CN1172765C - Adaptive control method of welding torch height in welding autotracking system and its equipment - Google Patents
Adaptive control method of welding torch height in welding autotracking system and its equipment Download PDFInfo
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- CN1172765C CN1172765C CNB021207992A CN02120799A CN1172765C CN 1172765 C CN1172765 C CN 1172765C CN B021207992 A CNB021207992 A CN B021207992A CN 02120799 A CN02120799 A CN 02120799A CN 1172765 C CN1172765 C CN 1172765C
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Abstract
The present invention relates to an adaptive control method and a device of welding torch height in a welding autotrack system. The present invention relates to a method for controlling the welding torch height in submerged-arc welding technology by using a linear array CCD sensor and a proximity switch. The present invention comprises a computer, an A/D and I/O interface circuit, a linear array CCD sensor, a horizontal position actuating mechanism, a high-low position actuating mechanism, two proximity switches and a software control program, wherein the computer is used for treating groove images. The two proximity switches are arranged at the same height. The software control program is stored in the computer and is used for selecting the two proximity switches. When the smoothness on a workpiece surface is greatly changed, one proximity switch is automatically selected by the computer to control welding height according to the treating result of the groove images. The high-low position actuating mechanism is driven so that a welding torch descends or ascends by one step size by judging whether the current position of the welding torch is high or low. Thereby, the adaptive control of the welding torch height is realized. The present invention effectively ensures welding quality and has a high cost performance ratio.
Description
Technical field
The present invention relates to welding torch in the welding procedure in the horizontal direction with the automatic tracking system of vertical direction, relate in particular in line array CCD vision tracking system the control method and the device of torch height, belong to the Welding Technology and Equipment technical field of automation.
Background technology
Making welding torch in welding process is the important prerequisite that guarantees welding quality with weld seam centering all the time.Submerged welding process is invisible because welding arc is embedded in welding flux layer under, welding wire and the welding seam bias frequent problem of appearance especially in welding process.This problem has seriously influenced welding quality, production efficiency and economic benefit.By seam tracking system make welding torch in the welding overall process all the time with weld seam centering, obviously be the key that guarantees the submerged-arc welding welding quality.
The automatic tracking system that is used for submerged-arc welding has been carried out a large amount of research both at home and abroad, produced several generations and followed the tracks of the sensor of usefulness.The sensor that first generation welding tracking is used is a feeler lever formula sensor, and its operation principle is mechanical substantially.The sensor that second generation welding tracking is used is the photoelectric sensor of forming with discrete component, and its signal receiving screen is the matrix that is made of discrete light-sensitive element.And the sensor that third generation welding tracking is used has used highly integrated charge-coupled image sensor (being called the CCD device) to the reception of photosignal, is divided into area array CCD (being gamma camera) and line array CCD again.It contains much information area array CCD vision tracking system, by to Signal Processing, obtains three-dimensional information easily, not only can realize seam tracking, but also can realize intelligent control to welding process.But its signal processing time is longer, and cost of equipment is higher, and the cost of system is improved.Though it is and line array CCD vision tracking system has only one-dimension information, then enough fully for tracking (as left and right directions) in one direction.And it is cheap, and the time of information processing is short, and is therefore real-time.Linear array vision tracking system has higher performance on the whole.
