CN103203526A - Laser visual tracking system - Google Patents
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Abstract
The invention discloses a laser visual tracking system, which mainly comprises an industrial personal computer, wherein a COM 1 (Component Object Model) port of the industrial personal computer is connected with an X axis motor and a Z axis motor through a motor control and drive circuit; output ends of the X-axis motor and the Z-axis motor are connected with a welding torque; the controller of the welding torque and a welding machine control circuit are connected with the industrial personal computer; the industrial personal computer is also connected with a laser sensor for acquiring information on the welding torque and a workpiece in real time and delivering the acquired information to the industrial personal computer; the laser sensor is a visual sensing module and mainly comprises a camera and a laser diode; the camera is vertically aligned with the workpiece; a laser is slantwise arranged and forms an angle of 30 degrees with the laser; laser emitted by the laser irradiates the workpiece to form a narrow light strip; after the light strip is reflected or refracted by the workpiece, the light strip enters the camera to image, and the image is transferred to the industrial personal computer for processing; after the image is analyzed and processed by the industrial personal computer, an action command is emitted to the welding torque, the X-axis motor and the Z-axis motor.
Description
Technical field
The present invention relates to detection, machine vision technique field, specifically is to be applied in the welding process soldering joint automatic tracking, is fit to the laser vision tracking system from motion tracking of present multiple weld seam type.
Background technology
What a lot of automation equipments all adopted in the market is that electric arc is followed the tracks of and the playback robot, and the electric arc tracking structure is simple, and is convenient, flexible, but it is to the butt joint welding bead (the frequent square groove of submerged arc welding) of square groove, is difficult to realize the centering tracking.And teaching is reproduced the formula tracking under the basicly stable situation of welding condition, can guarantee welding quality.But because the influence of various factors, the actual welding condition often changes and causes welding quality to descend even failure.The key of weld joint tracking is how to detect weld seam deviation, and people have attempted many detection methods all the time, and all there is certain limitation in they in application.Present laser-vision sensing has advantages such as initiative, noncontact, the three-dimensional information that can obtain object, sensitivity precision height, anti-electromagnetic field interference performance are strong, is considered to the main developing direction of weld seam detection.In order to ensure the welding quality of weldment, reduce human factor influences it as far as possible, shortens the production cycle, certainly will study the automatic welding tracking method that a kind of tracking accuracy height can satisfy scene welding condition complicated and changeable.
Summary of the invention
The objective of the invention is to propose a kind of tracking accuracy height (＜0.1mm), antijamming capability is strong, and can be suitable for the welding tracking system of various different weld seam types, different materials, it is little to have overcome moment sensor accommodation, a little less than the antijamming capability, the not obvious and problem that can't follow the tracks of of weld profile during to capping.
In order to reach above-mentioned purpose of design, the technical solution used in the present invention is as follows:
A kind of laser vision tracking system, mainly comprise industrial computer, the X-axis motor, the Z spindle motor, welding cabinet, video camera, laser diode, the COM1 port of described industrial computer inserts Electric Machine Control and drive circuit, and be connected to the X-axis motor by Electric Machine Control and drive circuit, the Z spindle motor, and then control X-axis motor, the operation of Z spindle motor, the X-axis motor, Z spindle motor output connects welding cabinet, by the X-axis motor, the Z spindle motor drives welding cabinet and moves, access controller and welding machine control circuit on the described welding cabinet, and controller and welding machine control circuit insert the COM2 port of industrial computer, by the work of industrial computer control controller and welding machine control circuit and then control welding cabinet; It is characterized in that: also insert laser sensor on the described industrial computer, be used for gathering in real time the information of welding cabinet and workpiece, and the information that collects is delivered to industrial computer; Described laser sensor is the visual sensing module, mainly formed by video camera and laser diode, video camera perpendicular alignmnet workpiece, laser instrument is in tilted layout, and becomes 30 ° of angles with laser instrument, the laser that laser instrument is got, shine the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, enter video camera imaging, and image transfer handled to industrial computer, industrial computer sends action command to welding cabinet and X-axis motor, Z spindle motor after with image analysis processing.
Preferably, finish image real-time acquisition by the visual sensing module, by the video camera of visual sensing module and the IMAQ card module of industrial computer the image that collects is delivered to the industrial computer processing, draw the deviation at welding gun and weld seam center, and this deviation sent to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor by serial ports, thereby reach the purpose of correction.
