CN107631699A - Weld seam three-dimensional appearance construction method based on network laser - Google Patents
Weld seam three-dimensional appearance construction method based on network laser Download PDFInfo
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Abstract
A kind of weld seam three-dimensional appearance construction method based on network laser, it is with fixed angle formed shape measurement sensor by network laser and industrial camera, the grid pattern structure light that network laser is sent forms grid shaped laser spot in component surface to be measured, reflected or scattered by component surface and enter industrial camera imaging, the skeleton image perpendicular to weld seam longitudinal direction is processed the image into again, absolute altitude of the face of weld each point apart from network laser exit facet is calculated, face of weld profile is built according to absolute altitude Value Data.Construction method of the present invention can use hand-held quick and precisely to be rebuild the three-dimensional appearance of component surface weld using laser shape measurement sensor collection face of weld image information, realized the automatic quick detection to weld appearance.
Description
Technical field
The invention belongs to weld seam detection technical field.It is related to one kind using network laser to component surface weld appearance
The method for carrying out quick three-dimensional measurement.
Background technology
The quality of weldquality, directly decide the final quality of product and performance safety.The inspection of welding quality, a side
Face is able to ensure that welding structural element workmanship, improves the reliability of product, it is ensured that its safe operation；On the other hand be advantageous to change
Enter welding technique, improve product quality.
With industrial automation, and the development in each essential industry field is welded on, weld seam is carried out using sophisticated equipment
Quality testing turns into an important research content of current welding field.Weld Quality Inspection content mainly includes at present：Weld seam
Outward appearance shaping and surface defects detection, weld seam Inner Defect Testing, the various performance detections of weld seam etc..Wherein, Inner Defect Testing
Mainly include the lossless detection methods such as X-ray diffraction, ultrasonic examination；Performance detection includes the inspection such as mechanical property, corrosive nature
Survey.These, which examine to have, improves strict quality inspection standard.
Weld appearance is molded and surface defects detection is to control an important component of welding quality, the letter of its method
Single, cost is cheap, is the higher detection methods of reliability, thus be widely used in checking the impression quality of weld seam, appearance and size,
Surface defect etc..But still rely primarily on to visually observe and simply measure at present and realize, such as：Low power magnifying glass, pipeline detection mirror, weldering
Stitch detection ruler（Weld gauge）Deng.Because this kind of detection method uses contact type measurement more, easily damage piece surface
Or deformation, its scientific, influence of all verified personnel's subjective factor of accuracy.
Line laser structured light is non-contact profile testing method more advanced in current commercial Application.Swept by line laser
Retouch, recycle laser triangulation to obtain contour of object, and then obtain the topographical information of object, be one kind good three
Measuring method is tieed up, has been applied to the detection of highway, railroad rail, tyre rim abrasion etc..
CN 104697467A disclose a kind of based on the weld visual shape of line laser structured light and surface defects detection side
Method, face of weld is scanned using single line laser shape measuring sensor, three-dimensional reconstruction obtains face of weld pattern, further according to obtaining
Each point feature of face of weld pattern the defects of judging whether surface pores, overlap, undercut, incomplete fusion.Also researcher
Line laser structured light is applied to the tracking of double V-groove in welding process, to realize welding bead centering.
Existing detecting system is typically all using Britain MEAT, Canadian Servo Robot, U.S. Worthington
The laser shape measurement sensor of Industries or Japanese OPTEX FA companies manufacture, handled using single line laser and carry out three-dimensional
Rebuild structure face of weld pattern.But also there is many in practical application in industry for single line laser shape measuring sensor
Problem.
1st, existing laser shape measurement sensor uses the preferable laser of monochromaticjty, and sensor Detection results are seldom by object
The influence of surface texture, therefore it is commonly used in the industrial environment that required precision is higher, environment is complex.And it is typically arranged with
Detecting system, cost is higher, system cost can be caused to improve, and is unfavorable for realizing the industrialization of weld inspection system.
2nd, existing laser shape measurement sensor is more using single line laser scanning tested surface, the object table that single-frame images obtains
Face information is very limited, and the length of general weld seam is longer, and the one-dimensional scanning collection of single line laser is time-consuming more again and again, adds
It is subsequently to need software platform to carry out data processing, it will to cause whole system detection efficiency low, against accelerated surface pattern
The original intention of detection.
3rd, existing laser shape measurement sensor typically uses fixed installation mode, once setting height(from bottom) is set beyond sensor
Fixed scope, larger error will be brought.And the device for installing equipment needs is complex, is equally unfavorable for industrialized reality
It is existing.
4th, the power supply of existing laser shape measurement sensor, data communication interface such as data acquisition modes, collection speed
Degree, transmission means, serial communication etc. have been fixed.The laser shape measurement sensor of most of company typically all supports the use
The Survey Software of our company's exploitation, although possessing certain versatility, for the detection of industrial all kinds of different components, very
The independent development of system can be limited in big degree.
It would therefore be highly desirable to invent a kind of reliable and effective weld seam three-dimensional appearance fast construction method.
The content of the invention
It is an object of the invention to provide a kind of weld seam three-dimensional appearance construction method based on network laser, with can be fast
Speed rebuilds the three-dimensional appearance of component surface weld exactly, realizes the automatic quick detection to weld appearance.