In welding process, follow the tracks of the tracking that is included on the both direction automatically.The one, be the tracking on the left and right directions in the horizontal direction, it be directly connected to welding wire whether with weld seam centering, therefore to guaranteeing that welding quality has of paramount importance relation.In addition, it is constant substantially apart from the height of surface of the work to remain welding torch in welding process, also closely related with welding quality.Because under the condition that circuit parameter is determined, if keep welding torch constant substantially apart from the height of surface of the work, then Han Jie electric current and voltage also can keep stable, so just can guarantee welding quality.If moreover in welding process, the height of welding torch is not made corresponding adjustment, when the large diameter tank body of welding, tank body its beating radially in rotating process is enough to make welding torch and workpiece short circuit, and therefore keeping the height distance of welding torch and surface of the work constant substantially in welding process also is the prerequisite that welding process can normally be carried out.So the tracking in welding process on both direction is for guaranteeing that welding quality is a no less important.For the vision tracking system of using line array CCD, the tracking of butt welded seam comprises both direction in welding process, promptly level (about) with vertical both direction on tracking.Line array CCD vision tracking system is the tracking with in the horizontal direction, and in vertical direction tracking, then realizes near switch by one.Effect near switch is exactly that welding torch and ccd sensor are stabilized on the definite height.For tracking in the horizontal direction, when using line array CCD to do receiving device, its light path principle is to have adopted the square neck oblique incidence in the past of laser structure light, and line array CCD is in the working method of vertical direction receiving scattered light signal.Owing to adopted this light channel structure and used high-intensity semiconductor laser as light source, make when surface of the work is dark (for example there is the steel plate of rust on the surface), also can receive signal preferably on the line array CCD, can be by realizing the tracking of butt welded seam after the Computer Processing.But when the fineness of surface of the work changes greatly, for example during polishing brighter, received signal just is tending towards saturated on the line array CCD, thereby can't handle it, can't follow the tracks of.Referring to " Hu Tiejun etc., the application of semiconductor laser in the CCD seam tracking system, electric welding machine, in March, 2002 ".
Summary of the invention
The self-adaptation control method and the device that the purpose of this invention is to provide torch height in a kind of development on welding automatic seam tracking, when this method and device can have greatly changed in the fineness of surface of the work, the automatic tracking transducer of used for submerged arc welding can both realize to welding torch about and vertical both direction on follow the tracks of, in submerged welding process, realize to bevel for welding from motion tracking, with further raising welding quality.
Purpose of the present invention and task are achieved by the following technical solution:
The adaptive controller of torch height in a kind of development on welding automatic seam tracking, this device comprises the computer that the groove image is carried out the signal processing, the line array CCD sensor that links to each other with computer by the A/D interface circuit, control of high and low position near switch by I/O interface circuit being used to of linking to each other with computer respectively, horizontal level executing agency and high and low position executing agency is characterized in that: this device also comprise with described one be installed on the sustained height another near switch and be stored in the described computer and near switch to two software control procedures of selecting near switch.
Implement the self-adaptation control method of torch height in the above-mentioned development on welding automatic seam tracking, this method comprises the steps:
(1) the weld groove picture intelligence that the line array CCD sensor is obtained is sent into computer through the A/D interface circuit and is carried out image processing, and obtains the characteristic value of right-left error value and vertical direction:
(2) according to the deviate of gained left and right directions, computer drives horizontal level executing agency by the I/O interface circuit and welding torch is carried out the tracking of left and right directions;
(3) the computer utilization stores software control procedure within it, and characteristic value and its critical value of resulting vertical direction compared judgement, sends the instruction decision and uses near switch 1 or near switch 2 and control weldering apart from highly;
Determine near behind the switch that (4) judge that the position of current weldering distance is " height " or " low " if high, then drive high and low position executing agency and make unit step-length of welding torch decline; If low, then drive high and low position executing agency and make unit step-length of welding torch rising, thereby realize the Self Adaptive Control of torch height.
The present invention compared with prior art, have the following advantages and beneficial effect: adopt the present invention, not only it is cheap, the time of information processing is short, and about when bigger the variation taken place for the fineness of surface of the work, also can realizing with vertical both direction butt welded seam from motion tracking, effectively guaranteed welding quality, thereby made automatic tracking system have stronger antijamming capability and in actual welding is produced, have more practicality.
Description of drawings
Fig. 1 is a line array CCD vision sensor operation principle.
The weld groove image that Fig. 2 exports for the line array CCD receiving scattered light.
When Fig. 3 changed for the line array CCD height, the scattered light that is received was from the diverse location schematic diagram of structure light belt.
Fig. 4 is the light intensity distributions rule figure in the structure light belt.
Fig. 5 is the line array CCD vision sensor, near switch and welding torch by connecting plate and the crosshead shoe structural representation that is rigidly connected.
Fig. 6 is that the F of Fig. 5 is to view.
Fig. 7 is the N-N cutaway view of Fig. 5.
Fig. 8 is the development on welding automatic seam tracking theory diagram.
