CN111563911A - Automatic label welding method and device based on multiple steel bundles - Google Patents

Automatic label welding method and device based on multiple steel bundles Download PDF

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CN111563911A
CN111563911A CN202010457835.5A CN202010457835A CN111563911A CN 111563911 A CN111563911 A CN 111563911A CN 202010457835 A CN202010457835 A CN 202010457835A CN 111563911 A CN111563911 A CN 111563911A
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steel
welded
face
welding
target
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CN111563911B (en
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孙茂杰
李福存
孙敬忠
钱静洁
朱正清
苏循亮
周鼎
汪光明
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Jiangsu Jinheng Information Technology Co Ltd
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Jiangsu Jinheng Information Technology Co Ltd
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    • G06COMPUTING; CALCULATING OR COUNTING
    • G06TIMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00Image analysis
    • G06T7/10Segmentation; Edge detection
    • G06T7/13Edge detection
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06TIMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00Image analysis
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Abstract

The application relates to the technical field of image processing, and discloses an automatic label welding method and device based on a plurality of steel bundles, wherein in the method, an end face image of a steel bundle to be welded is obtained at first, an end face outline of each steel product is extracted from the end face image of the steel bundle to be welded, and a central point coordinate of the end face outline of each steel product is obtained; expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle; acquiring end face outlines of all steel corresponding to each steel bundle according to the center point coordinates of the end face outline of each steel and the outline of each steel bundle; acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all steel materials corresponding to each steel bundle; and performing label welding according to the set of points to be welded of each steel bundle. According to the method, before the label welding points are selected, the outer contours of the overlapped and crossed steel bundles are extracted, all the steel products belonging to the overlapped and crossed steel bundles are divided, and the selection precision of the subsequent label welding points is improved.

Description

Automatic label welding method and device based on multiple steel bundles
Technical Field
The application relates to the technical field of image processing, in particular to a method and a device for automatically welding a label based on a plurality of steel bundles.
Background
After the steel products are bundled and packaged in steel mills, a certain number of labels are welded on the end face of each steel bundle, and the labels are used for displaying basic information of the steel bundles, such as model, specification, production date and the like. The traditional label welding mode is manual welding, so that the efficiency is low, and the label welding machine cannot be suitable for production with high yield. In order to improve the efficiency, a machine control mode is generally adopted by many steel mills at present to realize automatic welding of the labels.
The process for automatically welding signs generally comprises: when the current steel bundle is conveyed to a position to be welded, the system controls the binocular camera to acquire end face images of the steel bundle, a label welding point is selected through image processing, then the telescopic welding gun is controlled to weld a label of the current steel bundle according to three-dimensional coordinates of the label welding point, and after welding is completed, the system controls the binocular camera to acquire end face images of the next steel bundle, so that welding point selection and welding work are performed.
When a plurality of steel bundles are transported through a chain bed, the phenomenon of overlapping and crossing easily occurs, if three steel bundles are overlapped together, the end faces of the three steel bundles can be in a shape like a Chinese character 'pin' in an image obtained by shooting through a binocular camera, and if the steel bundles are close to each other side by side, the end face image can be in a shape like a Chinese character 'pin', under the condition, the system is difficult to identify the respective outline of each steel bundle, and the selection precision of a label welding point is influenced.
Disclosure of Invention
In order to solve the problem that when a plurality of steel bundles are overlapped and crossed, the system is difficult to identify the respective outline of each steel bundle, and the selection precision of a label welding point is influenced, the application discloses a method and a device for automatically welding a label based on the plurality of steel bundles through the following embodiments.
The application discloses in a first aspect an automatic sign welding method based on a plurality of steel bundles, comprising the following steps:
acquiring an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle;
extracting the end face outline of each steel from the end face image of the steel bundle to be welded, and acquiring the center point coordinate of the end face outline of each steel;
expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle;
acquiring the end face contour of all steel corresponding to each steel bundle according to the center point coordinate of each steel end face contour and the outer contour of each steel bundle;
acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle;
and performing label welding according to the set of points to be welded of each steel bundle.
Optionally, the obtaining, according to the center point coordinate of each steel end face profile and the outer profile of each steel bundle, the end face profiles of all steel corresponding to each steel bundle includes:
acquiring an outer contour curve of each steel bundle;
and dividing the central point of each steel end face profile into the corresponding outer profile curve according to the ray method, and obtaining the end face profiles of all the corresponding steel in each steel bundle.
Optionally, the obtaining a set of to-be-welded points of each steel bundle according to end surface profiles of all steel products corresponding to each steel bundle includes:
setting an end face welding area of a target steel bundle according to X values and Y values of coordinates of center points of end face outlines of all steel materials in the target steel bundle, wherein the target steel bundle is any one of the steel bundles to be welded;
dividing the end face welding area of the target steel bundle into a plurality of welding subareas, wherein the number of the welding subareas is consistent with the number of the labels to be welded of the target steel bundle;
screening a plurality of welding points to be welded from the center points of the end face outlines of all the steel products in the target steel bundle according to the Z values of the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle;
and generating a plurality of to-be-welded point sets of the target steel bundle according to the plurality of to-be-welded points, wherein the number of to-be-welded points contained in each to-be-welded point set is consistent with the number of the welding subareas, different to-be-welded points in each to-be-welded point set correspond to different welding subareas, and the distance between different to-be-welded points in each to-be-welded point set is not smaller than the size of the label to be welded.