Preferably, described laser diode bright dipping end is provided with the post lens, the video camera port is provided with polarizer and optical filter successively, the laser that laser instrument is got forms a mating plate through the post lens and shines the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, keep the light of the specific wavelength that laser instrument sends through optical filter, keep the light of specific direction again through polarizer, and the light that the light of other wavelength of filtering and other directions are disturbed enters video camera imaging at last.
Preferably, also insert LCD and remote-control box on the described industrial computer, be used for human-machine operation.
Preferably, described industrial computer mainly comprises image processing module, picture recognition module, tracking control module, image processing module is used for leaching original image to be disturbed, and calculates current location and relatively draws current deviation as the input information of following the tracks of control module with template; Picture recognition module is used for identification has maximum matching degree with template welding bead image-region; Follow the tracks of control module for start and stop, rotating speed and the rotation direction of control motor.
More preferably, described industrial computer comprises that also man-machine interface is used to arrange parameter, sends the action control signal, and can show the value of various real-time parameters intuitively.
Described vision is followed the tracks of concrete steps:
Step 1, system initialization comprise video camera initialization, interface initialization, thread initialization etc.;
Step 2, regulate motor and prepare for following the tracks of, make current welding gun aim under the situation of weld seam template is set, the template image that arranges is stored in specifies in the hard disk; Concrete operations are: click the template button is set, the image that computer is just gathered current laser sensor has existed in the industrial computer as template;
Step 3, startup are followed the tracks of, system will handle with the speed acquisition image of per second 25 frames and to it, and the control information that will obtain after will handling sends to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor, in this process if the artificial motor of regulating, should respond people's control earlier, artificial control is over to transfer to automatically again and follows the tracks of control;
Step 4, stop to follow the tracks of, close the thread of gathering image;
Step 5, withdraw from.
Preferably, the detailed process of following the tracks of in the described step 3 is:
1) image preliminary treatment: the collection image is carried out the image preliminary treatment (mainly comprise image filtering and figure image intensifying, medium filtering and morphologic filtering method have mainly been adopted in filtering, what the figure image intensifying was adopted here is that histogram strengthens), reduced picture noise by the image preliminary treatment, for the further computing in back is got ready;
2) template matches: will relatively draw current best match position through pretreated image and the template image pointwise that is stored in the hard disk in advance, deduct the template position coordinate with this position coordinates and namely get current deviation, this deviation is the deviation when the front sensor position, but not the welding gun lower deviation;
3) storage, processing deviation: by speed of welding is fetched, calculate the time difference t between laser sensor and the welding gun, the deviation that at every turn calculates is stored in the array that defines, the deviation of exporting to motor control module is not the deviation of this calculating but gets certain deviation of front, thereby eliminated above-mentioned time difference problem;
4) output bias: the deviation after will handling outputs to Electric Machine Control and drive circuit;
5) Electric Machine Control: Electric Machine Control and drive circuit are according to the Deviation Control X-axis motor that receives, the action of Z spindle motor; Realize self-regulating process.
The beneficial effect of laser vision tracking system of the present invention is, can follow the tracks of horizontal direction and vertical direction simultaneously, and tracking accuracy is all less than 0.1mm, and this system adapts to the tracking of various weld seam types; Wide accommodation, antijamming capability is strong.
The present invention fetches the speed of dolly and participate in the algorithm, has eliminated the leading error that sensor and welding gun do not bring at same horizontal line, has realized real real-time tracking.
Because weld profile is not obvious, much existing tracking equipment all can't carry out accurate tracking to it during capping.The present invention proposes when bottoming is filled, adopt the position data that records this welding welding-gun when having algorithm keeps track now in the welding, if weld seam during capping selects the welding torch position data of last registration to follow the tracks of as teaching under the not obvious situation about can't accurately follow the tracks of.
The present invention adopts the CCD that installs optical filter and polarizer combination additional to gather image, has leached interference on the hardware to greatest extent.
Traditional tracking only utilizes the point on the weld seam certain level line to go to calculate the weld seam center, and the interior every bit of the area-of-interest that the present invention selects the user has all participated in computing, is conducive to improve the reliability of tracking.
