CN104384762A - Control system and control method for movement of welding machine - Google Patents
Control system and control method for movement of welding machine Download PDFInfo
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- CN104384762A CN104384762A CN201410494728.4A CN201410494728A CN104384762A CN 104384762 A CN104384762 A CN 104384762A CN 201410494728 A CN201410494728 A CN 201410494728A CN 104384762 A CN104384762 A CN 104384762A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0211—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track
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Abstract
The invention discloses a control system and a control method for movement of a welding machine. The control system is composed of a control host machine, a movement control card, a digital quantity board card, CCD vision sensors, a servo motor, a driver, a guide rail, a light source, an AD board card and a limiting switch; a man-machine operation interface is adopted by the system for receiving a user instruction; the position and the operation area of the welding machine are monitored by the system through the remote CCD vision sensor in real time; a user can control the quick movement of the welding machine by clicking the position of a target welding slice with a mouse; after the welding machine reaches the position of the welding slice, a close-range CCD vision sensor for identifying a welding spot works; the secondary movement positioning is performed according to a space coordinate given by a welding spot image identifying algorithm, the welding spot is accurately positioned, and the subsequent welding operation is performed. According to the scheme, the accurate movement control within 6*4.5m wide scope is realized, the control precision reaches 0.1mm, and the control system can be applied to the movement control for a solar battery array resistance welding machine as well as the other industry fields requiring wide-scope quick accurate positioning.
Description
Technical field
The present invention relates to automated control technology, be specifically related to a kind of on a large scale, high accuracy welding machine mobile control system.
Background technology
The mobile control of welding machine can be applicable to the welding fields such as automobile, space flight and war industry.How can arrive assigned address fast and accurately, to reduce manual intervention, this has important effect for enhance productivity, ensure product quality and qualification rate.
At present, solder joint automatically identify be limited to closely more, the identification of small field of view scope, this method needs to operate on a large scale to some, the unfixed occasion in welding target position cannot be suitable for.
Summary of the invention
For existing welding machine automatic control technology existing for problem, the object of the present invention is to provide a kind of high efficiency and the welding machine intelligent movable control technology of high position precision, it comprises control system and corresponding control method.
In order to achieve the above object, the present invention adopts following technical scheme:
Scheme 1: a kind of welding machine mobile control system, this control system comprises: main control system, motion control card, digital quantity board, CCD vision sensor, servomotor and driver, guide rail, light source, AD board, limit switch;
Described guide rail is provided with welding machine, and described driven by servomotor welding machine is along rail moving; Described limit switch is arranged in orbit, and butt welding machine displacement is carried out spacing; Described CCD vision sensor coordinates with welding machine, obtains destination locations; Described light source provides light for CCD vision sensor;
Described main control system, by Ethernet interface control CCD vision sensor, controls welding machine by serial ports, by motion control card control motor servo driver, and described motor servo driver drived control servomotor; Light source is controlled, by AD board control connection limit switch by digital quantity board.
In above-mentioned control system, described CCD vision sensor comprises a CCD vision sensor of coarse positioning motor removing and the 2nd CCD vision sensor of accurate tack weld, a described CCD vision sensor is positioned at welding job region fore, and whole welding job region can be contained in its visual field; Described 2nd CCD vision sensor and light source are arranged on welding machine, and move with welding machine; A described CCD vision sensor and the mutual collaborative work of the 2nd CCD vision sensor.
Further, described main control system adopts user's mouse to click screen operator and chooses welding target position.
Further, described main control system adopts the accurate tack welder position of image recognition algorithm and bond pad locations.
Scheme 2: a kind of welding machine control method for movement, this control method adopts man machine operation interface to accept user instruction, first by remote CCD vision sensor Real-Time Monitoring welding machine position and operating area, then the movement fast of target weld tabs position control welding machine is clicked by user's mouse, after welding machine arrives weld tabs position, control closely for identifying the CCD vision sensor work of solder joint, the space coordinates provided according to weld point image recognizer again carries out secondary running fix, accurate tack weld, carries out follow-up welding operation.