Specifically, the weld seam three-dimensional appearance construction method of the present invention based on network laser is in a space
Coordinate systemXYZOThree dimensions in, carried out using shape measuring sensor, and provide the space coordinatesXYZO
In, using perpendicular to the direction of the weld seam be section of weld joint direction asYDirection of principal axis, the direction parallel to the weld seam are weld seam
Longitudinal direction isXDirection of principal axis, weld bead height direction areZDirection of principal axis.
Wherein, described shape measuring sensor is made up of a network laser and an industrial camera, and described
Network laser is fixed in a fixing device with industrial camera with fixed angle.In swashing for the network laser
Be provided with light-emitting face it is latticed go out optical slits, it is described go out optical slits by equidistantYAxial directionnBar slit andXAxially
'smBar slit composition arranged perpendicularly, and it is describednThe 1st article of slit in article slit is located in the network laser
Axial location.
Specifically, described network laser can be semiconductor network laser, and described industrial camera is preferred
Use CMOS industrial cameras.
And then the fixed angle between the network laser and industrial camera refers to the laser of network laser
Angle between axis and the camera lens optical axis of industrial cameraθ 0 。
Preferably, the present invention is that the industrial camera is fixed together with network laser with 12 ° of fixed angle,
That is,θ 0 =12°.Be readily appreciated that, the angle be also fromnThe incident laser line that the 1st article of slit in article slit is sent and camera lens light
Angle between axle.
Based on above-mentioned setting, the present invention builds the three-dimensional appearance of weld seam as steps described below.
1st, face of weld 3-D view is gathered using shape measuring sensor.
The shape measuring sensor is located at weld seamZDirection of principal axis, network laser light laser-emitting face send net
Trellis line-structured light is radiated on component to be measured, is formed in component surfaceXDirection of principal axis hasmBar light belt,YDirection of principal axisnBar light belt,
By(m-1)×(n-1)Individual small lattice into grid shaped laser spot, the grid shaped laser spot by component surface reflect or scatter, enter
Industrial camera is imaged.
In the present invention, preferably choose CMOS industrial cameras more than 3,000,000 pixels and carry out IMAQ, and by industrial camera
Obtain the BMP images that pixel is at least 1024 × 768.
And then the present invention also in the camera lens front end of CMOS industrial cameras equipped with optical filter, the wavelength of the optical filter and institute
State the consistent wavelength of network laser, the purpose is to only have the light of grid shaped laser spot can enter CMOS industrial cameras into
Picture, so as to get rid of the image background unrelated with the calculating of weld width Directional Contour, and it is regional reflective on component.
2nd, face of weld image preprocessing.
Latticed light spot image after imaging has certain line width, cannot be used directly for surface size and the meter of height
Calculate.Therefore the present invention needs to pre-process described image, to obtain the skeletonizing image of grid shaped laser spot.
Specific preprocess method of the invention is to handle the face of weld 3-D view using binaryzation-skeletonizing method,
Obtain bym×nBar skeleton the is formed, pixel of series of discrete (x i , y i ) composition latticed light spot image skeletonizing figure
Picture, then get rid ofXDirection of principal axismThe image of bar skeleton, it is only remaining parallel toYDirection of principal axisnThe image of bar skeleton.
Wherein, described binaryzation is by given threshold, and the coloured image of grid shaped laser spot is become and turns to black white image,
The gray value of pixel only has 0 and 1 in image.Various conventional methods can be used to carry out above-mentioned binary conversion treatment, for example, can
With reference papers《The vector technology of engineering image》(He Yongyixiajun Noboru, optical precision engineering, 2002,10 (4):
Specific processing mode in 374-378).
Described skeletonizing processing method is to calculate the center line of every light belt in the latticed light spot image, is removed
After other pixels in addition to center line, the contoured figure of latticed light spot image is obtained.
And then because it is possible that burr or discontinuous phenomenon, the present invention needs in the contoured figure after skeletonizing
Continue with flash removed algorithm, after removing the burr in contoured figure, finally give it is described bym×nBar skeleton is formed
Latticed light spot image skeletonizing image.
Therefore, heretofore described skeletonizing image is actually the axis of latticed light spot image each several part, by one
Serial variance pixel (x i , y i ) composition.
It should be clear that the above-mentioned processing method for latticed light spot image of the invention is conventional technique hand
Section, can be used as long as the various methods of the skeletonizing image of the latticed light spot image can be obtained.
In fact, in skeletonizing image obtained above, simply perpendicular to the longitudinal direction of weld seam, i.e., parallel to space coordinates
SystemXYZOInYDirection of principal axisnThe image of bar skeleton is for calculating weld bead height.Therefore, the present invention also needs to further to
It is unwanted in highly calculatingXDirection of principal axismThe image of bar skeleton removes.
Specifically, the gray value of pixel only has the picture of 0 and 1, wherein the image background part of black in skeletonizing image
The gray value of vegetarian refreshments is 0, and the gray value of the pixel of white skeletonizing image is 1.Using programmed algorithm to skeletonizing image
It is scanned, if the pixel coordinate system of image isX'OY', wherein being parallel to weld seamX'Direction, it is perpendicular to weld seamY'Direction,
By scanning, can obtain under pixel coordinate systemy=0、1、2、3……When, corresponding each rowxIn possessed gray value be 1
The number of pixel.The pixel number that gray value is 1 is more thannRowxAll remove, it becomes possible to be only left perpendicular to
The longitudinal direction of weld seam, i.e., parallel to space coordinatesXYZOInYDirection of principal axisnThe image of bar skeleton.