Optionally, the label welding is performed according to the set of to-be-welded points of each steel bundle, and includes:
acquiring the sum of Z values of all to-be-welded points in each to-be-welded point set of the target steel bundle;
setting the priority levels of all to-be-welded point sets of the target steel bundle according to the sequence of the Z value sum from small to large, wherein the priority level of the to-be-welded point set with the smallest Z value sum is the highest;
and welding the label to be welded to the end face of the target steel bundle from the point set to be welded with the highest priority level according to the points to be welded in the point set to be welded in sequence.
Optionally, the welding, starting from the set of to-be-welded points with the highest priority, of the to-be-welded points in the set of to-be-welded points in sequence, of the to-be-welded tag to the end face of the target steel bundle includes:
and in the welding process, if the label welding fails, the label is continuously welded by using the welding points to be welded in the welding point set with the next priority level.
Optionally, the step of screening out a plurality of to-be-welded points from the center points of all the steel end face contours of the target steel bundle according to the Z values of the coordinates of the center points of all the steel end face contours of the target steel bundle includes:
setting a reference surface of a target subregion, wherein the reference surface is a plane where a steel end face corresponding to a central point with the minimum Z value in the target subregion is located, and the target subregion is any welding subregion;
acquiring the minimum distance between a target end face and the reference surface, wherein the target end face is a plane where any one steel end face in the target sub-area is located;
and judging whether the minimum distance does not exceed the length of the gun head of the telescopic welding gun, if so, setting the outline center point of the steel end face corresponding to the target end face as the point to be welded.
Optionally, the setting of the end face welding area of the target steel bundle according to the X value and the Y value of the coordinates of the center points of the end face profiles of all steel materials in the target steel bundle includes:
extracting a maximum X value, a minimum X value, a maximum Y value and a minimum Y value from the coordinates of the center points of the end faces of all the steel products in the target steel bundle, and defining a rectangular area according to the four values;
setting the rectangular area as an end face welding area of the target steel bundle.
Optionally, the dividing the end face welding region of the target steel bundle into a plurality of welding subareas includes:
acquiring the area of the end face welding area;
and equally dividing the end face welding area into a plurality of welding subareas according to the area according to the number of the labels to be welded.
Optionally, the extracting an end face profile of each steel product from the end face image of the to-be-welded steel bundle and obtaining a center point coordinate of the end face profile of each steel product includes:
extracting the end face contour of each steel material from a first end face image to obtain a first end face contour set, wherein the first end face image is acquired by a first camera in a binocular camera;
extracting the end face contour of each steel product from a second end face image to obtain a second end face contour set, wherein the second end face image is acquired by a second camera in the binocular camera;
acquiring a first central point set and a second central point set, wherein the first central point set comprises central points of all end surface contours in the first end surface contour set, and the second central point set comprises central points of all end surface contours in the second end surface contour set;
matching all central points in the first central point set and the second central point set, wherein if the distance between only one central point in the second central point set and a target point does not exceed a preset threshold value, the matching is successful, otherwise, the matching fails, the target point is any central point in the first central point set, and the preset threshold value is the minimum value of the end surface radius of all steel products in the steel bundle to be welded;
taking all successfully matched central points in the first central point set as a first target point set, and taking all successfully matched central points in the second central point set as a second target point set;
and acquiring the center point coordinates of the end face profile of each steel product according to the first target point set and the second target point set.
The second aspect of the application discloses an automatic welding label device based on a plurality of steel bundles, which is applied to the automatic welding label device based on a plurality of steel bundles of the first aspect of the application, and the device comprises:
the end face image acquisition module is used for acquiring an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle;
the end face contour extraction module is used for extracting the end face contour of each steel product from the end face image of the steel bundle to be welded and acquiring the center point coordinate of the end face contour of each steel product;
the outer contour extraction module is used for performing expansion processing on the end face image of the steel bundle to be welded and extracting the outer contour of each steel bundle;
the end face contour dividing module is used for acquiring the end face contour of all the steel corresponding to each steel bundle according to the center point coordinate of each steel end face contour and the outer contour of each steel bundle;
the to-be-welded point set acquisition module is used for acquiring the to-be-welded point set of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle;
and the welding module is used for carrying out label welding according to the to-be-welded point set of each steel bundle.
Optionally, the end surface profile dividing module includes:
the outer contour curve acquisition unit is used for acquiring an outer contour curve of each steel bundle;
and the dividing unit is used for dividing the center point of each steel end face profile into the corresponding outer profile curve according to the ray method, and acquiring the end face profiles of all the corresponding steel in each steel bundle.
Optionally, the to-be-welded point set obtaining module includes:
the welding area setting unit is used for setting the end face welding area of the target steel bundle according to the X value and the Y value of the coordinates of the center points of the end face outlines of all steel materials in the target steel bundle, wherein the target steel bundle is any one of the steel bundles to be welded;
the welding area dividing unit is used for dividing the end face welding area of the target steel bundle into a plurality of welding subareas, and the number of the welding subareas is consistent with the number of the labels to be welded of the target steel bundle;
the to-be-welded point screening unit is used for screening a plurality of to-be-welded points from the center points of the end face outlines of all the steel products in the target steel bundle according to the Z values of the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle;
and the to-be-welded point set generating unit is used for generating a plurality of to-be-welded point sets of the target steel bundle according to the plurality of to-be-welded points, wherein the number of the to-be-welded points contained in each to-be-welded point set is consistent with the number of the welding subareas, different to-be-welded points in each to-be-welded point set correspond to different welding subareas, and the distance between different to-be-welded points in each to-be-welded point set is not smaller than the size of the label to be welded.
