CN117029680A - Weld joint detection method and welding system - Google Patents

Weld joint detection method and welding system Download PDF

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Publication number
CN117029680A
CN117029680A CN202310995928.7A CN202310995928A CN117029680A CN 117029680 A CN117029680 A CN 117029680A CN 202310995928 A CN202310995928 A CN 202310995928A CN 117029680 A CN117029680 A CN 117029680A
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China
Prior art keywords
weld
size information
welding
contour
standard
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CN202310995928.7A
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Chinese (zh)
Inventor
孟政宇
王鹏昌
陆智俊
彭根琛
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Jiangsu Xugong Construction Machinery Research Institute Co ltd
Xuzhou XCMG Environment Technology Co Ltd
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Jiangsu Xugong Construction Machinery Research Institute Co ltd
Xuzhou XCMG Environment Technology Co Ltd
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Application filed by Jiangsu Xugong Construction Machinery Research Institute Co ltd, Xuzhou XCMG Environment Technology Co Ltd filed Critical Jiangsu Xugong Construction Machinery Research Institute Co ltd
Priority to CN202310995928.7A priority Critical patent/CN117029680A/en
Publication of CN117029680A publication Critical patent/CN117029680A/en
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02—Carriages for supporting the welding or cutting element
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Physics & Mathematics (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

The application discloses a welding seam detection method and a welding system. The welding line detection method comprises the following steps of acquiring a plurality of contour images of a plurality of welding line sections at different positions in the extending direction of a welding line in real time; analyzing each contour image in the plurality of contour images to calculate and obtain actual weld size information corresponding to each contour image; and comparing the actual weld size information with the standard weld size information, and if the actual weld size information does not accord with the standard weld size information, acquiring the position of the weld segment which does not accord with the standard weld size information on the weld according to the plurality of contour images. The welding seam detection method can realize real-time detection of the welding seam, directly analyze and measure the size of the welding seam through the acquired image, accurately position the welding seam after detecting the unqualified welding seam, and improve the detection efficiency and quality compared with manual measurement.

Description

Weld joint detection method and welding system
Technical Field
The application relates to a welding seam detection method and a welding system.
Background
The welding process is complex, the quality of the welding seam is easily influenced by various factors, for example, fluctuation of a welding gun and a laser head caused by accidental factors in the welding process can have great influence on the welding seam forming. Therefore, in order to ensure the quality of the welded product, the appearance shaping of the welded seam and the detection of the inside of the welded seam are required.
Currently, the detection of the appearance of a weld joint is mainly performed by manual visual inspection or by using a gauge by a detector to manually measure the size of the weld joint. The detection mode has great dependence on human experience and operation technology, and the labor intensity of welding operators is increased.
Therefore, how to improve the efficiency and quality of weld detection is a problem to be solved.
It should be noted that the statements in this background section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
Disclosure of Invention
The application provides a welding seam detection method and a welding system, which are used for improving the quality and efficiency of welding seam detection.
The first aspect of the application provides a weld joint detection method, comprising the following steps:
acquiring a plurality of contour images of a plurality of welding seam sections at different positions in the extending direction of the welding seam in real time;
analyzing each contour image in the plurality of contour images to calculate and obtain actual weld size information corresponding to each contour image;
and comparing the actual weld size information with the standard weld size information, and if the actual weld size information does not accord with the standard weld size information, acquiring the position of the weld segment which does not accord with the standard weld size information on the weld according to the plurality of contour images.
In some embodiments, the weld detection method further comprises: the standard weld size information is preset before the plurality of contour images are acquired.
In some embodiments, analyzing each of the plurality of contour images to calculate actual weld size information corresponding to each contour image includes: and carrying out numerical processing on each contour image to obtain actual weld size information corresponding to each contour image.
In some embodiments, digitizing each of the contour images to obtain actual weld size information corresponding to each of the contour images includes binarizing the contour images to obtain binary images, and extracting feature information from the binary images.
In some embodiments, acquiring the location on the weld where the weld segment that does not meet the standard weld size information is based on the plurality of profile images includes: and establishing weld coordinates according to a plurality of profile images of a plurality of weld segments at different positions, and acquiring the coordinates of the weld segments which do not accord with the standard weld size information from the weld coordinates.