After above-mentioned processing, only need in next step using above-mentionednPoint on bar skeleton carries out face of weld height
Calculate.
3rd, calculatenThe absolute altitude of each point in bar skeleton image.
By above-mentioned processing, obtainnBar is parallel to space coordinatesXYZOInYThe curve of direction of principal axis.And then the present invention
Using the straight incident composite algorism with oblique incidence, it is possible to which the laser for calculating face of weld each point apart from network laser goes out
Penetrate the absolute altitude in faceH An 。
Specifically according to the following equation 1）It is described to calculatenIn bar skeleton image, appointing in any one skeleton image
A bitAThe absolute altitude distance of point and laser-emitting faceH An 's.
It following present above-mentioned formula 1）Meaning representated by middle parameters.
H An ：ThenAny point on bar skeletonAApart from the absolute altitude of laser-emitting face.
H On ：ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOPlace plan range laser-emitting face it is absolute
Highly.
H AOn ：ThenAny point in bar skeleton imageAThe incident laser line and camera lens optical axis of place plan range this skeleton
Intersection pointOThe absolute altitude of place plane.
b：The pixel dimension of pixel on image-forming component, determined according to the resolution ratio of industrial camera.
Δn AO ：APoint withOThe difference of pixel abscissa of the point on image-forming component.
l n ：ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOTo the distance of camera lens.
d：Image distance, the distance of the camera lens of industrial camera to image-forming component plane.
θ n ：ThenThe incident laser line of bar skeleton and the angle of camera lens optical axis.
α n ：ThenThe incident laser line of bar skeleton and the angle of laser axis.
Above-mentioned formula 1）Parameters in, pixel dimensionbAnd image distancedIt is constant, is determined by the industrial camera used, its
For allnAll it is identical for bar skeleton image.
Then, for any 1 skeleton image, its characteristic ginseng valueH O 、l、θWithαAlso the constant being all to determine.Cause
This, as long as measuring any point in the skeleton image from the skeleton image obtainedAWithOPixel horizontal seat of the point on image-forming component
Mark differenceΔn AO , according to formula 1）It can be obtained by the absolute altitude value of the point.
But for different skeleton images, due to its distance between with laser axis difference, its characteristic ginseng valueH O 、l、θWithαAlso all it is different.Therefore, for differentnBar skeleton image, the present invention need to determine its respective spy respectively
Levy parameter valueH On 、l n 、θ n Withα n , reuse respective characteristic ginseng valueH On 、l n 、θ n Withα n Take up an official post to calculate the skeleton image
Anticipate the absolute altitude value of a bit.
Wherein, due to described on laser-emitting facenThe 1st article of slit in article slit is located at laser axis line position, therefore,nThe 1st article in bar incident laser line by laser vertical incidence to treating side, itsα=0, using direct-injection type triangulation；Its
Afterwardsn-1Bar incident laser line is then incident with fixed angle tilt, itsα≠ 0, use oblique incidence triangulation.
It following present differentnThe respective characteristic ginseng value of bar skeleton imageH On 、l n 、θ n Withα n Confirmation method.
FornThe incident laser line of bar skeleton and the angle of laser axisα n And the angle with camera lens optical axisθ n For,
Due to what is set on laser-emitting facenSpacing between bar slit is equal, therefore between two incident laser lines of arbitrary neighborhood
Angleα 0 And it is equal, and its angle can determine according to slit spacing.
The present invention is by industrial camera and network laser with a fixed angleθ 0 It is fixed together, andnIn bar slit
The 1st article of slit be located at laser axis line position.Therefore, for the 1st article of skeleton, its incident laser line and laser axis
Angleα 1 For 0 °, the angle of incident laser line and camera lens optical axisθ 1 The as angle of laser axis and camera lens optical axisθ 0 。
It is readily appreciated that, thenThe incident laser line of bar skeleton and the angle of laser axisα n And incident laser line and mirror
The angle of head optical axisθ n Can be according to following formula 2）With 3）It is calculated.
Wherein,α 0 It is the angle between two incident laser lines of arbitrary neighborhood；θ 0 It is the laser axis of network laser
Angle between the camera lens optical axis of industrial camera.
For the 1st article of skeleton, itsH O1 It is the incident laser line that is, laser axis and camera lens optical axis of the 1st article of skeleton
Intersection pointOThe absolute altitude of place plan range laser-emitting face.Because network laser and industrial camera are with fixed
Angleθ 0 It is fixed together, therefore, by being demarcated to shape measuring sensor, you can obtainH O1 Concrete numerical value, its
An and fixed constant.
CalibrateH O1 Concrete numerical value after, then othernThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOPut down at place
Absolute altitude of the identity distance from laser-emitting faceH On Can be according to following formula 4）It is calculated.
Similarly, the 1st bar of incident laser line of skeleton and the intersection point of camera lens optical axisOTo the distance of camera lensl 1 An and fixation
Constant.