In the preferred version of this control method, control method specifically comprises the steps:
1) control system resets, System self-test;
2) main control system controls a CCD vision sensor job, shows whole welding job region;
3) user clicks the welding job region of main control system display by mouse, determines target weld tabs position;
4) correct a CCD vision sensor lens distortion, calculate the space coordinates 1 of weld tabs position;
5) calculate welding machine move before locus coordinate 2;
6) main control system calculates motor removing Distance geometry direction according to target location space coordinates 1 and welding machine locus coordinate 2;
7) main control system calculates the displacement and method control motor driver drive motors motion arrival target location determined according to step (6);
8) main control system controls light source unlatching, controls the 2nd CCD vision sensor work simultaneously, and shows weld point image;
9) main control system calculates the locus coordinate 3 of solder joint;
10) the Distance geometry direction of motor removing is calculated according to solder joint locus coordinate 3 and welding machine welding machine position coordinates 4;
11) main control system calculates the Distance geometry direction controlling motor driver drive motors motion determined according to step (10), arrives bond pad locations;
12) main control system control welding machine carries out welding job;
13) whether main control system detects all solder joints and all completes, and is go to step (14), otherwise according to weld tabs spacing parameter, goes to step (7);
14) terminate.
Further, in described step (2), a CCD vision sensor is positioned at welding job region fore 3.5m, and whole 6*4.5m welding job region can be contained in its visual field, a CCD vision sensor is presented on host display screen to main control system by Ethernet transmit image data.
Further, in described step (3), user's mouse beacon moves on the computer screen in the whole welding job region of display, and by left button of clicking the mouse, main control system comes select target weld tabs position by catching mouse position.
Further, the lens distortion calibration in described step (4) adopts grid scaling method.
Further, described step (5) is by the locus coordinate 2 of method tack welder before movement of Graphic Pattern Matching.
Further, the 2nd CCD vision sensor is presented on host display screen to main control system by Ethernet transmit image data in described step (8).
Further, the locus coordinate 3 of solder joint in present image is calculated by Recognition Algorithm for Digital Image (comprising Image semantic classification, edge extracting and Feature Correspondence Algorithm) in described step (9).
Further, the welding machine welding machine position coordinates 4 in described step (10) is the relative distance of welding machine center to the 2nd CCD vision sensor optical lens center.
Scheme provided by the invention can be applicable in the mobile control of solar array electric resistance welding welding machine, and can realize 6*4.5m accurately mobile control on a large scale, control accuracy reaches 0.1mm, and Dynamic System is easy, and efficiency is high.
Simultaneously, man machine operation interface is adopted to accept user instruction in this programme, system is by remote CCD vision sensor Real-Time Monitoring welding machine position and operating area, click target location by user's mouse and can realize welding machine movement fast, after welding machine arrives target location, closely for identifying the CCD vision sensor work of solder joint, the space coordinates that system provides according to weld point image recognizer carries out secondary running fix, accurate tack weld, carries out follow-up welding operation.
This programme also can be applicable to other to be needed on a large scale in quick pinpoint industrial circle.
Thus, with compared with first technology, scheme provided by the invention has following advantages:
1, can realize 6*4.5m accurately mobile control on a large scale, control accuracy reaches 0.1mm.
2, control system adopts user's mouse to click screen operator and chooses welding target position, avoids manual input position parameter, is particularly useful for relatively unfixing, the random larger industrial occasions in welding target position.
Accompanying drawing explanation
The present invention is further illustrated below in conjunction with the drawings and specific embodiments.
Fig. 1 is the welding machine intelligent movable Control system architecture block diagram that the present invention adopts;
Fig. 2 is the welding machine intelligent movable control system control method flow chart that the present invention adopts.
Detailed description of the invention
The technological means realized to make the present invention, creation characteristic, reaching object and effect is easy to understand, below in conjunction with concrete diagram, setting forth the present invention further.
See Fig. 1, it is depicted as the structured flowchart of welding machine mobile control system provided by the invention.As seen from the figure, this control system coordinates composition primarily of main control system 1, motion control card 2, motor driver 3, servomotor 4, digital quantity board 5, light source 6, AD board 7, limit switch 8, a CCD vision sensor 9 and the 2nd CCD vision sensor 10 and track (not shown).