Mate with the preceding template that arranges of welding by gathering weld image, welding gun is adjusted on the position that arranges before the welding, the relative position of assurance welding gun and weld seam is constant, makes welding gun centering weld seam all the time.
Description of drawings
Fig. 1 is the structure chart of the described laser vision tracking system of the embodiment of the invention;
Fig. 2 is the software architecture diagram of the described laser vision tracking system of the embodiment of the invention;
Fig. 3 is the schematic diagram of the described laser vision tracking system of the embodiment of the invention;
Fig. 4 is the flow chart of the described laser vision tracking system of the embodiment of the invention.
The specific embodiment
Below in conjunction with accompanying drawing optimum implementation of the present invention is described in further detail.
Based on the seam tracking system of laser vision as shown in Figure 1, mainly comprise industrial computer, the X-axis motor, the Z spindle motor, welding cabinet, video camera, laser diode, the COM1 port of described industrial computer inserts Electric Machine Control and drive circuit, and be connected to the X-axis motor by Electric Machine Control and drive circuit, the Z spindle motor, and then control X-axis motor, the operation of Z spindle motor, the X-axis motor, Z spindle motor output connects welding cabinet, by the X-axis motor, the Z spindle motor drives welding cabinet and moves, access controller and welding machine control circuit on the described welding cabinet, and controller and welding machine control circuit insert the COM2 port of industrial computer, by the work of industrial computer control controller and welding machine control circuit and then control welding cabinet; Also insert laser sensor on the described industrial computer, be used for gathering in real time the information of welding cabinet and workpiece, and the information that collects is delivered to industrial computer; Described laser sensor is used for gathering image information for the visual sensing module, mainly formed by video camera and laser diode, video camera perpendicular alignmnet workpiece, laser instrument is in tilted layout, and become 30 ° of angles with laser instrument, the laser that laser instrument is got, shine the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, enter video camera imaging, and image transfer handled to industrial computer, industrial computer sends action command to welding cabinet and X-axis motor, Z spindle motor after with image analysis processing; During use, finish image real-time acquisition by visual sensing module (laser sensor), by the video camera of visual sensing module and the IMAQ card module of industrial computer the image that collects is delivered to the industrial computer processing, draw the deviation at welding gun and weld seam center, and this deviation sent to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor by serial ports, thereby reach the purpose of correction.
Described laser diode bright dipping end is provided with the post lens, the video camera port is provided with polarizer and optical filter successively, the laser that laser instrument is got forms a mating plate through the post lens and shines the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, the light that keeps the specific wavelength that laser instrument sends through optical filter, the light that keeps specific direction again through polarizer, and the light that the light of other wavelength of filtering and other directions are disturbed enters video camera imaging at last.The degree of depth is different in the vertical direction with workpiece everywhere owing to groove, so look from the direction of vertical workpiece, reverberation becomes a broken line, and broken line has reflected the three-dimensional position relation at light line center and weld groove center.
Described laser sensor is provided with the cooling and dedusting device.
The laser diode that adopts in this vision system is ruddiness one word line laser diode, by the luminous laser stripe that is in line shape by a post lens transformation of dot laser diode.Select for use arc light to disturb the bar-shaped semiconductor laser diode of minimum centre wavelength 650 nm.
Native system adopts face formation CCD industry camera, mainly considers its stable performance, and the characteristics of reliable operation require CCD size 1/3 ", more than the frame per second 25fps.Before the narrow band pass filter (center wave band that cooperates laser light source) of employing centre wavelength 650 nm and polarizer are installed in the camera lens of ccd video camera.
Between laser sensor and welding torch design and installation an anti-splash guard, light barrier can stop the arc light of when welding part and splash and enter the coverage of ccd video camera, thereby reduce them to gathering the influence of image.
Image pick-up card is installed in the described industrial computer, and image pick-up card is electrically connected with video camera.
Described Electric Machine Control and drive circuit are installed in the control box of industrial computer outside, are connected with the industrial computer serial ports and carry out data communication.
Limit switch is equipped with at the X-axis motor that described control welding torch moves, Z spindle motor two ends, realizes being electrically connected with Electric Machine Control and drive circuit.
Described controller and welding machine control circuit are mainly finished the control of wire feed, walking and welding start and stop; It mainly is that information such as the speed of welding that will collect, arc voltage, electric current send to industrial computer and participate in computing and show that controller is communicated by letter with industrial computer.
