CN210548751U - Linear laser real-time welding seam tracking system of right-angle welding robot - Google Patents
Linear laser real-time welding seam tracking system of right-angle welding robot Download PDFInfo
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- CN210548751U CN210548751U CN201920467826.7U CN201920467826U CN210548751U CN 210548751 U CN210548751 U CN 210548751U CN 201920467826 U CN201920467826 U CN 201920467826U CN 210548751 U CN210548751 U CN 210548751U
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Abstract
The utility model discloses a real-time welding seam tracking system of right angle welding robot line laser, it includes the base, triaxial right angle motion module, digital welding machine, the switch board, the host computer, send the silk machine, welder, line laser visual sensor, buffer stop, the pedestal mounting is epaxial in the X of triaxial right angle motion module, the epaxial welder of installing of Zw of triaxial right angle motion module, the epaxial wired laser visual sensor that is provided with of Zc, digital welding machine sets up subaerial in triaxial right angle motion module one side, be provided with the switch board on the base, the host computer, send the silk machine, the host computer passes through data line and power cord and connects line laser visual sensor and switch board respectively, the switch board passes through data line and power cord and connects the triaxial right angle motion module respectively, digital welding machine, send the silk machine, digital welding machine passes through the power cord and connects. The utility model discloses can control welder automatic tracking welding seam and implement the welding, realize automatic "jump rifle" arc-closing, automatic, intelligent welding.
Description
Technical Field
The utility model relates to an industry welding field especially relates to a real-time welding seam tracking system of right angle welding robot line laser.
Background
The welding robot has very important application in many industrial fields, can use in abominable operational environment, has advantages such as welding quality is stable, the shaping is pleasing to the eye, work efficiency height. However, the conventional welding robot uses a "teach pendant" to operate the tip of the welding gun at the end of the robot to reach teaching points on the welding seam one by one, then the movement mode between the teaching points is defined by programming, and after the program is stored, the robot moves according to the programmed program in advance to complete the welding. When the teaching mode is used for welding objects with irregular shapes or large positioning errors, the teaching needs to be performed in advance every time, the workload is large, the time consumption is long, the efficiency is low, and the welding quality is difficult to ensure; the welding machine cannot work when the position and the width of a welding seam are changed in the welding process.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to provide a real-time welding seam tracker of right angle welding robot line laser to prior art not enough, realized welded automation, intellectuality.
In order to achieve the above purpose, the present invention is achieved by the following technical solutions.
A line laser real-time weld seam tracking system of a right-angle welding robot comprises a base, a three-axis right-angle motion module, a digital welding machine, a control cabinet, an upper computer, a wire feeder, a welding gun, a line laser visual sensor and an anti-collision device, wherein the base is arranged on an X axis of the three-axis right-angle motion module, Yc axes and Yw axes of the three-axis right-angle motion module are parallel to each other and are arranged on the base and are vertical to the X axis, Zc axes and Zw axes of the three-axis right-angle motion module are respectively arranged on the top ends of the Yc axes and the Yw axes and are vertical to a horizontal plane, the welding gun is arranged on the Zw axis, the line laser visual sensor is arranged on the Zc axis, the digital welding machine is arranged on the ground on one side of the three-axis right-angle motion module, the base is provided with the control cabinet, the upper computer is respectively connected, the control cabinet is respectively connected with the three-axis right-angle motion module, the digital welding machine and the wire feeder through a data line and a power line, and the digital welding machine is connected with the welding gun through the power line.
Further, line laser vision sensor includes line laser generator, industry camera, light filter, installation base and shell, the installation pedestal mounting is on the Zc axle, the shell is installed on the installation base, and laser generator, industry camera are installed in the inside of shell, the light filter is installed on industry camera.
Furthermore, an anti-collision device is arranged between the welding gun and the Zw shaft.
Further, buffer stop includes forward anticollision board, reverse anticollision board, first proximity switch, second proximity switch, dust cover, rotary disk, locking hand wheel, forward anticollision board vertically installs the side at reverse anticollision board, the locking hand wheel is installed welder on forward anticollision board, one side that forward anticollision board is close to welder's welding end is provided with first proximity switch, be provided with the dust cover on the first proximity switch, the second proximity switch sets up on reverse anticollision board and is relative with forward anticollision board's position, the rotary disk is installed between forward anticollision board, the reverse anticollision board and respectively with forward anticollision board, reverse anticollision board mutually perpendicular, the rotary disk passes through the bolt and installs on the Z axle, first proximity switch, second proximity switch pass through data line and power cord connection host computer.