Wherein, track provides mobile route for welding machine moves, and it distributes relative to to-be-welded region, for welding machine provides the mobile route of vertical and horizontal.
Limit switch 8 is correlation photoelectric sensor, and it is arranged on rail boundary, and the motion track of butt welding machine carries out spacing.When welding machine moves to rail boundary, when sheltering from the correlation light of photoelectric sensor, limit switch sends signal, and signal sends into main control computer by AD board, and computer is given an order and stopped welding machine moving.
AD board 7, for all kinds of limit sensors signal of acquisition system, it specifically connects with limit switch 8, and AD board adopts pci bus mode to communicate with main control computer.
One CCD vision sensor 9, it is remote CCD vision sensor, concrete employing Cognex industrial camera.One CCD vision sensor 9 is mainly used in Real-Time Monitoring welding machine position and operating area, coarse positioning is carried out to the position of motor removing, it is specifically positioned at welding job region fore 3.5m, and whole 6*4.5m welding job region can be contained in its visual field, and a CCD vision sensor adopts Ethernet transmit image data to main control system and is presented on host display screen.
2nd CCD vision sensor 10, it is closely CCD vision sensor, specifically adopts Cognex industrial camera.2nd CCD vision sensor 10 is mainly used in identifying solder joint, and butt welding point position is accurately located, and it is specifically arranged on welding machine together with light source 6, and with welding machine along rail moving.2nd CCD vision sensor adopts Ethernet transmit image data to main control system and is presented on host display screen.
Light source 6 coordinates the 2nd CCD vision sensor work, adopts side light source, and the edge feature of outstanding bonding wire and solder joint, ensures the 2nd CCD vision sensor shooting quality.
Digital quantity board 5, it connects the control end of light source 6, and the 2nd CCD vision sensor work while, digital quantity board 5 sends signal, controls light source 6 and opens.
Servomotor 4, is connected with welding machine, and control welding machine and move on guide rail, servomotor 4 is controlled by motor driver 3.
Motor driver 3, its control connection servomotor 4, drives servomotor 4 to work.
Motion control card 2, main control computer controls motor driver 3 by motion control card 2, and then control welding machine moves further.
Main control system 1 is the control core of native system, and it is by computer and settle Control System Software in a computer to form, and adopt man machine operation interface to accept user instruction, computer is industrial control computer.This main control system 1 is controlled two CCD vision sensors by Ethernet card, is controlled motor servo driver by motion control card 2, light source is controlled by digital quantity board 5, by all kinds of limit sensors signal of AD board 7 acquisition system, and by RS-232 serial ports control connection welding machine 11.
First main control system 1 starts a CCD vision sensor, by user's mouse action select target weld tabs, servomotor 4 is driven welding machine to be moved to target weld tabs region, light source and the 2nd CCD vision sensor are installed on welding machine top, move with welding machine, after welding machine arrives target weld tabs region, main control system 1 starts light source and the 2nd CCD vision sensor work, system calculates the accurate spatial locations of solder joint by the image of the 2nd CCD vision sensor shooting, and drive motors moves welding machine and carries out welding job to bond pad locations.
See Fig. 2, its be depicted as carry out accurately based on above-mentioned welding machine mobile control system butt welding machine, the process of Automated condtrol.Whole control procedure is as follows as seen from the figure:
1) system reset, System self-test.
2) main control system controls a CCD vision sensor job, shows whole welding job region.
One CCD vision sensor is positioned at welding job region fore 3.5m, whole 6*4.5m welding job region can be contained in its visual field, and a CCD vision sensor is presented on host display screen to main control system by Ethernet transmit image data.
3) user clicks the target weld tabs position on computer screen by mouse.
In this step, user's mouse beacon moves on the computer screen in the whole welding job region of display, and by left button of clicking the mouse, main control system comes select target weld tabs position by catching mouse position.
4) correct a CCD vision sensor lens distortion, calculate the space coordinates 1 of weld tabs position.
Due to a CCD vision sensor distance photographic subjects 3.5m, will in 6*4.5m welding job region the locus of localizing objects weld tabs more exactly, the distortion of CCD vision sensor optical lens be can not ignore, and when carrying out lens distortion calibration, specifically can adopt grid scaling method.The upper left corner in 6*4.5m welding job region is set to space coordinates initial point, and this space coordinates 1 is calculated by the screen mouse click location of system acquires and the relative position of space coordinates initial point and obtained.
