TWI574003B - Device for detecting a three-dimensional image of welds and method for detecting the same - Google Patents

Description

Weld bead three-dimensional image detecting device and detecting method thereof

The invention relates to a three-dimensional image detecting device for a bead and a detecting method thereof, in particular to a three-dimensional image detecting device for a bead which can quickly and accurately determine the quality of a bead from the appearance of a bead and a detecting method thereof.

According to the welding, the application in the fields of construction, automobile, aerospace and machinery industry is very extensive. However, in the welding construction, the quality of the weldment is poor due to factors such as negligence, unskilled technology or incorrect operation procedures. The quality of the good quality will seriously affect the strength and safety of the structure. Therefore, after the welding is completed, it is necessary to further pass the detection method to perform defect detection on the weld bead of the weldment to ensure the quality of the weldment.

At present, the commonly used methods for detecting welding defects include ultrasonic detection, measuring dynamic resistance or measuring electrical impedance function. Please refer to the "Method and Test System for Weld Defect Detection" of China No. I325496, which is mainly after welding. And a weldment to be tested electrically connected to the two electrodes is continuously connected to the alternating current, and an analog current signal and a analog voltage signal are measured between the electrodes for a predetermined time, and then the analog current signal and the analogy are respectively converted. The voltage signal is a digital current function and a digital voltage function, and then the digital current function and the digital voltage function are respectively converted into a complex current function and a complex voltage function. Then, dividing the complex voltage function by the complex current function to obtain an electrical impedance function, The electrical impedance function is converted to an electrical impedance waveform to indicate a weld bead defect of the weldment to be tested. However, the "Method and Test System for Weld Defect Detection" of the No. I325496 of China can detect the weld bead defects of the welded parts, but the detection and calculation process is too cumbersome. Visual inspection is straightforward and quick.

The strength of the weldment can be known from the appearance of the weld bead, the appearance of the bad weld bead, the stress concentration will weaken the strength of the weldment, and the shape of the weld bead will reduce the cross-sectional area of the weld bead, resulting in damage to the weldment, and too The raised bead shape produces a large concentrated stress, reducing fatigue life and the like. The American Welding Society has more clearly listed the appearance of the fillet welds of various fillet welds. Please refer to Figure 6 and sort out two good products, two acceptable and six defective products. The shape of the bead is shown in (a) and (b) as the ideal fillet weld profile, while those shown in (c) and (d) are acceptable fillet weld profiles. e) ~ Figure (j) shows the appearance of the weld bead of the six defective products, which are in the form of appearances such as insufficient throat depth, over-bending of the weld bead, welding, overlap, insufficient length of the foot and insufficient welding. However, although the appearance inspection method of the weld bead is extremely simple and has clear specifications to be followed, the existing visual inspection is mainly based on the use of the weld bead sample gauge. The specimen gauge is only energy-measured at a very short length, so the segmentation amount is obtained. Testing, but not fast and comprehensive testing, and using personal experience to judge the quality of the weld bead, it is easy to cause detection errors and non-objectivity and other missing.

Therefore, the present inventors have many of the above-mentioned shortcomings in the implementation of the existing weld bead appearance detection methods, and have been assisted by many years of ingenuity in research and design experience and knowledge. invention.

The invention relates to a bead three-dimensional image detecting device and a detecting method thereof, and the main purpose thereof is to provide a bead three-dimensional image detecting device capable of quickly and accurately determining the quality of a bead from the appearance of a bead and a detecting method thereof.

