CN100460166C - Welding robot multifunctional double-eye visual sensor and calibration method thereof - Google Patents
Welding robot multifunctional double-eye visual sensor and calibration method thereof Download PDFInfo
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- CN100460166C CN100460166C CNB2007100378903A CN200710037890A CN100460166C CN 100460166 C CN100460166 C CN 100460166C CN B2007100378903 A CNB2007100378903 A CN B2007100378903A CN 200710037890 A CN200710037890 A CN 200710037890A CN 100460166 C CN100460166 C CN 100460166C
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Abstract
A multifunctional binocular vision sensor of welding robot and relative marking method comprise a camera, a dimming filtering system, an aerating system, a reflector system, and a mounting support, while the camera, aerated system and the dimming filtering system and the reflector system are all fixed on the mounting support, the camera, aerated system, a dimming filtering system, and reflector system are vertically arranged at one side of a welding gum from up to down, the camera and the dimming filtering system are coaxial. The invention also provides relative marking method, while the invention can meet the demands of guiding, welding seam track and quality control in welding process, with high accuracy and effect.
Description
Technical field
What the present invention relates to is a kind of device and scaling method thereof of welding technology field, is specifically related to a kind of welding robot multifunctional double-eye visual sensor and scaling method thereof.
Background technology
At present, the sensing mode that is used on the welding robot is varied.In these method for sensing, the visual sensing method because the Information Monitoring amount is big, noncontact, fast, advantage such as high accuracy and detection range be big, be subjected to people's favor.The application of visual sensing technology in the welding robot field mainly is the guiding of carrying out initial welding position, the welding process intelligent control research such as identification, the tracking of weld seam vision and penetration control of welding point form.What study comparative maturity at present both at home and abroad is the visual sensing mode that adopts the fixed focal length video camera, exist the deficiency of function singleness, it can only finish a kind of specific welding job, if finish a plurality of welding jobs, the camera lens that also will change different focal just can be finished the task of visual sensing.
Literature search through prior art is found, Chinese patent application number: 200410067328.1, the patent of fame and position " servo binocular vision sensors on welding robot " provides a kind of vision sensor, this kind sensor mainly is made up of two ccd video cameras, realize the collection of butt welded seam image by image pick-up card and ccd video camera, this device can be real-time the image information that collects weld seam, tracking accuracy can reach the requirement of weld joint tracking, what but ccd video camera adopted is the camera lens of fixed focal length, because desired visual scene and resolution ratio are inequality when weld start position is guided and during weld joint tracking, so camera lens can't satisfy the precision at weld start position guiding and weld joint tracking simultaneously, if when requiring the sensing accuracy of above two processes all very high, then need manually to change the camera lens of video camera; Simultaneously, because the shooting angle of video camera immobilizes, make and when carrying out weld start position when guiding and carrying out weld joint tracking, need the shooting angle of manual adjustments video camera, and camera position also needs the inside and outside parameter of video camera is demarcated again after changing, and causes the automation of welding robot and intelligent degree to reduce.
Summary of the invention
The objective of the invention is to overcome deficiency of the prior art, a kind of welding robot multifunctional double-eye visual sensor and scaling method thereof are provided, make it pass through the autozoom function of video camera, the realization sensor is gathered image information and has been guaranteed that the image that collects is used for the precision that vision is calculated on different positions, simultaneously by automatic loading with remove dim light and filtering apparatus, can make sensor on different positions, gather image information, finish different welding jobs.
The present invention is achieved by the following technical solutions:
Welding robot multifunctional double-eye visual sensor of the present invention, comprise: video camera, pneumatic system, dim light and filter system, mirror system, mounting bracket, video camera, pneumatic system, dim light and filter system, mirror system all are fixed on the mounting bracket, video camera, pneumatic system, dim light and filter system, mirror system are by from top to bottom the order vertical out-fall side at welding gun, and video camera is coaxial with dim light and filter system.
Described mounting bracket comprises camera mount, dim light and optical filtering support, the mirror system support, pneumatic system comprises slide bar, cylinder, mirror system comprises the first order reflection mirror, the secondary reflex mirror, the secondary reflex mirror support, dim light and optical filtering support while and camera mount, the mirror system support, one end of secondary reflex mirror support and an end of slide bar connect, the other end of secondary reflex mirror support is connected with the secondary reflex mirror, the other end of slide bar is connected with cylinder, the first order reflection mirror is connected with the mirror system support, one-level, the reflection angle of secondary reflex mirror immobilizes, the first order reflection mirror is from the horizontal by 62 degree angles, near the main image information of welding gun rifle point of gathering, the secondary reflex mirror is from the horizontal by miter angle, mainly be that the image that the first order reflection mirror collects is reflexed to first video camera, the secondary reflex mirror support is connected with dim light and optical filtering support, make the relative position of secondary reflex mirror and dim light and filter system immobilize, simultaneously dim light and optical filtering support are connected with slide bar in the pneumatic system, dim light and optical filtering support slide on mounting bracket under the driving of cylinder, thereby realize the automatic loading of dim light and filter system and remove.