Fig. 9 is a torch height auto-adaptive controling software FB(flow block).
Figure 10 adjusts software flow block diagram for vertical height.
The specific embodiment
Further specify principle of the present invention, concrete structure and embodiment below in conjunction with accompanying drawing:
Be used for about the operation principle of tracking transducer is as shown in Figure 1 automatically on (level) direction.Adopted the square neck oblique incidence in the past of laser structure light, the line array CCD sensor is in the working method of vertical direction receiving scattered light signal.Device 1 among Fig. 1 is represented the radiating portion of CCD vision sensor, comprises laser diode and cylindrical lens.Laser sends from laser diode, through behind the cylindrical lens, pools very narrow light belt at surface of the work, is called structured light.This optical plane is incident on the workpiece at a certain angle, produces reflection and scattering on workpiece.Automatically the receiving unit of tracking transducer comprises optical filter 6 in Fig. 1, circle lens 7 and line array CCD device 8, and line array CCD device 8 receives only scattered light in vertical direction.At this moment, can regard the scattering light belt on the surface of the work as light source objects, be imaged on the line array CCD device 8 through circle lens 7.
In Fig. 1, the structure light belt that the radiating portion of sensor sends, variation along with groove place position height, to form a space curve ABCDE at surface of the work and groove inside, this curve also is a space curve in the projection of vertical direction, shape and the corresponding proportional relation of light belt on the workpiece.When the focal length of circle lens 7 was enough big, the depth of field of this optical system was also corresponding longer, can think to be imaged on the plane (as the plane), thinks that promptly image curve is a plane curve abcde.Line array CCD is placed on the picture plane, its sensitization part is overlapped with the straight line portion ab and the de of image curve, like this, drop on CCD from the luminous energy of surface of the work and go up and make its sensitization, and the light belt BC at groove place and CD imaging bc and cd drop on outside the photographic department branch of CCD, the position sensitization of CCD correspondence can not be made, the weld groove positional information can be extracted thus.The point imaging that part in the weld groove and surface of the work height difference are big more is far away more from CCD corresponding photosensitive part, and the light that CCD can receive is also just few more, even does not receive light.
In tracing process, the weld groove image that the pixel reception on the CCD is exported from the scattered light in surface of the work and the groove as shown in Figure 2.The received light intensity of pixel on ab corresponding with surface of the work and the de section is enough big, and therefore pairing pixel reaches capacity, and its corresponding brightness value is a maximum 255.And with groove in the received light intensity of corresponding bc and the pixel on the cd section change apart from the surface of the work height is different with each point, wherein the c briliancy of ordering is minimum.Obviously weld groove image as shown in Figure 2 is easy to handle, thereby can follow the tracks of.In the actual welding process, the pixel on ab corresponding and the de section with surface of the work, its brightness value not necessarily reaches capacity.But, just be easy to carry out image processing as long as the U-shaped curved portion in the image has certain depth.
In tracing process, find that the brightness of groove both sides surface of steel plate has direct influence to the signal that sensor received.When the control welding torch is that certain altitude is when following the tracks of, if CCD goes up received signal when fine to workpiece dark and this moment without polishing surface, in case on the very bright workpiece of polishing, the signal of receiving just makes the pixel on the line array CCD almost all saturated by force, (its degree of depth of U-shaped curved portion that is embodied in the image of Fig. 2 is very shallow) thus can't carry out image processing, thereby can't carry out from motion tracking.Analyzing its reason may be when the surface of steel plate of groove both sides is very bright, and stronger scattered light makes the pixel of line array CCD mid portion also by sensitization.If find in this case the height of sensor is improved a bit, signal will improve.Analyze its former because: in Fig. 3, the laser light belt of surface of the work, its width is about 1mm, the luminous intensity in the light belt satisfies with the outside rule of decay of the form of normal distribution, shown in two curve X1 and X2 among Fig. 4.In the wide scope light intensity maximum of the about 0.2mm in light belt center, outwards weaken gradually.In Fig. 4, curve X1 is corresponding with plane M1, and curve X2 is corresponding with plane M2.Its abscissa P is illustrated in the coordinate figure on the structured light bandwidth direction, and ordinate is represented light intensity, and the position at while ordinate place is the position of line array CCD receiving scattered light just.