In order to achieve the above-mentioned implementation, the inventors have developed the following three-dimensional image detecting device for a bead, comprising: a mobile unit having a horizontal moving component, the horizontal moving component comprising a straight track, and the straight track A pedestal is arranged on the top, and a track wheel is arranged at the bottom of the pedestal to connect the track wheel with the straight track, and the track wheel is provided with a displacement power source and moves in the horizontal direction. The component is provided with a vertical moving component, and the vertical moving component is set with a height adjusting power source, and the vertical moving component is provided with a working platform; an image capturing unit is disposed on the working platform. The invention comprises a horizontal rotating component, a vertical rotating component and a camera, wherein the horizontal rotating component is assembled with the working table, and the vertical rotating component is assembled on the horizontal rotating component, and The camera assembly is disposed on the vertical rotating component, and the horizontal rotating component and the vertical rotating component are respectively connected with an angle adjuster; a pattern projection unit is provided a feature projection component, and an infrared light source is disposed adjacent to the feature projection component, and the pattern projection unit is coupled to the mobile unit; a control unit mainly includes a microprocessor, an operation and a display, and a data storage component. And the operation and display device and the data storage component are coupled to the microprocessor, and the data storage component stores a detection program module, the detection program module includes at least a cloud processing program and a CAD software program, and The data storage component stores the shape of the weld bead of the American Society of Welding Society, and the control unit is one of wired or wireless, and the displacement power source and the vertical moving component of the horizontal moving component of the mobile unit. The height adjustment power source, the camera of the image capturing unit and the angle adjuster of the horizontal rotation component and the vertical rotation component, and the infrared light source of the pattern projection unit are connected.

The three-dimensional image detecting device for a bead as described above, wherein the vertical moving component of the moving unit is a vertical rod vertically disposed on the base, and the vertical rod is composed of an inner tube and an outer tube sleeve, and The height adjustment power source is disposed between the inner tube and the outer tube, and the bottom end of the outer tube of the pole is assembled to the base, and the upper end of the inner tube is provided with the table.

The three-dimensional image detecting device of the bead according to the above aspect, wherein the horizontally rotating component of the image capturing unit comprises a first frame, and the first frame is coupled to the first pivot, and the first a pivotal shaft is vertically pivoted to the table, and the first pivot end is provided with the angle adjuster, and the vertical rotating component comprises a second frame, so that the second frame is provided Between the first frame body, the second frame body and the first frame body are pivotally connected by a second pivot horizontally, and the second pivot end portion is provided with the angle adjuster, and The camera is assembled on the second frame.

The bead three-dimensional image detecting device as described above, wherein the camera is provided with a left lens and a right lens.

The bead three-dimensional image detecting device as described above, wherein the pattern projection unit is disposed on a table of the moving unit.

The inventor further develops the following method for detecting the three-dimensional image of the bead. The implementation steps include: A. Fixed point adjustment: the mobile unit is driven by the control unit before a certain point to set a group of images set on the mobile unit. The camera is adjusted to the position where the steel member to be inspected and its bead are photographed; B. feature pattern projection: following the control unit driving a pattern projection unit whose infrared light source emits infrared rays to transmit features through its characteristic projection unit a pattern projected onto the steel member and its weld bead; C. Moving Photographic Lens: Continued by the control unit to drive the image capturing unit set on the mobile unit to travel, and move the camera mode by time difference, so that the lens of the camera is continuously segmented along the steel member and its bead. Multiple overlapping images of angles; D. Triangulation calculus: the multiple overlapping images captured by the camera are calculated by the microprocessor of the control unit to calculate the three-dimensional depth by triangulation, and to capture two adjacent images at different times, using patterns The projection unit projects the image of the infrared characteristic pattern to calculate the baseline, and calculates the distance; E. Image sorting and feature point detection: the image of the steel member and its bead image is imaged by the microprocessor of the control unit. Corresponding to the feature points, find the basic matrix between the corresponding ones to establish the matching relationship between the images; F. Reconstruct the three-dimensional point cloud model of the bead: the matching between the images by the microprocessor of the control unit Or regional similarity matching, constructing the three-dimensional point cloud data of the steel member and its weld bead; G. Comparison of the dimensions of the bead appearance: continued use of the microprocessor of the control unit The bead profile is reconstructed from the weld bead section, and the weld bead appearance is detected by the bead 3D point cloud data, and compared with the shape of the inner weld of the American Welding Society (AWS) specification to detect the weld bead. The welding quality of the weld bead is good or bad.

The three-dimensional image detecting method for the bead as described above, wherein the step of reconstructing the three-dimensional point cloud model of the bead is further processed by the point cloud data to reduce the point cloud data and smooth the point cloud data, and filter the noise point and The point cloud data coordinates are re-formed, and then the bead appearance size comparison step is performed.

The method for detecting a three-dimensional image of a bead as described above, wherein in the step of moving the photographing lens, the lens of the camera is imaged by the front, back, and up and down angles of the steel member and the bead thereof.