The present invention is by using Zhang Zhengyou camera calibrations method (Zhengyou Zhang. Flexible camera
Calibration by viewing a plane from unknown orientations [C] .Proceedings of
the 7th International Conference on Computer Vision, 1999：666-673.) to the work of selection
Industry camera is demarcated, and can obtain the focal length of the industrial cameraf, image distancedDeng camera parameter.
And then according to formula1/f = 1/l 1 + 1/d, it is possible to the incident laser line and mirror of the 1st article of skeleton is calculated
The intersection point of head optical axisOTo the distance of camera lensl 1 。
It is aware ofl 1 Occurrence after, othernThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOTo camera lens away from
Froml n Equally can be according to following formula 5）It is calculated.
Therefore, be fixed together the shape formed for any one by network laser and industrial camera with fixed angle
Shape measurement sensor, its parameterα n Withθ n Can be by fixed angleθ 0 Derive and determine with slit spacing,bWithdDetermined by industrial camera,
As long as calculate againnCorresponding to bar skeleton image differencel 1 、l 2 、l 3 、……、l n , andH O1 、H O2 、H O3 、……、H On , for formula
1）In, it is possible to it is calculatednThe absolute altitude of arbitrfary point on bar skeleton, that is, calculate weld seam each point and sensed apart from shape measure
The absolute altitude of device laser-emitting face.
ObtainingnIn bar skeleton image after absolute altitude value a little, according to these absolute altitude Value Datas, with regard to energy
Enough construct the surface profile of scanned weld seam.
4th, to being calculatednThe correction of each point absolute altitude in bar skeleton image.
Shape measuring sensor used in the present invention is different from existing single line or dual laser shape measuring sensor,
It is a kind of latticed laser caused by it.Because the latticed laser selected by the present invention is not simple a branch of structure light, and
It is to be combined by multi beam structure light, it is impossible to calculate the height of laser beam using traditional laser triangulation again, therefore
Present invention employs the direct-injection type of innovation and the combined measurement method of two kinds of triangulations of oblique incidence.
Meanwhile the present invention uses above-mentioned improved laser triangulation, what is be calculated is weld seam each point Distance-sensing
The absolute altitude of device laser-emitting face, rather than the height for measuring two interplanars of component that traditional measurement method is calculated
Difference.Like this, the inventive method is not strict for the distance between shape measuring sensor and measured component and angle
Requirement, these problems can be corrected to obtain real member height by using the absolute altitude value measured.And
Traditional measurement method is due to that can not correct, it is necessary to measure laser sensor fixed position and height, otherwise can bring survey
Measure error.
Therefore, shape measuring sensor of the invention and conventional laser sensor ratio compared with, it is very easy to use, can during measurement
To correct height, so the present invention can be adopted by the way of hand-held using shape measuring sensor to weld image
Collection.
In weld seam three-dimensional appearance construction method of the present invention, surface information of the handheld form measurement sensor to weld seam
When being acquired, face of weld each point apart from the absolute altitude of laser-emitting face be horizontal based on laser-emitting face and
It is calculated.But the hand for holding shape measuring sensor inevitably produces certain swing or inclination, causes to swash
Light-emitting face is integral inclined left-right and front-back direction, and this will be to calculating face of weld each point apart from the absolute of laser-emitting face
Highly impact, produce error.
Therefore, weld seam three-dimensional appearance construction method of the invention further comprises to hand-held shape measuring sensor collection weld seam
The correction of laser-emitting face heeling error during information.
The calibration substance includes laser-emitting face in weld seamYDirection of principal axis tilt forward and back andXThe lateral tilting of direction of principal axis
Tiltedly.
When the laser-emitting face of shape measuring sensor is horizontal, the both sides of skeleton image for measuring to obtain are non-
The absolute altitude numerical value of any two points should be consistent in welded seam area.Therefore, according to non-welded seam area inside weldYDirection of principal axis
OrXAbsolute altitude difference between direction of principal axis specified point, it becomes possible to which judging laser-emitting face, whether there occurs left and right or front and rear
Tilt, and calculate its left and right or the angle tilted forward and back, so as to be corrected to the heeling error of laser-emitting face.
Therefore, whennDifference in height be present between the starting point absolute altitude of any 2 in bar skeleton imageΔH x When, it was demonstrated that
Shape measuring sensor is tilted, i.e., along weld seamXDirection of principal axis run-off the straight.Now, according to triangle geometrical relationship, with
The difference in height of above-mentioned 2 skeletons calculatedΔH x As the side opposite the angle at angle of inclination, the spacing between selected 2 skeletons
Adjacent angle side as angle of inclination, you can calculate laser-emitting face and existXThe angle that tilts of direction of principal axisβ。
Calculate angle of inclinationβAfterwards, it is possible to according to following formula 6）To obtained abovenIt is any one in bar skeleton image
Any point in bar skeleton imageAThe absolute altitude distance of point and laser-emitting faceH A Carry outXThe correction of direction of principal axis.
It following present above-mentioned formula 6）Meaning representated by middle parameters.
H A '：The after the correction of left and rightnAbsolute altitude of any point apart from laser-emitting face on bar skeleton.