Optionally, the welding module includes:
the Z value summing unit is used for acquiring the sum of the Z values of all to-be-welded points in each to-be-welded point set of the target steel bundle;
the priority level setting unit is used for setting the priority levels of all to-be-welded point sets of the target steel bundle according to the sequence from small to large of the Z value sum, wherein the priority level of the to-be-welded point set with the smallest Z value sum is the highest;
and the grade welding unit is used for welding the label to be welded to the end face of the target steel bundle from the point set to be welded with the highest priority grade according to the points to be welded in the point set to be welded in sequence.
Optionally, the grade welding unit comprises:
and the grade welding subunit is used for acquiring all the to-be-welded points in the to-be-welded point set from the to-be-welded point set with the highest priority grade, sequentially welding all the labels, and if label welding fails in the welding process, continuing welding by using the to-be-welded points in the to-be-welded point set with the next priority grade from the label.
Optionally, the screening unit for the points to be welded includes:
a reference surface setting subunit, configured to set a reference surface of a target sub-region, where the reference surface is a plane where a steel end surface corresponding to a center point where a Z value is the smallest in the target sub-region is located, and the target sub-region is any one of the welding sub-regions;
the distance obtaining subunit is configured to obtain a minimum distance between a target end face and the reference surface, where the target end face is a plane where any one of the steel end faces in the target sub-region is located;
and the stator unit for judging the point to be welded is used for judging whether the minimum distance does not exceed the length of the gun head of the telescopic welding gun, and if so, setting the outline center point of the steel end face corresponding to the target end face as the point to be welded.
Optionally, the welding area setting unit includes:
the area dividing subunit is used for extracting a maximum X value, a minimum X value, a maximum Y value and a minimum Y value from the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle and dividing a rectangular area according to the four values;
and the welding area setting stator unit is used for setting the rectangular area as an end surface welding area of the target steel bundle.
Optionally, the welding region dividing unit includes:
the area acquisition subunit is used for acquiring the area of the end face welding area;
and the area equal-dividing subunit is used for equally dividing the end surface welding area into a plurality of welding subareas according to the area according to the number of the labels to be welded.
Optionally, the end face contour extraction module includes:
the first end face contour extraction unit is used for extracting the end face contour of each steel product from a first end face image to obtain a first end face contour set, and the first end face image is acquired by a first camera in a binocular camera;
the second end face contour extraction unit is used for extracting the end face contour of each steel product from a second end face image to obtain a second end face contour set, and the second end face image is acquired by a second camera in the binocular camera;
a center point set obtaining unit, configured to obtain a first center point set and a second center point set, where the first center point set includes center points of all end surface contours in the first end surface contour set, and the second center point set includes center points of all end surface contours in the second end surface contour set;
the matching unit is used for matching all central points in the first central point set and the second central point set, wherein if the distance between only one central point in the second central point set and a target point does not exceed a preset threshold value, the matching is successful, otherwise, the matching fails, the target point is any central point in the first central point set, and the preset threshold value is the minimum value of the end face radii of all steel products in the steel bundle to be welded;
a target point set obtaining unit, configured to use all successfully matched central points in the first central point set as a first target point set, and use all successfully matched central points in the second central point set as a second target point set;
and the central point coordinate acquisition unit is used for acquiring the central point coordinate of each steel end face profile according to the first target point set and the second target point set.
The embodiment of the application discloses a method and a device for automatically welding a label based on a plurality of steel bundles, wherein in the method, an end face image of a steel bundle to be welded is obtained, and the steel bundle to be welded at least comprises one steel bundle; extracting the end face outline of each steel from the end face image of the steel bundle to be welded, and acquiring the center point coordinate of the end face outline of each steel; expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle; acquiring end face outlines of all steel corresponding to each steel bundle according to the center point coordinates of the end face outline of each steel and the outline of each steel bundle; acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all steel materials corresponding to each steel bundle; and performing label welding according to the set of points to be welded of each steel bundle. According to the method, before the label welding points are selected, the outer contours of the overlapped and crossed steel bundles are extracted, and all the steel products of the overlapped and crossed steel bundles are divided, so that the system can identify the respective contour of each steel bundle and all the steel products corresponding to the steel bundle, errors can be avoided when the label welding points are selected for each steel bundle subsequently, and the selection precision is guaranteed.
Drawings
In order to more clearly explain the technical solution of the present application, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious to those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic workflow diagram of a method for automatically welding a plate based on a plurality of steel bundles according to an embodiment of the present application;
FIG. 2 is a schematic diagram of a workflow of acquiring a set of points to be welded of each steel bundle in an automatic label welding method based on a plurality of steel bundles according to an embodiment of the present application;
FIG. 3 is a schematic diagram of an automatic label welding method based on multiple steel bundles, wherein an end face welding area is set;
FIG. 4 is a schematic diagram of a split end face welding area in an automatic label welding method based on multiple steel bundles according to an embodiment of the present application;
FIG. 5 is a schematic diagram of a workflow of label welding according to a set of points to be welded of each steel bundle in an automatic label welding method based on a plurality of steel bundles according to an embodiment of the present application;
fig. 6 is a schematic structural diagram of an automatic welding label device based on a plurality of steel bundles according to an embodiment of the present application.
Detailed Description
The first embodiment of the application discloses a method for automatically welding a label based on a plurality of steel bundles, which is shown in a work flow diagram in fig. 1 and comprises the following steps:
step S101, acquiring an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle.
The method comprises the steps of collecting end face images of a steel bundle to be welded through a binocular camera, wherein the binocular camera comprises a first camera and a second camera, and the collected end face images comprise a first end face image collected by the first camera and a second end face image collected by the second camera.