Described video camera is can autozoom, self-focusing integrated camera, is installed on the camera mount, and main being responsible for gathered welding scene and welded piece and weld pool image, and its serial communication port is connected with computer by serial.
Described dim light and filter system comprise dim light eyeglass, filter glass, and filter glass is installed on dim light and the optical filtering support, according to direction dim light eyeglass, the filter glass coaxial discharging successively in the face of video camera.
The present invention and welding gun all are fixed on the last joint of welding robot, in use, weld the last stage beginning, be used to finish the work that butt welded seam and weld start position are discerned and guided, video camera need collect the image information of whole workbench and welding work pieces, do not ignite owing to electric arc this moment, sensor-based system is to adopt natural lighting, by pneumatic system dim light and filter system and secondary reflex eyeglass are removed, make video camera can directly collect the image information of workbench, by camera acquisition to image carry out stereoscopic vision and calculate, thereby obtain the D coordinates value of weld start position.When welding, because electric arc ignites, illumination is very strong, in order to make the video camera can be clearly to welding pool and weld seam imaging, dim light and filter system and secondary reflex mirror are loaded into the lower end of video camera by cylinder, by the secondary reflex light path near the image information the welding gun rifle point is delivered in the video camera, use the latter half of image information in camera acquisition molten bath at rear, molten bath, thereby realize real-time Detection ﹠ Controling to welding pool characteristic parameter in the welding process, use the camera acquisition weld seam in the place ahead, molten bath and the image information of molten bath first half, thereby realize the real-time Detection ﹠ Controling of weld joint tracking and weld gap.
Because need video camera can collect the image information of whole workbench when carrying out the weld start position guiding, at this moment video camera needs less focal length value; Need video camera can collect molten bath forward-and-rearward topography information when carrying out weld joint tracking and Molten pool image gathering, at this moment video camera needs bigger focal length value and higher resolution ratio.So need video camera to change focal length automatically according to different job requirements.Because existing integrated camera does not have the closed-loop control of focusing, so, need externally be equipped with a gridiron pattern scaling board to realize closed-loop control to focal length of camera in order to guarantee the precision of each zooming transform.
The scaling method of welding robot multifunctional double-eye visual sensor of the present invention specifically comprises the steps;
(1) before the welding beginning, welding robot multifunctional double-eye visual sensor is moved to the position far away apart from workbench, by cylinder dim light and filtering apparatus and second level speculum are removed, made video camera directly collect the image information of whole workbench;
(2) welding robot multifunctional double-eye visual sensor is moved on the calibration position that configures in advance, FEEDBACK CONTROL by outside scaling board changes focus of camera, make it adjust to the focal length that satisfies welding starting point guiding work, simultaneous computer accesses the camera interior and exterior parameter under this focal length, and video camera is demarcated;
(3) welding robot multifunctional double-eye visual sensor is moved to the position described in the step (1), carry out the guiding work of IMAQ and initial welding position, calculate the initial point coordinate position of welding and note by vision;
(4) welding robot multifunctional double-eye visual sensor is moved on the position described in the step (2), again change focus of camera, make it adjust to the focal length that satisfies weld joint tracking work, simultaneous computer accesses the video camera internal and external parameter under this focal length, again video camera is demarcated;
(5) welding robot multifunctional double-eye visual sensor is moved to the coordinate position of the welding initial point that calculates in the step (3), by cylinder with dim light and filter system and second level speculum be loaded into video camera under, carry out the weld joint tracking under the welded condition and the quality control work of welding pool.
Sensor of the present invention is being carried out timing signal, at first set a calibration position, when the adjustment of at every turn carrying out focal length of camera, all welding robot multifunctional double-eye visual sensor is moved on this position, video camera carries out IMAQ to scaling board on this position, collect the tessellated number of pixels of unit in the image by calculating and realize FEEDBACK CONTROL focal length of camera, video camera is connected with computer by COM, serial command by the computer transmission, make the focal length value that video camera can change to automatically to be needed, after focal length of camera is adjusted, the calibrating parameters of this focal length that calculated in advance is good accesses from computer, realizes ° demarcation of each inside and outside parameter of video camera.