In the method of detecting a three-dimensional image of a bead as described above, in the step of moving the photographic lens, it is preferable that at least 50% of each of the images overlap with the adjacent image.

(1)‧‧‧Mobile units

(11) ‧ ‧ straight track

(12) ‧ ‧ pedestal

(121)‧‧‧ Track wheel

(122)‧‧‧ Displacement power source

(13) ‧‧‧ pole

(131) ‧ ‧ inner management

(132)‧‧‧External management

(14) ‧‧‧ Workbench

(2) ‧‧‧Image capture unit

(21)‧‧‧First frame

(22)‧‧‧First pivot

(23) ‧‧‧Second frame

(24) ‧‧‧Second pivot

(25)‧‧‧Angle adjuster

(26)‧‧‧Camera

(261)‧‧‧ lens

(3) ‧‧‧ pattern projection unit

(31)‧‧‧Feature projection parts

(4) ‧‧‧Control unit

(41)‧‧‧Microprocessor

(42)‧‧‧Operation & Display

(43) ‧‧‧Data storage components

(5) ‧‧‧Steel components

(51)‧‧‧weld

First picture: perspective view of the invention

Second figure: flow chart of the present invention

Third: Schematic diagram of image scanning imaging of the present invention

Fourth picture: schematic diagram of three-dimensional point cloud triangulation of image scanning of the present invention

Figure 5: Sectional view of the CAD construction weld bead of the present invention

Figure 6: Existing American Welding Society (AWS) fillet welds

In order to make the technical means of the present invention and the effects thereof can be more completely and clearly disclosed, the details are as follows. Please refer to the disclosed drawings and drawings: First, please refer to the first figure. The present invention is a three-dimensional image detecting device for a bead of the present invention, which is mainly composed of a mobile unit (1), an image capturing unit (2), a pattern projection unit (3) and a control unit (4); wherein: the mobile unit (1) comprising a horizontal moving component, the horizontal moving component comprising a straight track (11), and a base (12) disposed above the straight track (11), and the base (12) A rail wheel (121) is arranged on both sides of the bottom portion, so that the rail wheel (121) is coupled with the straight rail (11), and the rail wheel (121) is provided with a displacement power source (122). A vertical moving component is disposed, the vertical moving component is a vertical pole (13) vertically disposed on the base (12), and the vertical pole (13) is composed of an inner tube (131) and an outer tube (132) The sleeve is composed of a height-adjusting power source between the inner tube (131) and the outer tube (132). So that the upright (13) can be adjusted up and down, and the bottom end of the outer tube (132) of the upright (13) is assembled on the base (12), and the upper end of the inner tube (131) The department has a workbench (14); The image capturing unit (2) is disposed on the working table (14) and includes a horizontal rotating component and a vertical rotating component, wherein the horizontal rotating component comprises a first frame (21), and The first frame body (21) and the table (14) are vertically pivoted with the first pivot (22) so that the first frame body (21) can be rotated horizontally relative to the table (14). And providing an angle adjuster to the end of the first pivot (22), and the vertical rotating component is further disposed between the first frame (21), the vertical rotating component includes a second frame a body (23), and the second frame body (23) and the first frame body (21) are horizontally pivoted with the second pivot (24) so that the second frame body (22) is relatively a frame body (21) is rotated in a vertical direction, and an angle adjuster (25) is disposed at an end portion of the second pivot shaft (24) through which the second frame body (23) is disposed, and the second frame body is further disposed (23) The upper group is provided with a camera (26), which can be an infrared camera (26) or a digital camera, and the camera (26) is provided with left and right lenses (261); The pattern projection unit (3) is disposed on the table (14) and spaced apart from the image capturing unit (2) by a feature projection member (31), and the feature projection member (31) An infrared light source is disposed adjacent to the infrared light source, and the infrared light source (26) is projected by the infrared light source to project the feature projection member (31) on the weld bead (51) of the steel member (5) to be measured; The control unit (4) can be a computer or a mobile phone, etc., and includes a microprocessor (41), an operation and display (42), and a data storage component (43), and the operation and display (42) and Data storage component (43) and the microprocessor (41) Coupled in the data storage component (43), the detection program module stores at least a cloud processing program and a CAD software program, and the US data storage component (43) stores the US The shape information of the weld bead specified by the American Welding Society, and the displacement power source of the control unit (4), which is wired or wireless, and the track unit (1) of the mobile unit (1) (122), the height adjustment power source of the vertical pole (13), the camera (26) of the image capturing unit (2), and the first pivot (22) and the second pivot (24) end assembly The angle adjuster (25) and the pattern projection unit (3) are connected by an infrared light source or the like.