And S102, extracting the end face outline of each steel material from the end face image of the steel bundle to be welded, and acquiring the center point coordinate of the end face outline of each steel material.
Based on the first end face image and the second end face image acquired by the binocular camera, the step S102 includes:
and extracting the end face contour of each steel material from the first end face image to obtain a first end face contour set, wherein the first end face image is acquired by a first camera in a binocular camera.
And extracting the end face contour of each steel product from a second end face image to obtain a second end face contour set, wherein the second end face image is acquired by a second camera in the binocular camera.
And respectively carrying out approximate circle processing on each end face contour in the first end face contour set and the second end face contour set to obtain the center point of each end face contour.
And acquiring a first central point set and a second central point set, wherein the first central point set comprises the central points of all the end surface profiles in the first end surface profile set, and the second central point set comprises the central points of all the end surface profiles in the second end surface profile set.
And matching all the central points in the first central point set and the second central point set, wherein if the distance between only one central point in the second central point set and a target point does not exceed a preset threshold value, the matching is successful, otherwise, the matching fails, the target point is any central point in the first central point set, and the preset threshold value is the minimum value of the end surface radius of all the steel products in the steel bundle to be welded. In practical application, the minimum value of the radius of the end face of the steel can be obtained according to the production specification of the steel and is stored in the system in advance.
And taking all successfully matched central points in the first central point set as a first target point set, and taking all successfully matched central points in the second central point set as a second target point set. The number of the first target point set is consistent with that of the second target point set, and the first target point set and the second target point set correspond to each other one by one.
And acquiring the center point coordinates of the end face profile of each steel product according to the first target point set and the second target point set.
Specifically, the X, Y axis coordinate values, namely the X value and the Y value, of the center point of each steel end face profile can be generated by using binocular matching, and the Z axis coordinate values, namely the Z value, of the center point of each steel end face profile can be generated by using a binocular ranging principle. Wherein, X value represents the position of the center point of the steel end face contour in the horizontal direction, Y value represents the position of the center point of the steel end face contour in the vertical direction, and Z value represents the linear distance between the center point of the steel end face contour and the binocular camera.
And step S103, expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle.
The dilation process can segment out individual image elements. Gaps among all steel materials in the same steel bundle are relatively small and can be filled after expansion treatment, gaps among different steel bundles are large and can be reserved after expansion treatment, and finally the end face of each steel bundle can form a large curved surface.
And step S104, acquiring the end face contour of all steel corresponding to each steel bundle according to the center point coordinate of each steel end face contour and the outer contour of each steel bundle.
In the embodiment of the application, the end surface profiles of all steel materials corresponding to each steel bundle are obtained through the following steps:
firstly, an outer contour curve of each steel bundle is obtained. In practical application, based on the obtained outer contour of each steel bundle, an outer contour curve and a curve equation thereof are easy to calculate.
And then, dividing the center point of each steel end face profile into the corresponding outer profile curve according to a ray method, and acquiring the end face profiles of all the corresponding steel in each steel bundle.
The ray method is a method for determining whether a certain point is in an area. For example, if it is determined whether a target point is located within a polygon, a scan line (i.e., a ray) may be directed horizontally from the target point to the left, and the number of intersections between the line segment and the polygon boundary may be calculated. If the number of times of intersection is odd, it can be determined that the target point is within the polygon; if it is an even number, it may be determined that the target point is outside the polygon.
According to the method, the ray method is used, the ray is sequentially led out from the central point of each steel end face contour, the central point of each steel end face contour is divided into the corresponding outer contour curves by judging whether the number of times of intersection between the led-out ray and the outer contour of the steel bundle is odd or even, and finally the end face contours of all corresponding steel in each steel bundle can be obtained.
And S105, acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle.
And S106, performing label welding according to the to-be-welded point set of each steel bundle.
The embodiment of the application discloses an automatic label welding method based on a plurality of steel bundles, which comprises the steps of firstly obtaining an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle; extracting the end face outline of each steel from the end face image of the steel bundle to be welded, and acquiring the center point coordinate of the end face outline of each steel; expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle; acquiring end face outlines of all steel corresponding to each steel bundle according to the center point coordinates of the end face outline of each steel and the outline of each steel bundle; acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all steel materials corresponding to each steel bundle; and performing label welding according to the set of points to be welded of each steel bundle. According to the method, before the label welding points are selected, the outer contours of the overlapped and crossed steel bundles are extracted, and all the steel products of the overlapped and crossed steel bundles are divided, so that the system can identify the respective contour of each steel bundle and all the steel products corresponding to the steel bundle, errors can be avoided when the label welding points are selected for each steel bundle subsequently, and the selection precision is guaranteed.
Further, referring to the schematic workflow shown in fig. 2, the obtaining a set of to-be-welded points of each steel bundle according to the end surface profiles of all steel products corresponding to each steel bundle includes:
step S201, setting an end face welding area of a target steel bundle according to X values and Y values of coordinates of center points of end face outlines of all steel products in the target steel bundle, wherein the target steel bundle is any one of the steel bundles to be welded.
Since the end face of the steel bundle is generally rectangular-like, in the embodiment of the present application, the maximum X value, the minimum X value, the maximum Y value, and the minimum Y value are extracted from the coordinates of the center points of the profile of all the steel end faces, and a rectangular area is defined according to the four values. And then setting the rectangular area as an end face welding area of the target steel bundle.