The present invention is by the autozoom function of video camera, can make video camera finish different welding jobs and do not need to change camera lens, the realization sensor is gathered image information and has been guaranteed that the image that collects is used for the precision that vision is calculated on different positions, simultaneously by automatic loading with remove dim light and filtering apparatus, can make sensor on different positions, gather image information, finish different welding jobs.Sensor of the present invention and scaling method can well satisfy the weld seam starting point guiding in the welding process and the work of weld joint tracking.Each step in the inventive method all realizes in the programming of computer, does not need people's intervention.
Description of drawings
Fig. 1 present embodiment welding robot multifunctional double-eye visual sensor structural representation
The specific embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment has provided detailed embodiment and process being to implement under the prerequisite with the technical solution of the present invention, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 1, the present embodiment welding robot multifunctional double-eye visual sensor comprises: first video camera 1, second video camera 13, first and second pneumatic system, first and second dim light and filter system, first and second mirror system and mounting bracket; First video camera 1, second video camera 13, first, two pneumatic systems, first, two dim lights and filter system and first, the two-mirror system all is fixed on the mounting bracket, first video camera 1, first pneumatic system, first dim light and filter system, first mirror system respectively with second video camera 13, second pneumatic system, second dim light and filter system, second mirror system is axle center symmetry discharging with welding gun 12, first video camera 1, first dim light and filter system, first mirror system is pressed order vertical out-fall from top to bottom, and first video camera 1 is coaxial with first dim light and filter system, second video camera 13, second pneumatic system, second dim light and filter system and second mirror system are discharged by same mode.
Described mounting bracket comprises: camera mount 9, dim light and optical filtering support 10, mirror system support 11, camera mount 9 and dim light and optical filtering.Support 10 connections, dim light and optical filtering support 10 are connected with mirror system support 11; First and second video camera 1,13 all is can the self-focusing integrated camera of autozoom, its focal length variations scope is 3.9mm-85.5mm, can satisfy the requirement of image acquisition in the welding process, first video camera 1 is positioned at the place ahead, molten bath, second video camera 13 is positioned at the rear, molten bath, first and second video camera 1,13 all is installed on the camera mount 9, main being responsible for gathered welding scene and welded piece and weld pool image, and their serial communication port is connected with computer by serial; Described first pneumatic system comprises slide bar 2, cylinder 3, one end of slide bar 2 is connected with cylinder 3, the other end is connected with dim light and optical filtering support 10, second pneumatic system comprises slide bar 14, cylinder 15, and the connected mode of slide bar 14, cylinder 15 and function and slide bar 2, cylinder 3 are identical; Described first dim light and filter system comprise dim light eyeglass 7, filter glass 8, filter glass 8 is installed on dim light and the optical filtering support 10, according to direction dim light eyeglass 7, filter glass 8 coaxial dischargings successively in the face of video camera 1, the discharging modes that second dim light and filter system comprise each assembly in dim light eyeglass 19, filter glass 20, the first dim lights and the filter system and function are identical with first dim light and filter system; Described first mirror system comprises the first secondary reflex mirror 5, the first secondary reflex mirror support 4, the first first order reflection mirror 6, the first secondary reflex mirror support, 4 one ends are connected with the first secondary reflex mirror 5, the other end is connected with dim light and optical filtering support 10, the first first order reflection mirror 6 is connected with mirror system support 11, the first first order reflection mirror 6, the reflection angle of the first secondary reflex mirror 4 immobilizes, the first first order reflection mirror 6 is from the horizontal by 62 degree angles, near the main image information of welding gun 12 rifle points of gathering, the first secondary reflex mirror 4 is from the horizontal by miter angle, mainly be that the image that the first first order reflection mirror 6 collects is reflexed to video camera 1, the first secondary reflex mirror support 4 is connected with dim light and optical filtering support 10, the relative position of win secondary reflex mirror 5 and first dim light and filter system is immobilized, they are connected with first cylinder 3 simultaneously, dim light and optical filtering support 10 slide on mounting bracket under the driving of first cylinder 3, thereby realize the automatic loading of dim light and filter system and remove.The discharging modes that second mirror system comprises each assembly in the second secondary reflex mirror 17, the second secondary reflex mirror support 14, the second first order reflection mirror, 18, the second mirror systems and function are identical with first mirror system.