Furthermore, the uniaxial length range of the Yc axis, the Yw axis, the Zc axis and the Zw axis of the three-axis right-angle motion module is 100-500mm, the bearing is more than or equal to 30 kg, the length range of the X axis is 1-20m, the bearing is more than or equal to 100 kg, and the running speed of the X axis, the Yc axis, the Yw axis, the Zc axis and the Zw axis of the three-axis right-angle motion module is 0-500 mm/s.
Further, the wire feeder is a 1.2mm or 1.6mm double-pressure wire feeder.
Further, the line laser generator is a semiconductor laser, the wavelength of the output light beam of the line laser generator is 0.36-1 micron, the output light beam is in a fan shape, the output light spot is a straight line, and the output light power is greater than or equal to 5 mW.
Further, the resolution of the industrial camera is greater than or equal to 640x480 pixels, and the frame rate is greater than or equal to 30 frames/second.
The utility model discloses can measure spatial position and the width of welding seam in real time to control welder autotracking welding seam and implement the welding, when the welding seam width is greater than the width that the robot can be welded, realize automatic "jump rifle" arc-ending, carry out the repair welding by the manual work, realize automatic, intelligent welding.
Drawings
Fig. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic view of the position of the weld joint of the present invention;
FIG. 3 is a schematic view of the position of the weld joint during welding according to the present invention;
FIG. 4 is a schematic diagram of three-dimensional coordinates of the weld position of the present invention;
FIG. 5 is a three-dimensional schematic view of the position of the welding tip and the welding seam of the present invention;
fig. 6 is a schematic structural diagram of the three-axis right-angle motion module of the present invention;
fig. 7 is a schematic structural view of the anti-collision device of the present invention;
in the figure: 1. a base; 2. a three-axis right-angle motion module; 3. a digital welding machine; 4. a control cabinet; 5. an upper computer; 6. a wire feeder; 7. a welding gun; 8. a line laser vision sensor; 21. an X axis; 22. the Yc axis; 23. a Yw axis; 24. the Zc axis; 25. a Zw axis; 81. a laser generator; 82. an industrial camera; 83. an optical filter; 84. installing a base; 85. a housing; 9. an anti-collision device; 91. a forward crashproof plate; 92. a reverse anti-collision plate; 93. a first proximity switch; 94. a second proximity switch; 95. a dust cover; 96. rotating the disc; 97. and locking the hand wheel.
Detailed Description
The present invention is further illustrated by the following examples, but is not limited to the contents of the specification.
As shown in the figure: the utility model provides a real-time welding seam tracking system of right angle welding robot line laser, it includes base 1, triaxial right angle motion module 2, digital welding machine 3, switch board 4, host computer 5, send a machine 6, welder 7, line laser vision sensor 8, buffer stop 9.
The three-axis rectangular motion module 2 is an existing rectangular coordinate robot, is programmed based on a space XYZ rectangular coordinate system, has three and more degrees of freedom, can realize automatic control and repeated programming repeated application, and is suitable for automation equipment with different tasks. Y, Z the length range of single shaft is selectable within 100-500mm, the length range of X shaft is selectable within 1-20m, the speed range is 0-500mm/s, the weight of Y, Z bearing is not less than 30 kg, and the bearing of X shaft is not less than 100 kg.
The digital welder 3 is prior art and is capable of programmed control welding, such as the loose digital welder YD-500GR or other welders of the same type.
The control cabinet 4 is a control device of the system, is a system master control unit in the prior art, is respectively connected with the three-axis right-angle motion module 2, the digital welding machine 3, the wire feeder 6 and the anti-collision device 9, and has the functions of multi-machine linkage control, guiding and controlling the three-axis right-angle motion module to drive the welding gun to move, and starting/shutting down, displaying and emergency stopping of the system.
The upper computer 5 is a computer capable of directly sending an operation command, and is a computer capable of processing image information of the line laser vision sensor 8 through a data line and a power line connecting line laser vision sensor 8 in the prior art, obtaining a weld coordinate, storing and sending an instruction to the control cabinet 4 so as to control each device of the system.