If now hypothesis is in Fig. 3, surface of the work M1 is pairing to be the dark steel plate that rust is arranged, and surface of the work M2 pairing be bright steel plate through polishing.The situation of the optical signal that is received on the line array CCD this moment just as shown in Figure 4 so.Because the scattered light intensity of plane M2 is greater than plane M1, the therefore amplitude difference of two curves in Fig. 4.But when surface of the work was M1, the optical signal that is received on the line array CCD was from the center of structure light belt, the Q1 point in the corresponding diagram 4 on the curve X1 just as shown in Figure 4.When the height of sensor is improved a bit, when surface of the work became M2, the optical signal that is received on the line array CCD was from the edge of structure light belt, the Q2 point in the corresponding diagram 4 on the curve X2.Since the difference in height between plane M1 and the plane M2, and Q1 and 2 of Q2 are coincided with a bit.So under the situation that the fineness (claiming brightness again) of surface of the work changes, remain unchanged substantially by the intensity that changes the height of sensor, can make on the line array CCD optical signal that is received.
By to above analysis of phenomenon, in system, be provided with two control torch heights near switch, basicly stable in vertical direction in order to guarantee welding torch, two detection distance values near switch differ 1.5～2.5mm, and two switches are installed in same height.
In automatic tracing process, computer decides the height of selecting for use switch 1 or switch 2 to control welding torch by the processing and the judgement of weld groove image that line array CCD is exported.Processing and deterministic process for as shown in Figure 2 weld groove image are:
The width of processed whole image (by a to d) is 400 pixels.Each to getting 20 pixels, divided by 40 obtains Y1 after the brightness value addition with these 40 pixels to the third side from both sides; Respectively get 20 pixels to both sides respectively from center line again, obtain Y2 divided by 40 after the brightness value addition with these 40 pixels.In Fig. 2, the maximum brightness value of each pixel is 255, and this moment, pixel reached capacity.Even light intensity increases again, brightness value also can not increase again.Therefore when light intensity is very strong, be a horizontal line at peak 255 places.In sensor, owing to used high-intensity semiconductor laser as light source and adopted aforesaid light channel structure, when selecting for use when controlling the height of welding torch near switch 1, even there is the dark steel plate of rust on the surface, the received light intensity of ab section corresponding with the surface of steel plate of groove both sides and de section is also near saturated on line array CCD.But when the welding torch position is improved, use instead when controlling the height of welding torch near switch 2, if workpiece is the surface the dark steel plate of rust is arranged, then the Y1 value will be lower.The critical value of now setting Y1 is 230, and the critical value of Y2 is 130.
The self-regulating process of the height of sensor is as follows in welding process: before the welding beginning, and the original position of selected welding.For fear of unnecessary interference, the groove inclined-plane of original position and surface of steel plate all should be level and smooth, do not have projection.At first select the height of controlling welding torch near switch 1 for use.Obtain the weld groove image with sensor.Computer calculates the value of Y1 and Y2 by the processing to image.If Y2 is less than or equal at 130 o'clock, determine to select for use the height of controlling welding torch near switch 1; If Y2 greater than 130 o'clock, then selects the height of controlling welding torch near switch 2 for use, begin welding then.If when beginning to weld, selected the height of controlling welding torch near switch 1 for use, carry out in the process in welding so, when having Y2 greater than 130 the time, show that the surface of the work of this moment is brighter, then use the height of controlling welding torch near switch 2 instead.For normal situation, when use instead control the height of welding torch near switch 2 after, the weld groove image that line array CCD is exported will return to Y2 again and be less than or equal to 130 situation.But do not need to carry out again switching this moment, but continue to keep using the height of controlling welding torch near switch 2 near switch.And, showing that the surface of the work of this moment is darker when Y1 in welding process, occurring less than 230 the time, computer will be chosen the height of controlling welding torch near switch 1 again by judging.Up to occurring Y2 once more, then use the height of controlling welding torch near switch 2 once more instead greater than 130 o'clock.