5) main control system by image recognition algorithm 1 calculate welding machine move before locus coordinate 2.
This step is by the locus coordinate 2 of method tack welder before movement of Graphic Pattern Matching, because the upper left corner in 6*4.5m welding job region is set to space coordinates initial point, the relative position of the welding machine that this locus coordinate 2 is obtained by Graphic Pattern Matching method current location and space coordinates initial point in the picture calculates and obtains.
6) main control system calculates motor removing Distance geometry direction according to target location space coordinates 1 and welding machine locus coordinate 2.
7) main control system is according to step 6) in determine motor removing Distance geometry direction controlling motor driver drive motors motion arrive target location;
8) after motor reaches target location, main control system controls light source by digital quantity board and opens, and controls the 2nd CCD vision sensor work, display weld point image simultaneously.
In this step, light source 6 coordinates the 2nd CCD vision sensor work, adopts side light source, and the edge feature of outstanding bonding wire and solder joint, ensures the 2nd CCD vision sensor shooting quality.
2nd CCD vision sensor distance photographic subjects 5cm, to be presented on host display screen to main control system by Ethernet transmit image data.
9) main control system calculates the locus coordinate 3 of solder joint by image recognition algorithm 2.
The Recognition Algorithm for Digital Image 2 adopted in this step comprises Image semantic classification, edge extracting and Feature Correspondence Algorithm, 2mm place above line place is dialled because solder joint is positioned at bonding wire on weld tabs, can obtain extracting bonding wire by edge extracting and characteristic matching and dial position in the picture, line place, be scaled the locus coordinate 3 of solder joint in present image by the method for adding constant offset amount.
10) main control system calculates the Distance geometry direction of motor removing according to solder joint locus coordinate 3 and welding machine welding machine position coordinates 4 (preset parameter);
Here welding machine welding machine position coordinates 4 is the relative distance of welding machine center to the 2nd CCD vision sensor optical lens center.
11) main control system controls motor driver and drives servomotor motion, and servomotor will drive welding machine to arrive bond pad locations.
The control accuracy of servomotor reaches 1 micron, can ensure that welding machine accurately arrives target bond pad locations.
12) main control system welding machine carries out welding job;
13) inquiring whether detect solder joint all completes by user session frame mode, is go to step 14), otherwise according to weld tabs spacing (preset parameter can be arranged on software interface), go to step 7);
14) terminate.
As from the foregoing, this programme adopts man machine operation interface to accept user instruction, first, by remote CCD vision sensor Real-Time Monitoring welding machine position and operating area, click target weld tabs position by user's mouse and can realize welding machine movement fast, after welding machine arrives weld tabs position, closely for identifying that the CCD vision sensor 2 of solder joint works, the space coordinates provided according to weld point image recognizer again carries out secondary running fix, accurate tack weld, carry out follow-up welding operation, thus 6*4.5m accurately mobile control on a large scale can be realized, control accuracy reaches 0.1mm, and whole control procedure is easy and simple to handle, efficiency is high
More than show and describe general principle of the present invention, principal character and advantage of the present invention.The technical staff of the industry should understand; the present invention is not restricted to the described embodiments; what describe in above-described embodiment and description just illustrates principle of the present invention; without departing from the spirit and scope of the present invention; the present invention also has various changes and modifications, and these changes and improvements all fall in the claimed scope of the invention.Application claims protection domain is defined by appending claims and equivalent thereof.
Claims (13)
1. a welding machine mobile control system, is characterized in that, described control system comprises: main control system, motion control card, digital quantity board, CCD vision sensor, servomotor and driver, guide rail, light source, AD board, limit switch;
Described guide rail is provided with welding machine, and described driven by servomotor welding machine is along rail moving; Described limit switch is arranged in orbit, and butt welding machine displacement is carried out spacing; Described CCD vision sensor coordinates with welding machine, obtains destination locations; Described light source provides light for CCD vision sensor;
Described main control system, by Ethernet interface control CCD vision sensor, controls welding machine by serial ports, by motion control card control motor servo driver, and described motor servo driver drived control servomotor; Light source is controlled, by AD board control connection limit switch by digital quantity board.
