light section image is 30 mm, there is a margin of 3 seconds for adjusting the welding conditions when the welding speed is 10 mm / s.
【００３６】なお、上記実施例では、撮像機構に１台の
カメラを用いたが、複数のカメラを用いてそれぞれの対
象を同時に撮影して、それぞれの映像出力を合成して利
用することもできる。この方法によれば、絞りや色感度
あるいはフィルタなど、対象それぞれに最適な撮影条件
を設定することができる。In the above embodiment, one camera is used as the image pickup mechanism. However, it is also possible to use a plurality of cameras to simultaneously photograph the respective objects and synthesize the respective video outputs. . According to this method, it is possible to set the optimum shooting conditions for each target such as the aperture, color sensitivity, or filter.
【００３７】[0037]
【発明の効果】以上説明した通り、本発明の溶接用セン
サを用いれば、溶接中の溶接ワイヤ先端と溶融池をこれ
から溶接すべき開先位置が１枚の画面中にリアルタイム
で写し込まれるので、これを利用して溶接条件の調整や
正確な開先倣い制御を行って、品質の高い溶接をするこ
とができる。As described above, when the welding sensor of the present invention is used, the welding wire tip during welding and the groove position to be welded from the weld pool are imprinted on one screen in real time. Using this, it is possible to perform welding with high quality by adjusting welding conditions and performing accurate groove tracking control.
【図１】本発明の溶接用センサの１実施例における部品
配置を説明する構成図である。FIG. 1 is a configuration diagram illustrating a component arrangement in an embodiment of a welding sensor of the present invention.
【図２】本実施例の溶接用センサで取得される画像を説
明する図面である。FIG. 2 is a diagram illustrating an image acquired by the welding sensor according to the present embodiment.
【図３】本実施例の溶接用センサにより特徴点の３次元
座標を求める手順を説明する流れ図である。FIG. 3 is a flowchart illustrating a procedure for obtaining three-dimensional coordinates of feature points by the welding sensor according to the present embodiment.
１ 溶接トーチ ３ 撮像機構 ５ 画像処理装置 ７ 演算装置 ９ フィルタ １１ 光学系 １３ 撮像面 １５ 開先 １７ レーザ光走査面 １９ 光切断像 ２１ 溶接トーチ ２３ 溶接ワイヤ ２５ 溶融池 ２７ 溶接トーチ軸を含む平面 ２９ モニタ画面 ３１ 減光フィルタ部 ３３ バンドパスフィルタ部 1 welding torch 3 Imaging mechanism 5 Image processing device 7 arithmetic unit 9 filters 11 Optical system 13 Imaging surface 15 groove 17 Laser light scanning surface 19 Light section image 21 welding torch 23 Welding wire 25 molten pool 27 Plane including welding torch axis 29 Monitor screen 31 Dark filter section 33 Bandpass filter section
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B23K 9/095 B23K 9/127 G01B 11/00 ─────────────────────────────────────────────────── ─── Continuation of the front page (58) Fields surveyed (Int.Cl. 7 , DB name) B23K 9/095 B23K 9/127 G01B 11/00
Claims (4)
にレーザ投光器と、同じく溶接進行方向前方に備えた撮
像機構と画像処理機構を含む撮像装置と、演算装置を備
えて、前記レーザ投光器により溶接進行方向前方の溶接
部に光切断像を形成し、前記撮像装置により前記溶接ト
ーチから延出した溶接ワイヤと溶融池とを含む溶接部お
よび該溶接部の前に位置する前記光切断像が１つの画面
に写し込まれた画像をリアルタイムで取得し、前記演算
装置が前記撮像機構を基準とする前記溶接トーチと前記
レーザ光の実際の空間位置情報および前記画像の情報を
用いて、前記光切断像と溶接ワイヤの現実の３次元空間
における位置を求めることを特徴とする溶接用センサ。1. A laser projector including a laser projector in front of the welding torch in the direction of welding progress, an imaging device including an imaging mechanism and an image processing mechanism also provided in the front of the welding progress, and an arithmetic unit. A light cut image is formed in the weld portion in the front of the welding progress direction, and the light cut image located in front of the weld portion including the welding wire and the molten pool extended from the welding torch by the imaging device is located in front of the weld portion. The image captured on one screen is acquired in real time, and the computing device uses the welding torch with the imaging mechanism as a reference, the actual spatial position information of the laser light, and the information of the image to obtain the light. Real three-dimensional space of cutting image and welding wire
Welding sensor and obtains the position of.
断像の領域と溶接部分の領域に対応して異なる透過特性
を有するフィルタを備えたことを特徴とする請求項１記
載の溶接用センサ。2. The welding sensor according to claim 1, further comprising a filter having different transmission characteristics corresponding to a region of the light section image and a region of a welded portion which are projected on a screen of the image pickup device. .