If instead when beginning to weld, selected the height of controlling welding torch near switch 2 for use, carry out in the process in welding so, when Y1 occurring less than 230 the time, show that the surface of the work of this moment is darker, computer will be reelected the height of controlling welding torch near switch 1 by judging.All the other processes are same as described above.
For fear of the misoperation that causes system owing to interference, in the above-described situation, when each computer by to image processing and judgement, when needing to change near switch, must be the result of continuous 3 images when all consistent, computer just sends the instruction of switching near switch.By following the tracks of surface of the work brightness to this Self Adaptive Control that torch height carried out, realized to the groove of different workpieces surface brightness from motion tracking, thereby make automatic tracking system have stronger antijamming capability and in actual welding is produced, have more practicality.
Fig. 5 is the line array CCD sensor, near switch and welding torch by connecting plate and the rigidly connected structural representation of crosshead shoe.10 is welding torch among the figure, and it and crosshead shoe 20 are rigidly connected.When the vertical axis of crosshead shoe 20 or trunnion axis are driven when rotating by stepper motor, drive welding torch and move with sensor, realize butt welded seam about and tracking on the vertical both direction.The position of welding torch 10 just do up and down or about adjust the line array CCD sensor 11 that is used for following the tracks of in the horizontal direction and being used for all being rigidly connected that vertical direction is followed the tracks of with welding torch near switch.Line array CCD sensor 11 is rigidly connected with welding torch 10 by connecting plate 12 and connecting plate 13.Near switch 15 with near switch 16 is to be rigidly connected with welding torch by connecting plate 14 and connecting plate 13.But before the welding beginning, after torch height was determined, the line array CCD vision sensor reached and all should be able to adjust respectively apart from the height of surface of the work near switch.Only after all height were all adjusted, fastening again realization was rigidly connected.The design of crosshead shoe will be satisfied the requirement of system's adjustable range and mechanical stiffness, should try one's best simultaneously reducing mechanism size and weight.
Fig. 6 be F among Fig. 5 to view, black heavy line K1 in Fig. 6 and the line of K2 promptly are the positions at weld groove place.Direction of advance during welding is by the direction of K1 to K2.The height of line array CCD sensor 11 relative surface of the works can be realized by the upper-lower position of adjusting connecting plate 12, be installed in same height near switch 15 with near switch 16, the height of their relative surface of the works can be realized by the upper-lower position of adjusting connecting plate 14.
Fig. 8 is the development on welding automatic seam tracking theory diagram.System comprises the line array CCD sensor, and two near switch, computer, A/D and I/O interface circuit, upright position executing agency and horizontal level executing agency.The weld groove picture intelligence that is obtained by the line array CCD sensor, after the A/D interface circuit was sent into computer and carried out image processing and judge, computer sent the instruction decision and uses near switch 1 or control the height of welding torch near switch 2.System moves the entry altitude adjustment process then.Near the signal level that switch is exported, send into computer through the I/O interface circuit and judge, judge that current position near switch is " height " or " low ".If high, then drive stepper motor and make step-length 0.2mm of unit of welding torch decline.And then scanning port, if still height then the step-length that continues to descend, till the signal level of exporting near switch would be by high step-down.This moment, expression was low near the position of switch, so the adjustment of back is again to the height adjustment the position of welding torch.Therefore in whole tracing process, in fact the position of welding torch is in the concussion up and down near the control height value of switch.But because its amplitude of vibration is little, frequency is low, so to not influence of welding process.According to above control method, each cycle period in main program work all will carry out once to judge and regulate the height of a welding torch near the selection of switch, therefore the height with welding torch that can be real-time in welding process is controlled near the height value of setting, and each regulated quantity and adjusting time are all very short.Contrast Fig. 9 and Figure 10 further are illustrated below:
Fig. 9 is the flow chart of torch height self-adaptive control module.CCD interrupts to the computer application behind picked-up groove image.After computer received and interrupts application, collection groove image and shielding were interrupted.Then image is handled, obtained characteristic value Y1 and Y2.Judge then whether be in work near switch 1 this moment.(1) if near switch 1 work, judge that then whether the Y2 value is greater than critical value (130).If greater than, then reelect near switch 2 and work; If be not more than then still keep using near switch 1 work.Just change the vertical height adjusting module then over to and carry out Height Adjustment, return at last.(2) if near switch 2 work, judge that then whether the Y1 value is less than critical value (230).If less than, then reelect near switch 1 and work; If be not less than then still keep using near switch 2 work.Just change the vertical height adjusting module then over to and carry out Height Adjustment, return at last.