H A ：The before the correction of left and rightnAbsolute altitude of any point apart from laser-emitting face on bar skeleton.
β：Laser-emitting face existsXOn direction of principal axis with the angle of inclination of horizontal plane.
α n ：ThenThe incident laser line of bar skeleton and the angle of laser axis.
Similarly, when difference in height being present between the starting point of any 1 skeleton image and cut off absolute altitudeΔH y When, card
Bright shape measuring sensor is tilted forward and back, i.e., along section of weld joint direction, that is,YDirection of principal axis tilts.
The starting point of the skeleton image and the difference of cut off absolute altitude can now be calculatedΔH y , and the bone
Frame image existsYThe pixel value difference of direction of principal axisn.Because the difference in height between each point in same skeleton image linearly changes,
That is the height difference of each pixel and previous pixel is identical in skeleton image, so, single pixel it
Between difference in height can be expressed as：Δh 0 =ΔH y /n。
Then, each height correction value put should be existed according to itself and starting point in the skeleton imageYDirection of principal axis
Pixel value difference is several to increase or decreaseΔh 0 , specifically according to following formula 7）To above-mentioned progressXDirection of principal axis corrects exhausted
To heightH A 'ContinueYThe correction of direction of principal axis.
It following present above-mentioned formula 7）Meaning representated by middle parameters.
H A ''：After front and rear correctionnAbsolute altitude of any point apart from laser-emitting face on bar skeleton.
H A '：Before front and rear correctionnAbsolute altitude of any point apart from laser-emitting face on bar skeleton.
n y ：ThenAny point exists with starting point on bar skeletonYThe pixel value difference of direction of principal axis.
ΔH y ：ThenStarting point and the difference of cut off absolute altitude on bar skeleton.
After above-mentioned left and right correction and front and rear correction, it is possible to obtain the true of any point in any 1 skeleton image
Real absolute altitude value.
The light source of traditional single line laser shape measuring sensor only has a laser rays, therefore can not pass through the spy of laser rays
Sign is positioned.Weld seam three-dimensional appearance construction method provided by the invention based on network laser, selected is latticed
There is multi-stripe laser line in laser shape measurement sensor, can not only collect the face of weld image letter of certain length simultaneously
Breath, altitude location can also be carried out by the position where the mutual alignment relation pair sensor between laser rays, and to improve
Laser triangulation calculate the absolute altitude of weld seam each point range sensor plane, and then sensor can also be accessed and existed
Inclination conditions in three dimensions, the absolute altitude of the weld seam each point range sensor plane to obtaining are corrected, and make measurement
As a result it is more accurate.
Based on above-mentioned principle, the face of weld pattern construction method that the present invention designs can use net by the way of hand-held
Trellis laser shape measurement sensor efficiently gathers face of weld image information, and one two field picture of collection can obtainnBar weld seam
Cross section contour, the detection efficiency of face of weld is greatly improved, be very useful to the realization of system industrial.
Laser sensor of the present invention is the latticed laser with one fixed width, shorter for some length
Industrial weld seam when testing, it is not necessary to face of weld is scanned, tested weldering is can detect that using only single imaging
The surface appearance feature of seam.
Brief description of the drawings
Fig. 1 is the optical principle schematic diagram of shape measuring sensor detection face of weld absolute altitude of the present invention.
Fig. 2 is the weld seam original image collected with shape measuring sensor of the present invention.
Fig. 3 is that the present invention carries out pretreated result to Fig. 2 original images.
Fig. 4 is that edge occurs for shape measuring sensor of the present inventionXLaser optical path figure when tilting of direction of principal axis.
Fig. 5 is that edge occurs for shape measuring sensor of the present inventionYLaser optical path figure when tilting forward and back of direction of principal axis.
Fig. 6 is the uncorrected weld profile image that the present invention obtains.
Fig. 7 is the weld profile image after correction.
Embodiment
Following embodiments are only the preferred technical solution of the present invention, are not used to carry out any restrictions to the present invention.For
For those skilled in the art, the present invention can have various modifications and variations.Within the spirit and principles of the invention, made
Any modification, equivalent substitution and improvements etc., should be included in the scope of the protection.
The present embodiment builds the three-dimensional appearance of weld seam using the latticed laser shape measurement sensor of a hand-held.For just
In description, weld seam is placed in a space coordinatesXYZOThree dimensions in, and set the longitudinal direction of weld seam asXDirection of principal axis,
Cross-wise direction isYDirection of principal axis, highly it isZDirection of principal axis.
The latticed laser shape measurement sensor is by wavelength 650nm semiconductor network laser and one
CMOS industrial cameras are formed, and both are fixed in a fixing device, the axis of semiconductor network laser and CMOS
Angle between the camera lens optical axis of industrial camera is 12 °.