System building well after, must demarcate video camera, namely determine video camera the practise physiognomy measuring distance of each pixel correspondence and the mapping relations between the actual range.
Also insert LCD and remote-control box on the described industrial computer, be used for human-machine operation.
Described industrial computer mainly comprises image processing module, picture recognition module, tracking control module, image processing module mainly comprises image preliminary treatment, template matches, output bias, be used for leaching original image and disturb, calculate current location and relatively draw current deviation as the input information of following the tracks of control module with template; Picture recognition module is used for identification has maximum matching degree with template welding bead image-region; Follow the tracks of control module and mainly comprise motor control module and motor drive module, be used for start and stop, rotating speed and the rotation direction of control motor; Described industrial computer comprises that also man-machine interface comprises that mainly tracking control, current collection image show, trace information shows, welding parameter shows, in order to make whole system that parameter can be set quickly and easily, to send the control signal of exercises, and can show the value of various real-time parameters intuitively.The parameter that can arrange comprises: matching degree, horizontal extension, extends perpendicular; Control in real time can provide following function: Keyboard Control, move to left, move to right, on move, move down, arrange template, function such as begin, stop.
Fig. 4 is the flow chart of laser vision seam tracking system, and its concrete steps are:
Step 1, system initialization comprise video camera initialization, interface initialization, thread initialization etc.;
Step 2, regulate motor and prepare for following the tracks of, make current welding gun aim under the situation of weld seam template is set, the template image that arranges is stored in specifies in the hard disk; Concrete operations are: click the template button is set, the image that computer is just gathered current laser sensor has existed in the industrial computer as template;
Step 3, startup are followed the tracks of, system will handle with the speed acquisition image of per second 25 frames and to it, and the control information that will obtain after will handling sends to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor, in this process if the artificial motor of regulating, should respond people's control earlier, artificial control is over to transfer to automatically again and follows the tracks of control;
Step 4, stop to follow the tracks of, close the thread of gathering image;
Step 5, withdraw from.
The detailed process of following the tracks of in the described step 3 is:
1) image preliminary treatment: the collection image is carried out the image preliminary treatment, and (mainly comprise image filtering and figure image intensifying, medium filtering and morphologic filtering method have mainly been adopted in filtering, and what the figure image intensifying was adopted here is that histogram strengthens; It all is to continue to use present existing classic algorithm that medium filtering herein, morphologic filtering, histogram strengthen), reduced picture noise by the image preliminary treatment, for the further computing in back is got ready;
2) template matches: will relatively draw current best match position through pretreated image and the template image pointwise that is stored in the hard disk in advance, deduct the template position coordinate with this position coordinates and namely get current deviation, this deviation is the deviation when the front sensor position, but not the welding gun lower deviation;
3) storage, processing deviation: by speed of welding is fetched, calculate the time difference t between laser sensor and the welding gun, the deviation that at every turn calculates is stored in the array that defines, this array size is relevant with the image processing time (referring to the time from the IMAQ to the output bias) with time difference t, and array size is directly proportional divided by the merchant in image processing time with time difference t; The deviation of exporting to motor control module is not the deviation of this calculating but gets certain deviation of front, thereby eliminated above-mentioned time difference problem;
4) output bias: the deviation after will handling outputs to Electric Machine Control and drive circuit;
5) Electric Machine Control: Electric Machine Control and drive circuit are according to the Deviation Control X-axis motor that receives, the action of Z spindle motor; Realize self-regulating process.
This specific embodiment can not limit the present invention only as the preferred embodiments of the present invention, and concrete every rights protection scope is defined by the claims.
Claims (8)
1. laser vision tracking system, mainly comprise industrial computer, the X-axis motor, the Z spindle motor, welding cabinet, video camera, laser diode, the COM1 port of described industrial computer inserts Electric Machine Control and drive circuit, and be connected to the X-axis motor by Electric Machine Control and drive circuit, the Z spindle motor, and then control X-axis motor, the operation of Z spindle motor, the X-axis motor, Z spindle motor output connects welding cabinet, by the X-axis motor, the Z spindle motor drives welding cabinet and moves, access controller and welding machine control circuit on the described welding cabinet, and controller and welding machine control circuit insert the COM2 port of industrial computer, by the work of industrial computer control controller and welding machine control circuit and then control welding cabinet; It is characterized in that: also insert laser sensor on the described industrial computer, be used for gathering in real time the information of welding cabinet and workpiece, and the information that collects is delivered to industrial computer; Described laser sensor is the visual sensing module, mainly formed by video camera and laser diode, video camera perpendicular alignmnet workpiece, laser instrument is in tilted layout, and becomes 30 ° of angles with laser instrument, the laser that laser instrument is got, shine the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, enter video camera imaging, and image transfer handled to industrial computer, industrial computer sends action command to welding cabinet and X-axis motor, Z spindle motor after with image analysis processing.