In some embodiments, computing the actual weld dimension information corresponding to each contour image includes: different actual weld size information is obtained for different weld types.
In some embodiments, for a butt weld, obtaining a melt width and a residual height; or, for the fillet weld, obtaining the leg size and the throat size.
A second aspect of the present application provides a welding system comprising:
the welding equipment comprises a main body, a welding head and an image acquisition device, wherein the image acquisition device is arranged on the main body and is used for moving under the driving of the main body to weld a workpiece to be welded, and the image acquisition device is used for moving along the extending direction of a welding line under the driving of the main body to acquire a plurality of profile images of a plurality of welding line sections at different positions after the welding head finishes welding;
and the controller is in signal connection with the image acquisition device and is configured to analyze each contour image in the plurality of contour images acquired by the image acquisition device to calculate and obtain actual weld seam size information corresponding to each contour image, and is further configured to compare the actual weld seam size information with the standard weld seam size information, and if the actual weld seam size information does not accord with the standard weld seam size information, the position of the weld seam section which does not accord with the standard weld seam size information on the weld seam is acquired according to the plurality of contour images.
In some embodiments, the image acquisition device comprises a CCD camera.
In some embodiments, the image acquisition device further comprises a light supplementing light source disposed on one side of the CCD camera.
Based on the technical scheme provided by the application, the welding line detection method comprises the following steps of acquiring a plurality of contour images of a plurality of welding line sections at different positions in the extending direction of the welding line in real time; analyzing each contour image in the plurality of contour images to calculate and obtain actual weld size information corresponding to each contour image; and comparing the actual weld size information with the standard weld size information, and if the actual weld size information does not accord with the standard weld size information, acquiring the position of the weld segment which does not accord with the standard weld size information on the weld according to the plurality of contour images. According to the welding seam detection method, the plurality of contour images of the welding seam sections at different positions are obtained in real time in the extending direction of the welding seam, and each contour image is directly analyzed on line to obtain the actual welding seam size information corresponding to each contour image. And comparing the obtained actual weld size information with the standard weld size information, and if the weld size information does not meet the standard weld size information, obtaining the position of the weld segment corresponding to the weld size information which does not meet the standard weld on the weld. Therefore, the welding seam detection method can realize real-time detection of the welding seam, directly analyze and measure the size of the welding seam through the acquired image, accurately position the unqualified welding seam after detecting the unqualified welding seam, and improve the detection efficiency and quality compared with manual measurement.
Other features of the present application and its advantages will become apparent from the following detailed description of exemplary embodiments of the application, which proceeds with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
fig. 1 is a step diagram of a weld detection method according to an embodiment of the present application.
Fig. 2 is a schematic structural diagram of a welding system according to an embodiment of the present application.
Fig. 3 is a schematic diagram of extracting actual weld dimension information of a butt weld.
Fig. 4 is a schematic diagram of extracting actual weld dimension information of a diagonal weld.
Detailed Description
The following description of the embodiments of the present application will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present application, but not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the application, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present application unless it is specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to one of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods, and apparatus should be considered part of the specification. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
Spatially relative terms, such as "above … …," "above … …," "upper surface at … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial location relative to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the exemplary term "above … …" may include both orientations of "above … …" and "below … …". The device may also be positioned in other different ways and the spatially relative descriptions used herein are construed accordingly.
Referring to fig. 1, an embodiment of the present application provides a method for detecting a weld, including the steps of:
s310, acquiring a plurality of contour images of a plurality of welding seam segments at different positions in the extending direction of the welding seam in real time;
s320, analyzing each contour image in the plurality of contour images to calculate and obtain actual weld size information corresponding to each contour image;
s330, comparing the actual weld size information with the standard weld size information, and if the actual weld size information does not accord with the standard weld size information, acquiring the position of the weld segment which does not accord with the standard weld size information on the weld according to the plurality of contour images.
According to the welding seam detection method, the plurality of contour images of the welding seam sections at different positions are obtained in real time in the extending direction of the welding seam, and each contour image is directly analyzed on line to obtain the actual welding seam size information corresponding to each contour image. And comparing the obtained actual weld size information with the standard weld size information, and if the weld size information does not meet the standard weld size information, obtaining the position of the weld segment corresponding to the weld size information which does not meet the standard weld on the weld. Therefore, the welding seam detection method provided by the embodiment of the application can realize real-time detection of the welding seam, and the obtained image is used for directly analyzing and measuring the size of the welding seam, so that the position of the unqualified welding seam can be accurately positioned after the unqualified welding seam is detected, and compared with manual measurement, the detection efficiency and quality are improved.