Referring to fig. 3, an end face image of the target steel bundle is shown, the origin of coordinates is located at the upper left corner of the whole end face image, the coordinate origin extends horizontally from the origin of coordinates to the right as an X positive axis, the coordinate origin extends vertically from the origin of coordinates to the down as a Y positive axis, each circle represents the profile of all steel end faces in the target steel bundle, and the rectangular frame is a rectangular area defined according to the maximum X value, the minimum X value, the maximum Y value and the minimum Y value, that is, an end face welding area of the target steel bundle.
Step S202, dividing the end face welding area of the target steel bundle into a plurality of welding subareas, wherein the number of the welding subareas is consistent with the number of the labels to be welded of the target steel bundle.
In one implementation, dividing the end face weld region into a plurality of weld sub-regions includes:
and acquiring the area of the end face welding area.
And equally dividing the end face welding area into a plurality of welding subareas according to the area according to the number of the labels to be welded.
Referring to fig. 3 and 4, as an example, if the number of the labels to be welded is four, the end surface welding area is divided into four welding sub areas, that is, the welding sub area a, the welding sub area B, the welding sub area C, and the welding sub area D in fig. 4, equally by area, and each welding sub area is used for welding only one label.
Step S203, according to the Z values of the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle, screening out a plurality of welding points to be welded from the center points of the end face outlines of all the steel products in the target steel bundle.
Step S204, generating a plurality of to-be-welded point sets of the target steel bundle according to the to-be-welded points, wherein the number of to-be-welded points contained in each to-be-welded point set is consistent with the number of the welding subareas, different to-be-welded points in each to-be-welded point set correspond to different welding subareas, and the distance between different to-be-welded points in each to-be-welded point set is not smaller than the size of the label to be welded.
In the existing automatic label welding process, after one label is welded, a binocular camera is required to acquire an end face image of a steel bundle again, image processing is carried out, and a welding point of the next label is obtained.
In the embodiment of the application, a plurality of to-be-welded point sets are obtained for each steel bundle before welding, so that in the welding process, image acquisition and image processing work do not need to be repeated, the to-be-welded point sets can be used for welding all labels, a large amount of time can be saved, and the welding efficiency is effectively improved.
Generally, all tags of a target steel bundle can be welded at one time by using a welding point concentrated with the welding point. However, in consideration of the fact that a certain label welding failure may exist in an actual working condition, in the embodiment of the application, a plurality of sets of points to be welded are generated for standby application for one steel bundle, so that the situation that image acquisition and image processing are required to be performed again to select a new label welding point under the condition that a certain label welding failure occurs is prevented, the system processing time is shortened to the greatest extent, and the welding efficiency is improved.
Specifically, a plurality of welding points to be welded of the target steel bundle are combined to generate a plurality of welding point sets to be welded, and the following principle is followed in the combining process: (1) each point to be welded is from a different welding sub-area; (2) after the labels are hung on each point to be welded, the labels cannot be shielded mutually. Each set of points to be welded obtained after the completion of the combination satisfies the three-point requirement described in step S204, in which case each set of points to be welded can be welded for all the tags of the target steel bundle. To reduce the data processing amount, the number of sets of to-be-welded points may be set to four in advance, as an example.
The distance between different welding points in each welding point set of the target steel bundle is not smaller than the size of the label to be welded, so that the labels cannot be shielded mutually after the label is hung on the welding points in different welding sub-areas.
Referring to fig. 4, one welding point is concentrated, the horizontal distance between two welding points in the welding sub-area a and the welding sub-area B cannot be smaller than the length of the sign, and the horizontal distance between two welding points in the welding sub-area C and the welding sub-area D cannot be smaller than the length of the sign; the vertical distance between two to-be-welded points in the welding subarea A and the welding subarea C cannot be smaller than the width of the label, and the vertical distance between two to-be-welded points in the welding subarea B and the welding subarea D cannot be smaller than the width of the label; the linear distance between two to-be-welded points in the welding sub-area a and the welding sub-area D cannot be smaller than the length of the hypotenuse of the sign, and the linear distance between two to-be-welded points in the welding sub-area B and the welding sub-area C cannot be smaller than the length of the hypotenuse of the sign.
When the to-be-welded point set is generated, if a to-be-welded point does not exist in a certain welding subarea of the target steel bundle, the to-be-welded point with the minimum Z value can be selected from other welding subareas, and the to-be-welded point set and other selected to-be-welded points form the to-be-welded point set. Referring to fig. 4, if the welding sub-area a has no point to be welded, a point to be welded with the smallest Z value can be selected from the other three welding sub-areas, and the point to be welded and the other three selected points to be welded form a point set to be welded. When the welding point with the minimum Z value is selected, the other three selected welding points are excluded.
Further, referring to the schematic workflow shown in fig. 5, the performing label welding according to the set of points to be welded of each steel bundle includes:
step S501, acquiring the sum of Z values of all to-be-welded points in each to-be-welded point set of the target steel bundle.
And step S502, setting the priority levels of all to-be-welded point sets of the target steel bundle according to the sequence from small to large of the sum of the Z values, wherein the to-be-welded point set with the smallest sum of the Z values has the highest priority level.
And S503, starting from the set of points to be welded with the highest priority, sequentially welding the labels to be welded to the end face of the target steel bundle according to the points to be welded in the set of points to be welded.
The minimum sum of the Z values means that the moving distance of the head of the telescopic welding gun is the minimum in all the label processes of the target steel bundle, and the time required for welding is relatively the minimum. In the embodiment of the application, the priority levels of all to-be-welded point sets are set according to the sequence from small to large of the sum of the Z values, and the to-be-welded point set with the minimum sum of the Z values is set as the point set with the highest welding priority, so that the actual welding time can be effectively shortened, and the welding efficiency is improved.