On the laser-emitting face of semiconductor network laser be provided with byYAxial direction 5 slits withX9 of axial direction are narrow
What seam was formed5×9It is latticed go out optical slits, the wide 0.5mm of slit.Wherein,Y1st article of slit of axial direction is located at semiconductor grid knot
The axis line position of structure laser, therefore the emergent light of the 1st article of slit and the angle of laser axisα 1 =0°.From the 1st article of slit to
5th article of slit, angle increase by 1 ° successively, that is,α 2 =1 °,α 3 =2 °,α 4 =3 °,α 5 =4°。
Because the angle between the axis of semiconductor network laser and the camera lens optical axis of CMOS industrial cameras is
12 °, therefore, the 1st article of emergent light of slit and the angle of camera lens optical axisθ 1 =12 °, other slits increase by 1 ° successively, that is,θ 2 =
13 °,θ 3 =14 °,θ 4 =15 °,θ 5 =16°。
The present embodiment chooses the CMOS industrial cameras of 3,000,000 pixels, and obtains pixel by industrial camera and be1024×768's
BMP images.In CMOS industrial camera front-end configuration wavelength 650nm optical filter.
Above-mentioned CMOS industrial cameras are demarcated using Zhang Zhengyou camera calibrations method, obtain the focal length of camerafAnd image distanced.According to
Formula1/f = 1/l 1 + 1/d, the 1st article of emergent light of slit and the intersection point of camera lens optical axis is calculatedOTo the distance of camera lensl 1 ,
According still further to formula 5）Can calculates the emergent light of other 4 slits and the intersection point of camera lens optical axisOTo the distance of camera lensl n 。
Latticed laser shape measurement sensor is held, from three dimensionsZDirection of principal axis toXOYPlane is scanned throwing
Penetrate, the grid pattern structure light that semiconductor network laser light laser-emitting face is sent is radiated atXOYIn plane,XOY
Plane is formedXDirection of principal axis has9Bar light belt,YDirection of principal axis5Bar light belt, by equidistant8×4=32The individual small lattice of square into
Grid shaped laser spot.The grid shaped laser spot quiltXOYPlane reflection or scattering, it is imaged into industrial camera.
Now,XOYAny 1 of the grid shaped laser spot formed in planeYThe length of direction of principal axis light belt, the light belt is in industry
The length corresponding to image formed in camera, and the laser-emitting face distance of semiconductor network laserXOYPlane
Height can all be measured, according to triangle principle, you can calculate the emergent light of the 1st article of slit that is, laser axis with
The intersection point of camera lens optical axisOThe absolute altitude of place plan range laser-emitting faceH O1 .CalibrateH O1 Concrete numerical value after, then its
The emergent light of his 4 slits and the intersection point of camera lens optical axisOThe absolute altitude of place plan range laser-emitting faceH On Can also root
According to formula 4）It is calculated.
Accordingly, obtainYAxially each self-corresponding characteristic ginseng value of 5 slit emergent lightsH On 、l n 、θ n Withα n 。
Optical principle using shape measuring sensor detection face of weld absolute altitude is as shown in Figure 1.It is hand-held latticed
Laser shape measurement sensor, from weld seamZDirection of principal axis, edgeXDirection of principal axis is scanned projection, semiconductor grid to face of weld
The grid pattern structure light that structure laser light laser-emitting face is sent is radiated on weld seam to be measured, is formed in face of weldXAxle
Direction has9Bar light belt,YDirection of principal axis5The grid shaped laser spot of bar light belt.The grid shaped laser spot is reflected or scattered by face of weld, warp
After wavelength 650nm optical filter filters, retain the light that wavelength is 650nm, after the light for filtering other wavelength, into CMOS industry phases
Machine is imaged.
A fixed angle, CMOS industrial cameras be present with the line-structured light that network laser is sent in CMOS industrial cameras
The line laser on face of weld is imaged from another angle.When line-structured light is irradiated to face of weld, due to weld seam table
The position height of each dot grid laser irradiation in face is different, incident light band can be caused to be moved along incident light axis, CMOS industrial cameras connect
Scattered or the angle of reflection laser is different, the imaging point on industrial camera also can be moved accordingly.For grid laser
Any one laser spots, industrial camera can all obtain the position of laser image spot, ultimately form shown in a Fig. 2, can embody
Face of weld pattern, the latticed light spot image deformed.According to the light spot image, the whole surface of weldering may finally be calculated and swashed
The position height of illumination exit point, so as to obtain the height profile of whole grid laser reflection, that is, weld seam in some cross section
Contour curve.
Weld seam it is actually detected in, face of weld image that industrial camera collects removes the light spot image of grid laser
Outside, in addition to weld seam in itself, other positions of component, and component surface is regional reflective.In image with weld seam lateral contour
Error can all be increased by calculating unrelated part, directly affect the accuracy of whole system measurement.The quality of processing result image, directly
Connecing influences the testing result of face of weld, therefore the processing of digital picture is to obtain the vital ring of face of weld accurate information
Section.
The regionality removed by optical filter in the image background unrelated with the calculating of weld width Directional Contour and component is anti-
After light, obtained latticed light spot image also has certain line width, cannot be used directly for surface size and height calculates.Cause
This, CMOS industrial cameras transmit the latticed light spot image of the face of weld collected to computer, and image is entered by software
The methods of going and further handle, including using gray proces, binary conversion treatment, skeletonizing processing, Image erosion, obtains Fig. 3
Shown only grid laser facula contoured figure5×9Latticed skeletonizing image.So enable to subsequently calculate
Journey is not influenceed by unrelated images factor, ensure that the authenticity of systematic survey.