Accordingly, when the bead three-dimensional image detecting device of the present invention performs the detection of the weld bead (51) defect of the steel member (5), the straight track (11) of the moving unit (1) is set to be the steel member to be inspected. (5) The weld bead (51) is parallel to each other, and then the control unit (4) controls the moving unit (1), the image capturing unit (2) and the pattern projection unit (3) to perform the appearance of the bead (51). Scanning measurement, and program analysis and bead (51) comparison operations, the implementation steps are included, please refer to the second figure: A. Fixed point adjustment: the control unit is before a certain point (4) The microprocessor (41) adjusts the telescopic height of the upright (13) of the moving unit (1), and adjusts the vertical rotation and the horizontal rotation angle of the camera (26) of the image capturing unit (2), To enable the camera (26) to capture the position of the steel member (5) and its weld bead (51) to be inspected; B. Feature pattern projection: Please refer to the third figure, followed by the control unit (4) The pattern projection unit (3) emits infrared rays from the infrared light source to project a point or line feature pattern through the feature projection member (31) to display the feature map Projecting the steel member (5) and the bead (51); C. Moving Photographic Lens: Continued operation of the mobile unit (1) by the control unit (4) to operate the displacement power source (122) at the track wheel (121) to drive the group to the mobile unit (1) The image capturing unit (2) on the base (12) travels on the straight track (11) and moves the camera (26) with a time difference so that the camera (26) has its left and right lenses (261) along the steel member ( 5) and the bead (51) draws multiple overlapping images of different angles in a continuous segment, and each image and the adjacent image overlap at least 50% is optimal; D. Triangulation calculus: Please refer to the fourth figure together, the multiple overlapping images captured by the camera (26) are transmitted to the control unit (4) to be controlled by the microprocessor of the control unit (4). 41) The detection program module calculates the three-dimensional depth by triangulation, and extracts the two adjacent images at different times, calculates the baseline by using the image of the infrared characteristic pattern projected by the pattern projection unit (3), and calculates the distance; E. Image sorting and feature point detection: the microprocessor (41) of the control unit (4) performs image sorting by the captured steel component (5) and its weld bead (51) image through the detection program module. And corresponding to the feature points, find the basic matrix between the corresponding ones to establish a matching relationship between the images; F. Reconstructing the bead 3D point cloud model: The microprocessor (41) of the control unit (4) reconstructs the steel component (5) and its bead (51) 3D point cloud model through the detection program module, and passes the image. The three-dimensional point cloud data of the steel member (5) and its bead (51) are constructed by feature matching or regional similarity matching; G. Point cloud data processing: following the microprocessor (41) of the control unit (4) through the detection program module for point cloud data reduction and point cloud data smoothing, noise point filtering and point cloud data coordinate reorganization Waiting for work; H. Appearance size comparison of the bead: Please refer to the fifth figure as shown in the figure. Continued by the microprocessor (41) of the control unit (4) through the test program module, the weld bead (51) is sectioned to reconstruct The bead (51) curved surface is then subjected to the appearance inspection of the bead (51) by the bead (51) three-dimensional point cloud data, and the shape information of the weld bead of the American Welding Society (AWS) specification stored with the data storage component (43). The comparison (as shown in the sixth figure) is to achieve the effect of detecting the quality of the weld bead (51).