Figure 10 is a vertical height adjusting module flow chart.Each cycle period in the main program operation all will call the torch height self-adaptive control module so that to making a choice near switch.And when the torch height self-adaptive control module moves, all to call the vertical height adjusting module.At first sample near the output signal of switch, see that the position of welding torch this moment is higher or on the low side.(1) if higher, then drive upright position executing agency and adjust a unit step-length downwards, sample again, if also Gao Zezai adjusts a unit step-length downwards near the output signal of switch.Until near the output signal step-down of switch the time, just return.(2) if on the low side, then drive upright position executing agency and adjust upward a unit step-length.Sample again near the output signal of switch, if also low then adjust upward a unit step-length again.When uprising, the output signal near switch just returns.
Claims (4)
1. the adaptive controller of torch height in the development on welding automatic seam tracking, this device comprises the computer that the groove image is carried out the signal processing, the line array CCD sensor that links to each other with computer by the A/D interface circuit, control of high and low position near switch by I/O interface circuit being used to of linking to each other with computer respectively, horizontal level executing agency and high and low position executing agency is characterized in that: this device also comprise with described one be installed on the sustained height another near switch and be stored in the described computer and near switch to two software control procedures of selecting near switch.
2. according to torch height adaptive controller in the described development on welding automatic seam tracking of claim 1, it is characterized in that: described two detection distance values near switch differ 1.5～2.5mm.
3. according to the adaptive controller of torch height in claim 1 or the 2 described development on welding automatic seam tracking, it is characterized in that: described line array CCD sensor, two are rigidly connected by connecting plate and crosshead shoe near switch and welding torch.
4. implement the method as torch height adaptive controller as described in the right 1, this method is carried out as follows:
(1) the weld groove picture intelligence that the line array CCD sensor is obtained is sent into computer through the A/D interface circuit and is carried out image processing, and obtains the characteristic value of right-left error value and vertical direction;
(2) according to the deviate of gained left and right directions, computer drives horizontal level executing agency by the I/O interface circuit and welding torch is carried out the tracking of left and right directions;
(3) the computer utilization stores software control procedure within it, and characteristic value and its critical value of resulting vertical direction compared judgement, sends the instruction decision and uses near switch (1) or near switch (2) and control weldering apart from highly;
Determine near behind the switch that (4) judge that the position of current weldering distance is " height " or " low " is if " height " then drives high and low position executing agency and make unit step-length of welding torch decline; If " low " then drives high and low position executing agency and make unit step-length of welding torch rising, thereby realize the Self Adaptive Control of torch height.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| FI117426B (en) * | 2003-06-12 | 2006-10-13 | Aker Yards Oy | A method for controlling welding of a three-dimensional structure |
| US10665128B2 (en) * | 2014-06-27 | 2020-05-26 | Illinois Tool Works Inc. | System and method of monitoring welding information |
| CN105855743B (en) * | 2016-05-04 | 2018-06-12 | 华中科技大学 | A kind of Weld pool dynamic process on-line monitoring system and method |
| CN106825914B (en) * | 2017-03-13 | 2019-08-02 | 湘潭大学 | A kind of integrated laser welding gun with welding line tracking function |
| CN107442901B (en) * | 2017-08-24 | 2019-11-05 | 湘潭大学 | A kind of self-adaptation control method of arc sensing formula seam tracking system |
| CN111132788B (en) * | 2017-09-01 | 2021-12-10 | 弗罗纽斯国际有限公司 | Method and apparatus for providing a reference distance signal for controlling the position of a welding gun |
| CN107738023B (en) * | 2017-11-29 | 2023-04-21 | 威海职业学院 | Automatic weld joint tracking device and method based on linear array CCD |
| CN109317883A (en) * | 2018-11-29 | 2019-02-12 | 合肥常青机械股份有限公司 | A kind of ring disk-like accessory robot automation's welding system |
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