The real-time acquisition of a plurality of contour images of a plurality of weld segments at different positions in the extending direction of a weld described in the embodiment of the present application means that: the image acquisition device is utilized to move along the welding line and acquire a plurality of contour images at a set frequency in the moving process. The frequency of acquiring the profile image is adaptively changed according to the length of the weld and different weld types. Generally, the acquired plurality of contour images are in one-to-one correspondence with the plurality of bead segments at different locations. In the actual detection process, if overlapping exists between adjacent contour images in the acquired plurality of contour images, the overlapping portion of the contour images can be processed in subsequent image processing and analysis.
In some embodiments, the weld detection method further comprises: the standard weld size information is preset before the plurality of contour images are acquired. That is, in order to compare the actual weld size information with the standard weld size information after the actual weld size information is obtained in real time, so as to further improve the efficiency, the detection method according to the embodiment of the present application stores the standard weld size information in the controller in advance according to the detected weld type.
In some embodiments, analyzing each of the plurality of contour images to calculate actual weld size information corresponding to each contour image includes: and carrying out numerical processing on each contour image to obtain actual weld size information corresponding to each contour image. For example, a weld measurement coordinate system is established, the obtained contour image is subjected to numerical processing, and then the position of the contour image is adjusted to be matched with the weld measurement coordinate system, so that the size of the weld is automatically read in the coordinate system, and the actual weld size information can be obtained. Of course, the reading here is also automatically by the controller in the coordinate system.
Specifically, performing the digitizing process on each contour image to obtain the actual weld size information corresponding to each contour image includes performing the binarizing process on the contour image to obtain a binary image, and performing the feature information extraction on the binary image. And carrying out binarization processing on the contour image. Binarization of the image can change the picture into a black-and-white image, which facilitates subsequent feature extraction.
In some embodiments, acquiring the location on the weld where the weld segment that does not meet the standard weld size information is based on the plurality of profile images includes: and establishing weld coordinates according to a plurality of profile images of a plurality of weld segments at different positions, and acquiring the coordinates of the weld segments which do not accord with the standard weld size information from the weld coordinates. Specifically, the welding seam coordinates are established in real time in the process of acquiring a plurality of contour images of a plurality of welding seam segments at different positions in the extending direction of the welding seam in real time, so that the welding seam coordinates can be established while the contour images are acquired, the accurate position of the welding seam segment corresponding to each contour image in the whole welding seam can be clearly acquired, and the welding seam segment can be accurately positioned after the welding seam segment which does not meet the standard welding seam size information is detected conveniently.
The application can accurately record the weld position information in the detection process, realize the rapid locking of unqualified weld information and improve the post-welding detection efficiency.
In order to enable the weld detection method of the embodiment of the present application to perform online monitoring on different types of welds, in some embodiments, calculating to obtain actual weld size information corresponding to each profile image includes: different actual weld size information is obtained for different weld types. For example, before detection, the type of the welding seam is received in a manual interaction mode, and the type of the actual welding seam size information which corresponds to the type of the welding seam and needs to be calculated and analyzed is automatically obtained according to the type of the welding seam. For example, the welding system includes an input device for receiving a weld type input by a user, and the controller automatically obtains a type of actual weld size information to be calculated and analyzed corresponding to the weld type according to the weld type.
In other embodiments, the type of the welding seam does not need to be input by a user, the whole image of the welding seam is directly acquired through the image acquisition device, and the controller judges the type of the welding seam according to the whole image of the welding seam, so that the automation of the welding system is further improved.
As shown in fig. 3, the fusion width b and the residual height h are obtained for the butt weld. That is, if the user inputs the butt weld or the controller determines that the butt weld is the butt weld, the controller analyzes the contour image to obtain the actual weld size information, that is, the actual width and the actual residual height.