した画像に基づいて撮像画面中の前記溶接トーチから延
出した溶接ワイヤの先端位置および前記光切断像の特徴
点それぞれの２次元座標値を求め、前記演算装置が、該
２次元座標値それぞれと前記撮像装置の光学中心を結ぶ
各直線を算出し、前記溶接ワイヤ先端位置と結ぶ直線と
前記溶接トーチの軸が含まれる面の交点を用いて前記溶
接ワイヤ先端の３次元位置を算出することにより溶接位
置および溶融池位置を推定し、前記光切断像特徴点と前
記光学中心を結ぶ直線と前記レーザ投光器のレーザ光走
査面との交点を用いて前記特徴点の３次元位置を算出す
ることにより開先位置を推定することを特徴とする請求
項１または２記載の溶接用センサ。3. The two-dimensional coordinate values of the tip position of the welding wire extended from the welding torch in the imaging screen and the characteristic points of the light-section image based on the image acquired by the imaging mechanism by the image processing mechanism. The computing device calculates each straight line connecting each of the two-dimensional coordinate values and the optical center of the image pickup device, and calculates an intersection of the straight line connecting the welding wire tip position and the surface including the axis of the welding torch. The welding position and the weld pool position are estimated by calculating the three-dimensional position of the welding wire tip using the intersection point of the straight line connecting the optical cutting image feature point and the optical center and the laser light scanning surface of the laser projector. The welding sensor according to claim 1 or 2, wherein the groove position is estimated by calculating a three-dimensional position of the feature point using.
るいは前記光切断像特徴点の撮像画面中の２次元位置Ｍ
（ｍ1，ｍ2）と空間における３次元位置Ｒ（ｒ1，ｒ2，
ｒ3）がαを媒介変数として６点以上の既知点の撮像結
果に基づいて算出されたカメラパラメータＣ（ｃij（た
だしｉ＝１〜３，ｊ＝１〜４））により下式で関連付け
られていることを利用して前記溶接ワイヤ先端あるいは
前記特徴点と撮像装置の主点を結ぶ直線を算出すること
を特徴とする請求項１から３のいずれかに記載の溶接位
置計測装置。 【数１】 4. The two-dimensional position M in the imaging screen of the tip of the welding wire or the characteristic point of the light section image is calculated by the arithmetic unit.
(M 1 , m 2 ) and the three-dimensional position R (r 1 , r 2 ,
r 3 ) is associated with the following equation by the camera parameter C (c ij (where i = 1 to 3, j = 1 to 4)) calculated based on the imaging result of 6 or more known points with α as a parameter. The welding position measuring device according to any one of claims 1 to 3, wherein a straight line connecting the tip of the welding wire or the characteristic point and the principal point of the imaging device is calculated by utilizing the fact that the welding position is measured. [Equation 1]
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000312268A JP3398657B2 (en) | 2000-10-12 | 2000-10-12 | Welding sensor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000312268A JP3398657B2 (en) | 2000-10-12 | 2000-10-12 | Welding sensor |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2002120066A JP2002120066A (en) | 2002-04-23 |
| JP3398657B2 true JP3398657B2 (en) | 2003-04-21 |
Family
ID=18791897
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2000312268A Expired - Fee Related JP3398657B2 (en) | 2000-10-12 | 2000-10-12 | Welding sensor |
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| Country | Link |
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| JP (1) | JP3398657B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105479029A (en) * | 2015-12-30 | 2016-04-13 | 中北大学 | Automatic tracking and monitoring system of direct welding machine |
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| US6977357B2 (en) * | 2003-07-09 | 2005-12-20 | Lincoln Global, Inc. | Welding wire positioning system |
| WO2005100910A1 (en) * | 2004-04-09 | 2005-10-27 | Techno Dream 21 Co., Ltd. | Three-dimensional shape measuring method and its equipment |
| AT502283B1 (en) * | 2005-07-15 | 2007-05-15 | Fronius Int Gmbh | WELDING PROCESS AND WELDING SYSTEM DETERMINING THE POSITION OF THE WELDING BURNER |
| JP4783834B2 (en) * | 2009-01-13 | 2011-09-28 | 川崎重工業株式会社 | Groove measurement system |
| WO2011102142A1 (en) * | 2010-02-18 | 2011-08-25 | 株式会社 東芝 | Welding device and welding method |
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| JP5338890B2 (en) | 2011-12-15 | 2013-11-13 | Ｊｆｅスチール株式会社 | Laser welding welding position detection apparatus and welding position detection method |
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-
2000
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105479029A (en) * | 2015-12-30 | 2016-04-13 | 中北大学 | Automatic tracking and monitoring system of direct welding machine |
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| Publication number | Publication date |
|---|---|
| JP2002120066A (en) | 2002-04-23 |
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