Further, the welding the to-be-welded label to the end face of the target steel bundle sequentially according to the to-be-welded points in the to-be-welded point set from the to-be-welded point set with the highest priority level includes:
and in the welding process, if the label welding fails, the label is continuously welded by using the welding points to be welded in the welding point set with the next priority level.
Specifically, label welding is carried out on a first welding subarea of the target steel bundle from a point set to be welded with the highest priority level, after successful welding, label welding is carried out on a second welding subarea, if welding fails, the current point set to be welded is abandoned, the point set to be welded with the next priority level is used, label welding is carried out on the second welding subarea from the second point set to be welded, and the like until all labels are welded.
It should be noted that, every time a label is welded, a binocular camera is used to collect an image of the end face of the steel bundle, so as to determine whether the label welding is successful. When the welding of the sign is detected to be successful, the end face image collected by any one camera is selected, image preprocessing (such as graying, filtering and corrosion processing) is carried out on the end face image to obtain the outline of the sign, if the outline is larger than a preset area threshold value, the welding is successful, and otherwise, the welding is failed. As an example, the area threshold is set in the range of: not less than half the area of the current sign.
If all the to-be-welded point sets are abandoned but the target steel bundle label is not completely welded, the system gives an alarm to prompt a worker that welding fails, and welding point selection work needs to be carried out on the target steel bundle again.
If the specifications of the steel bundles overlapped and crossed together are not consistent, the welding sequence of different steel bundles is determined according to the specification of a label currently provided for the telescopic welding gun. For example, if three steel bundles are stacked in a delta shape, the next two steel bundles are in a specification, the top steel bundle is in a specification, and the telescopic welding gun is provided with an a specification label on site, the next two steel bundles should be welded, and similarly, if the telescopic welding gun is provided with a b specification label on site, the top steel bundle should be welded. This ensures the accuracy of the welding in case of a non-uniform label to bundle specification.
Generally, the end face of a steel bundle is uneven, the end face of some steel is recessed, and if the recessed depth is larger than the length of the gun head of the telescopic welding gun, the telescopic welding gun can be damaged when the end face of the steel is welded.
In order to prevent the telescopic welding gun from being collided, in the embodiment of the present application, the screening out a plurality of welding points to be welded from the central points of all the end face profiles of the steel products in the target steel bundle according to the Z values of the coordinates of the central points of all the end face profiles of the steel products in the target steel bundle includes:
setting a reference surface of a target sub-region, wherein the reference surface is a plane (namely the steel end surface closest to the binocular camera) where the steel end surface corresponding to the central point with the minimum Z value in the target sub-region is located, and the target sub-region is any welding sub-region.
And acquiring the minimum distance between a target end face and the reference surface, wherein the target end face is a plane where any steel end face in the target sub-area is located.
And judging whether the minimum distance does not exceed the length of the gun head of the telescopic welding gun, if so, setting the outline center point of the steel end face corresponding to the target end face as the point to be welded.
The benchmark face is the most convex steel terminal surface in the target steel bundle terminal surface, through the screening, will be sunken the degree of depth and be greater than the steel filtering of flexible welder rifle head length, with remaining steel terminal surface profile central point as treating the welding point, can prevent the emergence accident in the later stage welding process, effectively ensures the security among the welding process.
The following are embodiments of the apparatus disclosed herein for performing the above-described method embodiments. For details which are not disclosed in the device embodiments, reference is made to the method embodiments.
The second embodiment of the present application discloses an automatic welding signage device based on a plurality of steel bundles, which is applied to the automatic welding signage method based on a plurality of steel bundles according to the first embodiment of the present application, and referring to the schematic structural diagram shown in fig. 6, the device comprises:
the end face image obtaining module 10 is configured to obtain an end face image of a steel bundle to be welded, where the steel bundle to be welded includes at least one steel bundle.
And the end face contour extraction module 20 is configured to extract an end face contour of each steel product from the end face image of the steel bundle to be welded, and obtain a center point coordinate of the end face contour of each steel product.
And the outer contour extraction module 30 is used for performing expansion processing on the end face image of the steel bundle to be welded and extracting the outer contour of each steel bundle.
And the end face contour dividing module 40 is configured to obtain the end face contours of all steel products corresponding to each steel bundle according to the center point coordinates of each steel product end face contour and the outer contour of each steel bundle.
And the to-be-welded point set obtaining module 50 is configured to obtain a to-be-welded point set of each steel bundle according to the end surface profiles of all steel corresponding to each steel bundle.
And the welding module 60 is used for performing label welding according to the set of points to be welded of each steel bundle.
Further, the end surface profile dividing module includes:
and the outer contour curve acquiring unit is used for acquiring the outer contour curve of each steel bundle.
And the dividing unit is used for dividing the center point of each steel end face profile into the corresponding outer profile curve according to the ray method, and acquiring the end face profiles of all the corresponding steel in each steel bundle.
Further, the module for acquiring the set of points to be welded includes:
and the welding area setting unit is used for setting the end face welding area of the target steel bundle according to the X value and the Y value of the coordinates of the center points of the end face outlines of all steel materials in the target steel bundle, wherein the target steel bundle is any one of the steel bundles to be welded.
And the welding area dividing unit is used for dividing the end surface welding area of the target steel bundle into a plurality of welding subareas, and the number of the welding subareas is consistent with the number of the labels to be welded of the target steel bundle.
And the to-be-welded point screening unit is used for screening a plurality of to-be-welded points from the center points of the end face outlines of all the steel products in the target steel bundle according to the Z values of the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle.