As shown in fig. 4, for the fillet weld, leg sizes a1, a2 and a throat size a are obtained, wherein the throat size a refers to the distance from the junction of two workpieces to be welded to the highest point of the weld surface. That is, if the user inputs a fillet weld or the controller determines that the fillet weld is the fillet weld, the controller obtains the contour image, and then analyzes the contour image to obtain the actual weld size information, that is, the actual fillet weld size and the actual throat size.
As shown in FIG. 2, an embodiment of the present application also provides a welding system including a welder apparatus and a controller. The welding apparatus 2 includes a main body, a welding head 21, and an image acquisition device 3 provided on the main body. The welding head 21 is configured to move under the drive of the main body to weld the workpiece 7 to be welded. The image acquisition device 3 is configured to be moved in the extending direction of the weld 71 by the driving of the main body to acquire a plurality of profile images of a plurality of weld segments at different positions after the welding of the welding head 21 is completed. The controller is in signal connection with the image acquisition device 3 and is configured to analyze each of the plurality of contour images acquired by the image acquisition device 3 to calculate and obtain actual weld dimension information corresponding to each contour image, and is further configured to compare the actual weld dimension information with standard weld dimension information, and if the actual weld dimension information does not conform to the standard weld dimension information, acquire the position of the weld segment on the weld, which does not conform to the standard weld dimension information, according to the plurality of contour images.
The welding system acquires a plurality of profile images of a plurality of welding seam segments at different positions in real time in the extending direction of the welding seam. And each contour image is directly subjected to online analysis to obtain the actual weld size information corresponding to each contour image. And comparing the obtained actual weld size information with the standard weld size information, and if the weld size information does not meet the standard weld size information, obtaining the position of the weld segment corresponding to the weld size information which does not meet the standard weld on the weld. Therefore, the welding seam detection system provided by the embodiment of the application can realize real-time detection of welding seams, and the obtained images are used for directly analyzing and measuring the sizes of the welding seams, so that the positions of the unqualified welding seams can be accurately positioned after the unqualified welding seams are detected, and compared with manual measurement, the detection efficiency and quality are improved.
In some embodiments, the image acquisition device 3 is further configured to detect in real time the gap size of the groove on the front side of the working point of the butt joint, e.g. the laser spot, during welding. That is, the image acquisition device 3 of the embodiment of the application not only can realize the detection of the gap size of the groove in the welding process, so that the welding head can adjust the swing amplitude according to the gap size of the groove. And the image acquisition device 3 also acquires an image of the weld after the detection is completed to detect the quality of the weld. Therefore, the welding system provided by the embodiment of the application can directly detect the welding seam after welding by utilizing the existing image acquisition device 3 for detecting the size of the groove, and realizes the integration of welding on-line monitoring and a post-welding real-time detection device, thereby reducing the cost of an additional detection device and simultaneously reducing the load of a welding gun on the detection device.
In some embodiments, the image acquisition device 3 comprises a CCD camera. Wherein, detection device includes CCD camera and line laser generator. The CCD camera is referred to as charge coupled device.
To avoid adverse effects of the laser beam on the detection of the gap size, in some embodiments, the image acquisition device further includes a filter disposed in front of the lens of the CCD camera to avoid environmental interference.
In some embodiments, the image acquisition device further comprises a light supplementing light source 4 arranged at one side of the CCD camera.
A welding system in accordance with an embodiment of the present application is described in detail below with reference to fig. 2.
The welding system of the present embodiment includes a power source 1, a welding apparatus 2, an image acquisition device 3, a supplemental light source 4, and a controller. Wherein the controller comprises a processor 5 and an information acquisition system 6.
After the welding is finished, the supplementary light source 4 is automatically turned on, the welding gun 21 slowly moves on the surface of the welding line 71 along the extending direction X of the welding line 71, the image acquisition device 3 is used for realizing the real-time acquisition of the contour image of the welding line 71, the processor 5 and the information acquisition system 6 are used for carrying out the numerical processing on the contour image, so that the size information of the welding line is calculated in real time, and the position of the welding line which does not meet the standard set value is calibrated.
The image acquisition device 3 is a CCD camera. The CCD camera comprises a high-resolution lens, for example, the high-resolution lens has a minimum resolution of 800 x 800, so that the shooting range is within a 100mm x 100mm field of view, and an optical filter is arranged in front of the lens to prevent arc light interference in the welding process;
the information acquisition system 6 can realize the functions of coordinate conversion, vision acquisition, numerical conversion, data storage and the like, and can interact with an industrial CCD camera to count the numerical information of welded seams.