Therefore, the present invention uses the 3D image scanning technology to introduce a feature projection component (31), and directly projects the feature pattern of the feature projection component (31) on the steel component (5) through the infrared ray, by pairing from the camera (26). The steel member (5) takes continuous image data, performs surface profile measurement of the bead (51), and uses the image capturing unit (2) to mount the first frame (21) and the first part on the table (14) The two frames (23) can be rotated vertically and horizontally with respect to the table (14) to perform continuous image scanning at different angles, and the upper and lower telescopic adjustment poles of the moving unit (1) (13), to perform a video scan on the upper and lower trajectories of the weld bead (51) of the steel member (5), and the image recognition scan is different from the steel member (5) and the weld bead (51). Depth, that is, the steel member (5) and its bead (51) are scanned in the next section, and the moving unit (1) is placed in parallel with the steel member (5) and its bead (51). Straight track (11), along the steel member (5), continuously carry out multiple images of steel members (5) and their weld bead (51) at different angles before, after and up and down. (51) the overall three-dimensional point cloud information. Following this, the surface image data of the weld bead (51) will be measured, and the 3D point cloud coordinate data conversion and pre-processing will be performed. The point cloud data on the surface of the weld bead (51) obtained by the measurement is the first point cloud data. Pre-processing, for point cloud data reduction and point cloud data smoothing, noise point filtering and point cloud data coordinate reorganization, etc., and then establish a cross-section numerical model of the bead (51) according to the set spacing. The numerical data is used to construct the CAD model of the weld bead (51). Subsequently, the appearance of the weld bead (51) obtained by measurement is measured, and the weld bead (51) surface is reconstructed by the weld bead (51) section technique, and then The microprocessor (41) according to the American Welding Society (AWS) welding specification, compares the superior and inferior shape and size, to determine the quality of the weld bead (51), and set the base material portion by the equidistant cross-section point cloud data. The surface portion of the road (51) and the root of the weld bead (51) are determined according to the American Welding Society (AWS) specification to determine the qualified and unqualified parts of the appearance of the weld bead (51), and the base material portion is displayed on the CAD software. Qualified weld bead (51) and unqualified weld bead (51), and calculate the volume change and standard deviation analysis. The result can be systematically and quickly judged the effect of the appearance and quality of the entire weld bead (51).

The foregoing embodiments or drawings are not intended to limit the three-dimensional image detecting device of the bead of the present invention and the method for detecting the same, and any suitable changes or modifications of those skilled in the art should be considered as not departing from the present invention. The patent field of the bead 3D image detecting device and its detecting method.

In summary, the embodiments of the present invention can achieve the expected functions, and the specific structures disclosed therein have not been seen in the same products, nor have they been disclosed before the application, and have fully complied with the provisions of the Patent Law. It is required that if an application for a patent for invention is filed in accordance with the law, and if the application is granted, the patent will be granted.

(1)‧‧‧Mobile units

(11) ‧ ‧ straight track

(12) ‧ ‧ pedestal

(121)‧‧‧ Track wheel

(122)‧‧‧ Displacement power source

(13) ‧‧‧ pole

(131) ‧ ‧ inner management

(132)‧‧‧External management

(14) ‧‧‧ Workbench

(2) ‧‧‧Image capture unit

(21)‧‧‧First frame

(22)‧‧‧First pivot

(23) ‧‧‧Second frame

(24) ‧‧‧Second pivot

(25)‧‧‧Angle adjuster

(26)‧‧‧Camera

(261)‧‧‧ lens

(3) ‧‧‧ pattern projection unit

(31)‧‧‧Feature projection parts

(4) ‧‧‧Control unit

(41)‧‧‧Microprocessor

(42)‧‧‧Operation & Display

(43) ‧‧‧Data storage components

(5) ‧‧‧Steel components

(51)‧‧‧weld

Claims (9)