And the to-be-welded point set generating unit is used for generating a plurality of to-be-welded point sets of the target steel bundle according to the plurality of to-be-welded points, wherein the number of the to-be-welded points contained in each to-be-welded point set is consistent with the number of the welding subareas, different to-be-welded points in each to-be-welded point set correspond to different welding subareas, and the distance between different to-be-welded points in each to-be-welded point set is not smaller than the size of the label to be welded.
Further, the welding module includes:
and the Z value summing unit is used for acquiring the sum of the Z values of all to-be-welded points in each to-be-welded point set of the target steel bundle.
And the priority setting unit is used for setting the priority of all to-be-welded point sets of the target steel bundle according to the sequence from small to large of the sum of the Z values, wherein the priority of the to-be-welded point set with the smallest sum of the Z values is the highest.
And the grade welding unit is used for welding the label to be welded to the end face of the target steel bundle from the point set to be welded with the highest priority grade according to the points to be welded in the point set to be welded in sequence.
Further, the grade welding unit includes:
and the grade welding subunit is used for acquiring all the to-be-welded points in the to-be-welded point set from the to-be-welded point set with the highest priority grade, sequentially welding all the labels, and if label welding fails in the welding process, continuing welding by using the to-be-welded points in the to-be-welded point set with the next priority grade from the label.
Further, the screening unit of the points to be welded includes:
and the datum plane setting subunit is used for setting a datum plane of a target sub-region, wherein the datum plane is a plane where a steel end face corresponding to a central point with the minimum Z value in the target sub-region is located, and the target sub-region is any welding sub-region.
And the distance acquisition subunit is used for acquiring the minimum distance between a target end face and the reference surface, wherein the target end face is a plane where any one steel end face in the target sub-area is located.
And the stator unit for judging the point to be welded is used for judging whether the minimum distance does not exceed the length of the gun head of the telescopic welding gun, and if so, setting the outline center point of the steel end face corresponding to the target end face as the point to be welded.
Further, the welding region setting unit includes:
and the area dividing subunit is used for extracting a maximum X value, a minimum X value, a maximum Y value and a minimum Y value from the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle and dividing a rectangular area according to the four values.
And the welding area setting stator unit is used for setting the rectangular area as an end surface welding area of the target steel bundle.
Further, the welding-region dividing unit includes:
and the area acquisition subunit is used for acquiring the area of the end face welding area.
And the area equal-dividing subunit is used for equally dividing the end surface welding area into a plurality of welding subareas according to the area according to the number of the labels to be welded.
Further, the end face contour extraction module includes:
the first end face contour extraction unit is used for extracting the end face contour of each steel product from a first end face image to obtain a first end face contour set, and the first end face image is acquired by a first camera in the binocular camera.
And the second end face contour extraction unit is used for extracting the end face contour of each steel product from a second end face image to obtain a second end face contour set, and the second end face image is acquired by a second camera in the binocular camera.
The central point set acquiring unit is used for acquiring a first central point set and a second central point set, wherein the first central point set comprises central points of all end surface contours in the first end surface contour set, and the second central point set comprises central points of all end surface contours in the second end surface contour set.
And the matching unit is used for matching all the central points in the first central point set and the second central point set, wherein if the distance between only one central point in the second central point set and a target point does not exceed a preset threshold value, the matching is successful, otherwise, the matching fails, the target point is any one central point in the first central point set, and the preset threshold value is the minimum value of the end face radii of all the steel products in the steel bundle to be welded.
And the target point set acquisition unit is used for taking all the successfully matched central points in the first central point set as a first target point set and taking all the successfully matched central points in the second central point set as a second target point set.
And the central point coordinate acquisition unit is used for acquiring the central point coordinate of each steel end face profile according to the first target point set and the second target point set.
The present application has been described in detail with reference to specific embodiments and illustrative examples, but the description is not intended to limit the application. Those skilled in the art will appreciate that various equivalent substitutions, modifications or improvements may be made to the presently disclosed embodiments and implementations thereof without departing from the spirit and scope of the present disclosure, and these fall within the scope of the present disclosure. The protection scope of this application is subject to the appended claims.

Claims (10)

1. A method for automatically welding signage based on a plurality of steel bundles, the method comprising:
acquiring an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle;
extracting the end face outline of each steel from the end face image of the steel bundle to be welded, and acquiring the center point coordinate of the end face outline of each steel;
expanding the end face image of the steel bundle to be welded, and extracting the outer contour of each steel bundle;
acquiring the end face contour of all steel corresponding to each steel bundle according to the center point coordinate of each steel end face contour and the outer contour of each steel bundle;
acquiring a set of points to be welded of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle;
and performing label welding according to the set of points to be welded of each steel bundle.
2. The method for automatically welding the sign based on the plurality of steel bundles according to claim 1, wherein the step of obtaining the end surface profile of all the steel products corresponding to each steel bundle according to the center point coordinates of each end surface profile of the steel products and the outer profile of each steel bundle comprises the following steps:
acquiring an outer contour curve of each steel bundle;
and dividing the central point of each steel end face profile into the corresponding outer profile curve according to the ray method, and obtaining the end face profiles of all the corresponding steel in each steel bundle.