The welding line testing method of the welding system comprises the following steps:
according to standard rules, the weld parameter standard value is set in advance, and the method comprises the following steps: a relation between the width and the rest of the butt weld, and a relation between the fillet weld leg size and the throat;
starting the equipment, and checking the image acquisition device 3 to ensure that the equipment works normally;
the image acquisition device 3 is adjusted so that its shooting position is in the center region of the weld.
The image acquisition device 3 continuously acquires welding seam information through a welding gun along a welding seam walking path;
transmitting the weld information to a numerical analysis module, performing numerical processing, and comparing the weld size with a standard size range;
judging whether the welding line value exceeds the standard specified range, calibrating the exceeding position, and facilitating the rapid position locking after the whole welding line detection is finished.
The welding system and the welding seam detection method provided by the embodiment of the application are suitable for various welding occasions such as MIG welding, laser welding, compound welding and the like, have high equipment flexibility, are easy to install and operate, and can be applied to butt welding seams, fillet welding, girth welding and the like.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present application and not for limiting the same; while the application has been described in detail with reference to the preferred embodiments, those skilled in the art will appreciate that: modifications may be made to the specific embodiments of the present application or equivalents may be substituted for part of the technical features thereof; without departing from the spirit of the application, it is intended to cover the scope of the application as claimed.

Claims (10)

1. The welding seam detection method is characterized by comprising the following steps of:
acquiring a plurality of contour images of a plurality of welding seam sections at different positions in the extending direction of the welding seam in real time;
analyzing each contour image in the plurality of contour images to calculate and obtain actual weld size information corresponding to each contour image;
and comparing the actual weld size information with the standard weld size information, and if the actual weld size information does not accord with the standard weld size information, acquiring the position of the weld segment which does not accord with the standard weld size information on the weld according to the plurality of contour images.
2. The weld detection method according to claim 1, characterized in that the weld detection method further comprises: the standard weld size information is preset before the plurality of contour images are acquired.
3. The weld detection method according to claim 1, wherein analyzing each of the plurality of contour images to calculate actual weld size information corresponding to each contour image includes: and carrying out numerical processing on each contour image to obtain actual weld size information corresponding to each contour image.
4. The weld inspection method of claim 3, wherein digitizing each of the contour images to obtain actual weld size information corresponding to each of the contour images includes binarizing the contour images to obtain binary images, and extracting feature information from the binary images.
5. The weld inspection method of claim 1, wherein acquiring the location of the weld segment on the weld that does not meet the standard weld size information based on the plurality of profile images comprises: and establishing weld coordinates according to a plurality of profile images of a plurality of weld segments at different positions, and acquiring coordinates of the weld segments which do not accord with standard weld size information from the weld coordinates.
6. The weld detection method according to claim 1, wherein the calculating to obtain actual weld size information corresponding to each profile image includes: different actual weld size information is obtained for different weld types.
7. The weld detection method according to claim 6, wherein, for the butt weld, a fusion width and a residual height are obtained; or, for the fillet weld, obtaining the leg size and the throat size.
8. A welding system, comprising:
a welding apparatus including a main body, a welding head configured to move under the drive of the main body to weld a workpiece to be welded, and an image acquisition device provided on the main body, the image acquisition device configured to move along an extending direction of a weld joint under the drive of the main body to acquire a plurality of profile images of a plurality of weld joint segments at different positions after the welding head finishes welding;
the controller is in signal connection with the image acquisition device and is configured to analyze each of the plurality of contour images acquired by the image acquisition device to calculate and obtain actual weld size information corresponding to each contour image, and the controller is further configured to compare the actual weld size information with standard weld size information, and if the actual weld size information does not accord with the standard weld size information, the position of a weld segment which does not accord with the standard weld size information on a weld is acquired according to the plurality of contour images.
9. The welding system of claim 8, wherein the image acquisition device comprises a CCD camera.
10. The welding system of claim 9, wherein the image capture device further comprises a light supplementing light source disposed on a side of the CCD camera.
CN202310995928.7A 2023-08-08 2023-08-08 Weld joint detection method and welding system Pending CN117029680A (en)

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Application Number Priority Date Filing Date Title
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