Then, then by above-mentioned skeletonizing imageXThe image of 9 skeletons of direction of principal axis removes, and only retains and is indulged parallel to weld seam
The image of 5 skeletons in direction, for finally calculating the height of weld seam.
According to this 5 parallel to space coordinatesXYZOInYThe curve of direction of principal axis, using straight incident compound with oblique incidence
Algorithm, utilize formula 1）Can calculates face of weld each point apart from the exhausted of the laser-emitting face of semiconductor network laser
To heightH A 。
Specifically, the absolute altitude distance of the point in this 5 skeleton images and laser-emitting faceH A It is according to following 5 respectively
What individual formula was calculated.
Obtained in 5 skeleton images after absolute altitude value a little, according to these absolute altitude Value Datas, you can just
Step obtains the transverse contour line of 5 weld seams, as shown in Figure 6.
, it can be seen that the non-position while welding in the both sides of 5 contour lines and not parallel from Fig. 6, and wherein contour line
Non- weld seam part absolute altitude simultaneously differs.The appearance of both of these case, all it is due to hold using sensor to face of weld
When being acquired, the small skew in direction all around can inevitably occur for hand, cause the integral inclined of sensor, it will
The absolute altitude for calculating weld seam each point range sensor plane is impacted, the inaccuracy for causing final profile line to shape, band
Carry out measurement error.
Therefore, it is necessary to be corrected to hand-held error.
The heeling condition of hand-held sensor can be divided into following 4 kinds of situations and carry out discriminatory analysis.Here, tiltedly refer to certain inclination
Be that sensor is integrally partial to certain side.
To the left side along bead direction, as shown in Figure 4.
Tilted to along the right side of bead direction, as shown in Figure 4.
Tilted to along perpendicular to the outside of bead direction, as shown in Figure 5.
Tilted to along the inboard perpendicular to bead direction, as shown in Figure 5.
In weld seam longitudinal direction, that is, edgeXWhen direction of principal axis tilts, laser optical path such as Fig. 4 that laser is sent
It is shown.At this moment the absolute altitude for the point that non-welded seam area can be located at according to any two contour lines whether there is difference, to demonstrate,prove
Bright whether there is tilts.
And then inclined angle can be obtained according to the changing value of specified point absolute altitude on differently contoured line, and to exhausted
To highly correcting, with the height value after being corrected.
Utilize figure intermediate cam shapeABCTriangle geometrical relationship, obtain the angle that tiltsβ.The 1st article of light belt is calculated in structure
The non-position while welding certain point of part and the absolute altitude put under the 5th article of same ordinate of light belt are poor, as figure intermediate cam shapeABC'sAB
Side, it is known thatACSide, the angle that tilts can be obtained according to triangle geometrical relationshipβ。
Calculate angle of inclinationβAfterwards, it is possible to according to formula 6）To the left and right that each is put on the 1st to the 5th article of contour line
Tilt and carry outXThe correction of direction of principal axis.
In seam cross-section direction, that is, edgeYWhen direction of principal axis tilts forward and back, the laser optical path that laser is sent is such as
Shown in Fig. 5.At this moment the absolute altitude for the point that non-welded seam area can be located at according to any one contour line whether there is difference, come
Prove whether to exist and tilt forward and back.
And then inclined angle can be obtained according to the changing value of specified point absolute altitude on same contour line, and to exhausted
To highly correcting, with the height value after being corrected.
The difference in height between first point and last point on the 5th article of contour line is calculated, while calculates first
Pixel value difference between point and last point, both ratio is the difference in height of single pixel.
After the difference in height for calculating single pixel, it is possible to according to formula 7）To each point on the 1st to the 5th article of contour line
Tilt forward and back progressYThe correction of direction of principal axis.
After above-mentioned left and right correction and front and rear correction, it is possible to obtain 5 weld profiles after the correction shown in Fig. 7
Line.
Claims (10)
1. a kind of weld seam three-dimensional appearance construction method based on network laser, is in space coordinatesXYZOThree dimensions
In, built using the shape measuring sensor being made up of network laser and industrial camera with fixed angle, the sky
Between coordinate systemXYZOIn, using perpendicular to the direction of weld seam asYDirection of principal axis, the direction parallel to weld seam areXDirection of principal axis, weld bead height
Direction isZDirection of principal axis；Set on the laser-emitting face of the network laser it is latticed go out optical slits, it is described go out optical slits
By equidistantYAxial directionnBar slit andXAxial directionmBar slit arrangement is formed, andnThe 1st article in article slit is located at the net
The axis line position of lattice structure laser；
The construction method includes：
1）, positioned at weld seamZThe network laser of the shape measuring sensor of direction of principal axis sends grid pattern structure light and is radiated at
On component to be measured, formed in component surfaceXDirection of principal axis hasmBar light belt,YDirection of principal axisnBar light belt, by(m-1)×(n-1)It is individual small
Lattice into grid shaped laser spot, the grid shaped laser spot by component surface reflect or scatter enter industrial camera be imaged, collect
The 3-D view of face of weld；
2）, using the binaryzation-skeletonizing method processing face of weld 3-D view, obtain bym×nBar skeleton form, one
Serial variance pixel (x i , y i ) composition latticed light spot image skeletonizing image, then get rid ofXDirection of principal axismBar bone
The image of frame, it is only remaining parallel toYDirection of principal axisnThe image of bar skeleton；
3）, according to the following equation 1）Calculate describednIn bar skeleton image, any point in any one skeleton imageAPoint with
The absolute altitude distance of laser-emitting faceH An ：
H An ：ThenAny point on bar skeletonAApart from the absolute altitude of laser-emitting face；
H On ：ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOThe absolute height of place plan range laser-emitting face
Degree；
H AOn ：ThenAny point in bar skeleton imageAThe friendship of the incident laser line and camera lens optical axis of place plan range this skeleton
PointOThe absolute altitude of place plane；
b：The pixel dimension of pixel on image-forming component；
Δn AO ：APoint withOThe difference of pixel abscissa of the point on image-forming component；
l n ：ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOTo the distance of camera lens；
d：Image distance；
θ n ：ThenThe incident laser line of bar skeleton and the angle of camera lens optical axis；
α n ：ThenThe incident laser line of bar skeleton and the angle of laser axis；
4）, according to obtainingnIn bar skeleton image a little absolute altitude Value Data structure weld seam surface profile.
2. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that described
Formula 1）In, thenThe incident laser line of bar skeleton and the angle of laser axisα n According to following formula 2）It is calculated：
Whereinα 0 It is the angle between two incident laser lines of arbitrary neighborhood；
ThenThe incident laser line of bar skeleton and the angle of camera lens optical axisθ n According to following formula 3）It is calculated：
Whereinθ 0 It is the angle between the laser axis of network laser and the camera lens optical axis of industrial camera；
ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOThe absolute altitude of place plan range laser-emitting faceH On
According to following formula 4）It is calculated：
WhereinH O1 It is laser axis and the intersection point of camera lens optical axis of the shape measuring sensor calibratedOPlace plan range swashs
The absolute altitude of light-emitting face；
ThenThe incident laser line of bar skeleton and the intersection point of camera lens optical axisOTo the distance of camera lensl n According to following formula 5）Calculate
Arrive：
Whereinl 1 According to formula1/f = 1/l 1 + 1/dIt is calculated,fFor the focal length of industrial camera.
3. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that described
Method is also included to being calculatednThe absolute altitude value of each point is corrected in bar skeleton image, and the correction is included to swashing
Light-emitting face is in weld seamYTilting forward and back for direction of principal axis is corrected, and in weld seamXTilting for direction of principal axis is corrected.
4. the weld seam three-dimensional appearance construction method according to claim 3 based on network laser, it is characterized in that described
The correction to tilt is to calculatenDifference in height in bar skeleton image between the starting point absolute altitude of any 2ΔH x , withΔ H x As the side opposite the angle at angle of inclination, adjacent angle side of the spacing as angle of inclination between selected 2 skeletons, laser is calculated
Exit facet existsXThe angle that tilts of direction of principal axisβ, according to following formula 6）To what is obtainednAny one bone in bar skeleton image
Any point on frame imageAThe absolute altitude distance of point and laser-emitting faceH A Carry outXThe correction of direction of principal axis：
Wherein：
H A '：The after the correction of left and rightnAbsolute altitude of any point apart from laser-emitting face on bar skeleton；
H A ：The before the correction of left and rightnAbsolute altitude of any point apart from laser-emitting face on bar skeleton；
β：Laser-emitting face existsXOn direction of principal axis with the angle of inclination of horizontal plane；
α n ：ThenThe incident laser line of bar skeleton and the angle of laser axis.
5. the weld seam three-dimensional appearance construction method according to claim 3 based on network laser, it is characterized in that described
The correction tilted forward and back is to calculate the difference in height between the starting point of any 1 skeleton image and cut off absolute altitudeΔH y ,
And according to the skeleton imageYThe pixel value difference of direction of principal axisnCalculate the difference in height between single pixelΔh 0 =ΔH y /n, under
State formula 7）To above-mentioned progressXThe absolute altitude of direction of principal axis correctionH A 'ContinueYThe correction of direction of principal axis：
Wherein：
H A ''：After front and rear correctionnAbsolute altitude of any point apart from laser-emitting face on bar skeleton；
H A '：Before front and rear correctionnAbsolute altitude of any point apart from laser-emitting face on bar skeleton；
n y ：ThenAny point exists with starting point on bar skeletonYThe pixel value difference of direction of principal axis；
ΔH y ：ThenStarting point and the difference of cut off absolute altitude on bar skeleton.
6. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that described
Industrial camera is fixed together with network laser with 12 ° of fixed angle.
7. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that using
CMOS industrial cameras more than 3000000 pixels carry out IMAQ to weld seam, and obtain pixel by industrial camera and be at least 1024
× 768 BMP images.
8. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that in institute
The camera lens front end of industrial camera is stated equipped with optical filter, the wavelength one of the wavelength of the optical filter and the network laser
Cause.
9. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that described
Binary processing method be by given threshold, the coloured image of grid shaped laser spot is become to the gray scale for turning to pixel in image
The black white image of value only 0 and 1.
10. the weld seam three-dimensional appearance construction method according to claim 1 based on network laser, it is characterized in that described
Skeletonizing processing method be to calculate the center line of every light belt in the latticed light spot image, remove in addition to center line
After other pixels, the contoured figure of latticed light spot image is obtained.
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