3. The method for automatically welding the signs based on the steel bundles according to claim 1, wherein the step of obtaining the set of points to be welded of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle comprises the following steps:
setting an end face welding area of a target steel bundle according to X values and Y values of coordinates of center points of end face outlines of all steel materials in the target steel bundle, wherein the target steel bundle is any one of the steel bundles to be welded;
dividing the end face welding area of the target steel bundle into a plurality of welding subareas, wherein the number of the welding subareas is consistent with the number of the labels to be welded of the target steel bundle;
screening a plurality of welding points to be welded from the center points of the end face outlines of all the steel products in the target steel bundle according to the Z values of the coordinates of the center points of the end face outlines of all the steel products in the target steel bundle;
and generating a plurality of to-be-welded point sets of the target steel bundle according to the plurality of to-be-welded points, wherein the number of to-be-welded points contained in each to-be-welded point set is consistent with the number of the welding subareas, different to-be-welded points in each to-be-welded point set correspond to different welding subareas, and the distance between different to-be-welded points in each to-be-welded point set is not smaller than the size of the label to be welded.
4. The automatic label welding method based on a plurality of steel bundles according to claim 3, wherein the label welding is performed according to the set of points to be welded of each steel bundle, and comprises the following steps:
acquiring the sum of Z values of all to-be-welded points in each to-be-welded point set of the target steel bundle;
setting the priority levels of all to-be-welded point sets of the target steel bundle according to the sequence of the Z value sum from small to large, wherein the priority level of the to-be-welded point set with the smallest Z value sum is the highest;
and welding the label to be welded to the end face of the target steel bundle from the point set to be welded with the highest priority level according to the points to be welded in the point set to be welded in sequence.
5. The method for automatically welding the labels based on the steel bundles according to claim 4, wherein the welding of the labels to be welded to the end surfaces of the target steel bundles is performed in sequence according to the points to be welded in the point sets to be welded, starting from the point set to be welded with the highest priority, and comprises the following steps:
and in the welding process, if the label welding fails, the label is continuously welded by using the welding points to be welded in the welding point set with the next priority level.
6. The method of claim 3, wherein the step of selecting a plurality of welding points from the center points of all the steel end surface profiles of the target steel bundle according to the Z values of the coordinates of the center points of all the steel end surface profiles of the target steel bundle comprises:
setting a reference surface of a target subregion, wherein the reference surface is a plane where a steel end face corresponding to a central point with the minimum Z value in the target subregion is located, and the target subregion is any welding subregion;
acquiring the minimum distance between a target end face and the reference surface, wherein the target end face is a plane where any one steel end face in the target sub-area is located;
and judging whether the minimum distance does not exceed the length of the gun head of the telescopic welding gun, if so, setting the outline center point of the steel end face corresponding to the target end face as the point to be welded.
7. The method for automatically welding labels on basis of a plurality of steel bundles according to claim 3, wherein the step of setting the welding area of the end face of the target steel bundle according to the X value and the Y value of the coordinates of the center point of the profile of the end face of all steel materials in the target steel bundle comprises the following steps:
extracting a maximum X value, a minimum X value, a maximum Y value and a minimum Y value from the coordinates of the center points of the end faces of all the steel products in the target steel bundle, and defining a rectangular area according to the four values;
setting the rectangular area as an end face welding area of the target steel bundle.
8. The method for automatically welding signs based on a plurality of steel bundles according to claim 3 or 7, wherein the step of dividing the end face welding area of the target steel bundle into a plurality of welding subareas comprises the following steps:
acquiring the area of the end face welding area;
and equally dividing the end face welding area into a plurality of welding subareas according to the area according to the number of the labels to be welded.
9. The method for automatically welding the signs based on the steel bundles according to claim 1, wherein the step of extracting the end face contour of each steel material from the end face image of the steel bundle to be welded and obtaining the center point coordinates of the end face contour of each steel material comprises the following steps:
extracting the end face contour of each steel material from a first end face image to obtain a first end face contour set, wherein the first end face image is acquired by a first camera in a binocular camera;
extracting the end face contour of each steel product from a second end face image to obtain a second end face contour set, wherein the second end face image is acquired by a second camera in the binocular camera;
acquiring a first central point set and a second central point set, wherein the first central point set comprises central points of all end surface contours in the first end surface contour set, and the second central point set comprises central points of all end surface contours in the second end surface contour set;
matching all central points in the first central point set and the second central point set, wherein if the distance between only one central point in the second central point set and a target point does not exceed a preset threshold value, the matching is successful, otherwise, the matching fails, the target point is any central point in the first central point set, and the preset threshold value is the minimum value of the end surface radius of all steel products in the steel bundle to be welded;
taking all successfully matched central points in the first central point set as a first target point set, and taking all successfully matched central points in the second central point set as a second target point set;
and acquiring the center point coordinates of the end face profile of each steel product according to the first target point set and the second target point set.
10. An automatic welding label device based on a plurality of steel bundles, which is applied to the automatic welding label method based on a plurality of steel bundles according to any one of claims 1 to 9, and comprises the following components:
the end face image acquisition module is used for acquiring an end face image of a steel bundle to be welded, wherein the steel bundle to be welded at least comprises one steel bundle;
the end face contour extraction module is used for extracting the end face contour of each steel product from the end face image of the steel bundle to be welded and acquiring the center point coordinate of the end face contour of each steel product;
the outer contour extraction module is used for performing expansion processing on the end face image of the steel bundle to be welded and extracting the outer contour of each steel bundle;
the end face contour dividing module is used for acquiring the end face contour of all the steel corresponding to each steel bundle according to the center point coordinate of each steel end face contour and the outer contour of each steel bundle;
the to-be-welded point set acquisition module is used for acquiring the to-be-welded point set of each steel bundle according to the end surface profiles of all the steel materials corresponding to each steel bundle;
and the welding module is used for carrying out label welding according to the to-be-welded point set of each steel bundle.
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