2. laser vision tracking system according to claim 1, it is characterized in that: finish image real-time acquisition by the visual sensing module, by the video camera of visual sensing module and the IMAQ card module of industrial computer the image that collects is delivered to the industrial computer processing, draw the deviation at welding gun and weld seam center, and this deviation sent to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor by serial ports, thereby reach the purpose of correction.
3. laser vision tracking system according to claim 2, it is characterized in that: described laser diode bright dipping end is provided with the post lens, the video camera port is provided with polarizer and optical filter successively, the laser that laser instrument is got forms a mating plate through the post lens and shines the light belt that forms a narrower in width on the workpiece, after this light belt is reflected by workpiece or reflects, the light that keeps the specific wavelength that laser instrument sends through optical filter, the light that keeps specific direction again through polarizer, and the light that the light of other wavelength of filtering and other directions are disturbed enters video camera imaging at last.
4. laser vision tracking system according to claim 3 is characterized in that, also inserts LCD and remote-control box on the described industrial computer, is used for human-machine operation.
5. laser vision tracking system according to claim 4, it is characterized in that, described industrial computer mainly comprises image processing module, picture recognition module, tracking control module, image processing module is used for leaching original image to be disturbed, and calculates current location and relatively draws current deviation as the input information of following the tracks of control module with template; Picture recognition module is used for identification has maximum matching degree with template welding bead image-region; Follow the tracks of control module for start and stop, rotating speed and the rotation direction of control motor.
6. laser vision tracking system according to claim 5 is characterized in that, described industrial computer comprises that also man-machine interface is used to arrange parameter, sends the action control signal, and can show the value of various real-time parameters intuitively.
7. according to any described laser vision tracking system of claim 1 ~ 6, it is characterized in that described vision is followed the tracks of concrete steps and is:
Step 1, system initialization comprise video camera initialization, interface initialization, thread initialization etc.;
Step 2, regulate motor and prepare for following the tracks of, make current welding gun aim under the situation of weld seam template is set, the template image that arranges is stored in specifies in the hard disk; Concrete operations are: click the template button is set, the image that computer is just gathered current laser sensor has existed in the industrial computer as template;
Step 3, startup are followed the tracks of, system will handle with the speed acquisition image of per second 25 frames and to it, and the control information that will obtain after will handling sends to the action of Electric Machine Control and drive circuit control X-axis motor, Z spindle motor, in this process if the manual adjustments motor, should respond people's control earlier, manually control is through with to transfer to automatically again and follows the tracks of control;
Step 4, stop to follow the tracks of, close the thread of gathering image;
Step 5, withdraw from.
8. laser vision tracking system according to claim 7 is characterized in that, the detailed process of following the tracks of in the described step 3 is:
1) image preliminary treatment: carry out the image preliminary treatment to gathering image, reduced picture noise by the image preliminary treatment, for the further computing in back is got ready;
2) template matches: will relatively draw current best match position through pretreated image and the template image pointwise that is stored in the hard disk in advance, deduct the template position coordinate with this position coordinates and namely get current deviation, this deviation is the deviation when the front sensor position, but not the welding gun lower deviation;
3) storage, processing deviation: by speed of welding is fetched, calculate the time difference t between laser sensor and the welding gun, the deviation that at every turn calculates is stored in the array that defines, the deviation of exporting to motor control module is not the deviation of this calculating but gets certain deviation of front, thereby eliminated above-mentioned time difference problem;
4) output bias: the deviation after will handling outputs to Electric Machine Control and drive circuit;
5) Electric Machine Control: Electric Machine Control and drive circuit are according to the Deviation Control X-axis motor that receives, the action of Z spindle motor; Realize self-regulating process.
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