A bead three-dimensional image detecting device comprises: a moving unit, which is provided with a horizontal moving component, the horizontal moving component comprises a straight track, and a base is arranged above the straight track, and at the bottom of the base The track wheel is arranged to connect the track wheel to the straight track, and the track wheel is provided with a displacement power source, and the vertical moving component is set on the horizontal moving component, and The vertical moving component is provided with a height adjusting power source, and the vertical moving component is provided with a worktable; an image capturing unit is disposed on the working platform, and includes a horizontal rotating component and a vertical rotation The component and the camera are arranged such that the horizontal rotating component is assembled with the working table, and the vertical rotating component is assembled on the horizontal rotating component, and the camera is assembled on the vertical rotating component. And the horizontal rotating component and the vertical rotating component are respectively connected with an angle adjuster; a pattern projection unit is provided with a characteristic projection component, and the feature projection component is An infrared light source is disposed, and the pattern projection unit is coupled to the mobile unit; a control unit mainly includes a microprocessor, an operation and display, and a data storage component, and the operation and display and data storage component are The microprocessor is coupled to the data storage component and stores a detection program module. The detection program module includes at least a cloud processing program and a CAD software program, and the data storage component stores the American Welding Society specification. The shape information of the bead, and the control unit is configured to adjust the power source of the displacement power source and the vertical moving component of the horizontal moving component of the mobile unit by one of wired or wireless, and the camera of the image capturing unit And its horizontally rotating components and An angle adjuster that is vertically coupled to the rotating component, and an infrared light source of the pattern projection unit are coupled. The three-dimensional image detecting device for bead according to claim 1, wherein the vertical moving component of the moving unit is a vertical pole disposed on the base, and the vertical rod is composed of an inner tube and an outer tube. The sleeve is composed of the height adjustment power source between the inner tube and the outer tube, and the bottom end of the outer tube of the vertical rod is assembled to the base, and the upper end of the inner tube is provided with the table. The three-dimensional image detecting device for bead according to claim 1, wherein the horizontally rotating component of the image capturing unit comprises a first frame, and the first frame is coupled with the first pivot. And the first pivot is vertically pivotally connected to the table, and the first pivot end portion is provided with the angle adjuster, and the vertical rotating assembly comprises a second frame, The second frame is disposed between the first frame, and the second frame is pivotally connected to the first frame by a second pivot horizontally, and the second pivot end is assembled with the second frame The angle adjuster further comprises the camera set on the second frame. The bead three-dimensional image detecting device according to claim 1, wherein the camera is provided with a left lens and a right lens. The bead three-dimensional image detecting device according to claim 1, wherein the pattern projection unit is disposed on a table of the mobile unit. A method for detecting a three-dimensional image of a bead comprises the following steps: A. fixed point adjustment: the system is driven by a control unit to drive a mobile unit to adjust the camera of the image capturing unit of the mobile unit. To the position where the steel member to be inspected and its weld bead are photographed; B. Feature pattern projection: a control unit drives a pattern projection unit to emit infrared rays from an infrared light source to project a feature pattern onto the steel member and its bead through its characteristic projection member; C. Moving photo lens: continued by the control unit Driving the image capturing unit disposed on the mobile unit to travel, and moving the camera mode by time difference, so that the camera lens captures multiple overlapping images of different angles continuously along the steel member and its weld bead; D. Triangulation Method calculation: the multiple overlapping images captured by the camera are calculated by the microprocessor of the control unit to calculate the three-dimensional depth by triangulation, and two adjacent images are captured at different times, and the image of the infrared characteristic pattern is projected by the pattern projection unit. Calculate the baseline and calculate the distance; E. Image sorting and feature point detection: the microprocessor and the bead image of the control unit are image sorted and corresponding to the feature points, and the corresponding points are found. The basic matrix to establish the matching relationship between the images; F. Reconstruct the bead 3D point cloud model: the microprocessor of the control unit Three-dimensional point cloud data of the steel member and its bead are constructed by feature matching or regional similarity matching between images; G. Appearance size comparison of the bead: the microprocessor of the continuous control unit is cut by the bead Reconstructing the weld bead surface, and then measuring the appearance of the weld bead by the three-dimensional point cloud data of the weld bead, and comparing with the shape of the weld bead of the built-in American Welding Society (AWS) specification to detect the weld of the weld bead Good quality and bad quality. For example, the method for detecting three-dimensional image of the bead according to item 6 of the patent application scope, wherein the step of reconstructing the three-dimensional point cloud model of the bead is further processed by the point cloud data to smooth the point cloud data and smooth the point cloud data. The signal filtering and the point cloud data coordinate reorganization are performed, and then the bead appearance size comparison step is performed. The method for detecting a three-dimensional image of a bead according to claim 6, wherein in the step of moving the lens, the lens of the camera is an image of the front, back, and upper and lower angles of the steel member and the bead thereof. Capture. The method for detecting a three-dimensional image of a bead according to claim 6, wherein in the step of moving the photographing lens, the overlap of each image with the adjacent image is preferably at least 50% or more.