Present embodiment welding robot multifunctional double-eye visual sensor and welding gun all are fixed on the last joint of welding robot, and when carrying out concrete welding job, the calibration process of this welding robot multifunctional double-eye visual sensor is as follows:
(1) before playing arc welding, at first robot will find the original position of welding by the sensor, at this moment by cylinder dim light and filter system and second level speculum are removed, video camera directly collects the image information of whole workbench, and this moment, the work focal length value of video camera should be decided to be 3.5mm;
(2) sending the serial ports instruction by computer makes the focus of camera value become 3.5mm, welding robot multifunctional double-eye visual sensor is moved on the calibration position of reserving in advance simultaneously, gather the image and the tessellated number of pixels of unit of account of outside scaling board, when focal length value changes when accurate, in each unit gridiron pattern 40 pixels should be arranged, if the tessellated number of pixels of unit is not 40 o'clock, it is inaccurate to illustrate that focus of camera changes, also need to adjust, the serial ports instruction that sends by computer at this moment changes the focus of camera value up or down.The image that changes focal length and collection scaling board carries out simultaneously, just stops to change when satisfying condition;
(3) after the focal length adjustment is finished, inside and outside parameter and the hand and eye calibrating parameter of video camera at this focal length place accessed from computer, thereby finish the staking-out work of video camera when weld start position is guided;
(4) welding robot multifunctional double-eye visual sensor is moved to the position described in the step (1), carries out the guiding work of weld start position, by two camera acquisitions to image calculation go out the coordinate figure of weld start position and note;
(5) the welding robot multifunctional binocular sensor is moved on the position of stating of contracting in the step (2), change the focus of camera value again to finish work such as subsequent weld tracking and penetration control.Focal length of camera value during with weld joint tracking is set at 24mm, and the variation of focal length is identical with method described in the step (2) with the Camera calibration method;
(6) welding robot multifunctional double-eye visual sensor is moved to the coordinate position of the welding initial point that calculates in the step (4), by cylinder with dim light and filter system and second level speculum be loaded into video camera under, carry out the weld joint tracking under the welded condition and the quality control work of welding pool.
Each step in the inventive method all realizes with the method for programming in main control computer, does not need people's intervention, by the variation of focal length of camera, can make video camera finish different welding jobs and does not need to change camera lens or adjust the angle of video camera.The present invention can satisfy job requirement such as quality control in guiding, weld joint tracking and the welding process of weld start position simultaneously, and automaticity, precision are higher, respond well.
Claims (7)
1. welding robot multifunctional double-eye visual sensor, comprise video camera, dim light and filter system, pneumatic system, mounting bracket, it is characterized in that, also comprise mirror system, video camera, pneumatic system, dim light and filter system, mirror system all are fixed on the mounting bracket, video camera, pneumatic system, dim light and filter system, mirror system are by from top to bottom the order vertical out-fall side at welding gun, and video camera is coaxial with dim light and filter system;
Described mounting bracket comprises camera mount, dim light and optical filtering support and mirror system support;
Described pneumatic system comprises slide bar and cylinder;
Described mirror system comprises first order reflection mirror, secondary reflex mirror and secondary reflex mirror support;
Wherein: dim light and optical filtering support are connected with an end of camera mount, mirror system support, secondary reflex mirror support and an end of slide bar simultaneously, the other end of secondary reflex mirror support is connected with the secondary reflex mirror, the other end of slide bar is connected with cylinder, and the first order reflection mirror is connected with the mirror system support.
2. welding robot multifunctional double-eye visual sensor according to claim 1 is characterized in that, described one-level, secondary reflex mirror, and its reflection angle immobilizes.
3. welding robot multifunctional double-eye visual sensor according to claim 2 is characterized in that, described first order reflection mirror is from the horizontal by 62 degree angles, and the secondary reflex mirror is from the horizontal by miter angle.
4. welding robot multifunctional double-eye visual sensor according to claim 1 is characterized in that described video camera is installed on the camera mount, and its serial communication port is connected with computer by serial.
5. according to claim 1 or 4 described welding robot multifunctional double-eye visual sensors, it is characterized in that described video camera is autozoom, self-focusing integrated camera.
6. welding robot multifunctional double-eye visual sensor according to claim 1, it is characterized in that, described dim light and filter system comprise dim light eyeglass, filter glass, filter glass is installed on dim light and the optical filtering support, according to direction dim light eyeglass, the filter glass coaxial discharging successively in the face of video camera.
7. welding robot multifunctional double-eye visual sensor according to claim 1 is characterized in that, described welding gun and this sensor are fixed on the last joint of welding robot.
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