2. according to a kind of welding machine mobile control system shown in claim 1, it is characterized in that, described CCD vision sensor comprises a CCD vision sensor of coarse positioning motor removing and the 2nd CCD vision sensor of accurate tack weld, a described CCD vision sensor is positioned at welding job region fore, and whole welding job region can be contained in its visual field; Described 2nd CCD vision sensor and light source are arranged on welding machine, and move with welding machine; A described CCD vision sensor and the mutual collaborative work of the 2nd CCD vision sensor.
3. according to a kind of welding machine mobile control system shown in claim 1, it is characterized in that, described main control system adopts user's mouse to click screen operator and chooses welding target position.
4. according to a kind of welding machine mobile control system shown in claim 1, it is characterized in that, described main control system adopts the accurate tack welder position of image recognition algorithm and bond pad locations.
5. a welding machine control method for movement, it is characterized in that, described control method adopts man machine operation interface to accept user instruction, first by remote CCD vision sensor Real-Time Monitoring welding machine position and operating area, then the movement fast of target weld tabs position control welding machine is clicked by user's mouse, after welding machine arrives weld tabs position, control closely for identifying the CCD vision sensor work of solder joint, the space coordinates provided according to weld point image recognizer again carries out secondary running fix, accurate tack weld, carries out follow-up welding operation.
6. a kind of welding machine control method for movement according to claim 5, it is characterized in that, described control method specifically comprises the steps:
1) control system resets, System self-test;
2) main control system controls a CCD vision sensor job, shows whole welding job region;
3) user is selected on whole welding job region by mouse beacon, clicks and determines target weld tabs position;
4) correct a CCD vision sensor lens distortion, calculate the space coordinates 1 of weld tabs position;
5) calculate welding machine move before locus coordinate 2;
6) main control system calculates motor removing Distance geometry direction according to target location space coordinates 1 and welding machine locus coordinate 2;
7) main control system calculates the displacement and method control motor driver drive motors motion arrival target location determined according to step (6);
8) main control system controls light source unlatching, controls the 2nd CCD vision sensor work simultaneously, and shows weld point image;
9) main control system calculates the locus coordinate 3 of solder joint;
10) the Distance geometry direction of motor removing is calculated according to solder joint locus coordinate 3 and welding machine welding machine position coordinates 4;
11) main control system is according to step 10) calculate the Distance geometry direction controlling motor driver drive motors motion determined, arrive bond pad locations;
12) main control system control welding machine carries out welding job;
13) whether main control system detects all solder joints and all completes, and is go to step (14), otherwise according to weld tabs spacing parameter, goes to step (7);
14) terminate.
7. a kind of welding machine control method for movement according to claim 6, it is characterized in that, in described step (2), a CCD vision sensor is positioned at welding job region fore 3.5m, and whole 6*4.5m welding job region can be contained in its visual field, a CCD vision sensor is presented on host display screen to main control system by Ethernet transmit image data.
8. a kind of welding machine control method for movement according to claim 6, it is characterized in that, in described step (3), user's mouse beacon moves on the computer screen in the whole welding job region of display, by left button of clicking the mouse, main control system catches mouse position and comes select target weld tabs position.
9. a kind of welding machine control method for movement according to claim 6, is characterized in that, the lens distortion calibration in described step (4) adopts grid scaling method.
10. a kind of welding machine control method for movement according to claim 6, is characterized in that, described step (5) is by the locus coordinate 2 of method tack welder before movement of Graphic Pattern Matching.
11. a kind of welding machine control method for movement according to claim 6, is characterized in that, in described step (8), the 2nd CCD vision sensor is presented on host display screen to main control system by Ethernet transmit image data.
12. a kind of welding machine control method for movement according to claim 6, is characterized in that, calculate the locus coordinate 3 of solder joint in present image in described step (9) by Recognition Algorithm for Digital Image.
13. a kind of welding machine control method for movement according to claim 6, is characterized in that, the welding machine welding machine position coordinates 4 in described step (10) is the relative distance of welding machine center to the 2nd CCD vision sensor optical lens center.
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