The wire feeder 6 is an existing device, is a 1.2mm or 1.6mm double-pressure wire feeder, and can provide various welding materials for welding equipment.
The welding gun 7 is connected with the digital welding machine 3 and is controlled by the digital welding machine 3 to work. And an anti-collision device 9 is arranged between the welding gun 7 and the Zw shaft, and when collision occurs, a power-off signal is triggered to stop the movement of the three-shaft right-angle movement module 2 and stop welding of the welding gun 7.
The anti-collision device 9 comprises a forward anti-collision plate 91, a reverse anti-collision plate 92, a first proximity switch 93, a second proximity switch 94, a dust cover 95, a rotating disc 96 and a locking hand wheel 97, wherein the forward anti-collision plate 91 is vertically arranged on the side edge of the reverse anti-collision plate 92, the welding gun 7 is arranged on the forward anti-collision plate 91 through the locking hand wheel 97, the first proximity switch 93 is arranged on one side, close to a gun head (welding end) of the welding gun 7, of the forward anti-collision plate 91, the dust cover 95 is arranged on the first proximity switch 93, and the second proximity switch 94 is arranged on the reverse anti-collision plate 92 and is opposite to the forward anti-collision plate 91. The rotating disc 96 is installed between the forward collision-proof plate 91 and the reverse collision-proof plate 92 and is perpendicular to the forward collision-proof plate 91 and the reverse collision-proof plate 92, the rotating disc is installed on the Zw shaft through bolts, and the welding point position of the welding gun 7 can be manually controlled by rotating the rotating disc 96. The first proximity switch 93 and the second proximity switch 94 are connected to the upper computer 5 through a data line and a power line.
During actual use, a welding gun is fixed on the anti-collision device through the locking hand wheel, the welding point position of the welding gun is adjusted by rotating the rotating disc, the anti-collision device responds to external forces on the left side and the right side of the outside, when the welding gun is subjected to any two-way external force, the proximity switch on the forward/reverse anti-collision plate gives a signal to trigger the system to stop welding, and after manual treatment, the position of the mechanism is manually restored, and welding is restored.
The line laser vision sensor 8 comprises a line laser generator 81, an industrial camera 82, a filter 83, a mounting base 84 and a shell 85, a certain included angle is formed between the line laser generator 81 and the industrial camera 82, the mounting base 84 is mounted on a Zc axis, the shell 85 is mounted on the mounting base 84, the laser generator 81 and the industrial camera 82 are mounted inside the shell 85, and the filter 83 is mounted on the industrial camera 82. Laser generator 81, industrial camera 82 pass through data line and power cord connection host computer 5, and laser generator 81 can send laser irradiation in the region that will weld, and industrial camera 82 gathers the laser spot image, calculates via host computer 5 and obtains the distance between welding seam and the welder 7, and industrial camera 82 can acquire the image of welding seam in real time to transmit to host computer 5, the host computer 5 of being convenient for is handled.
The line laser generator 81 is a semiconductor laser, the output wavelength range of the laser is selectable within 0.36-1 micron, a fan-shaped light beam is output, a light spot is linear, and the output light power is not less than 5 mW; the industrial camera 82 is an industrial CMOS camera with a resolution of no less than 640x480 pixels, a frame rate of no less than 30 frames/second, and a spectral response band covering a selected laser output wavelength.
This neotype theory of use:
the upper computer sends a command to a motion system of the three-axis right-angle motion module, the X axis starts to move, the line laser vision sensor sends a scanned welding seam image to the upper computer, and the upper computer extracts an imaging area of line laser through image processing; since the light intensity on the line laser imaging cross section follows a gaussian distribution:
The point with the highest light intensity on the Gaussian curve is the laser central point, so that a Gaussian secondary curve is obtained by fitting the gray value of the point on the laser section, the maximum point of the Gaussian secondary curve obtained by calculation is the central point of the laser line, and the position precision of the central point can reach the sub-pixel level.
Dividing the laser center point cloud obtained by calculation according to the straightness accuracy, fitting a linear equation after division, and adopting an improved least square method linear fitting algorithm because welding slag splashes to interfere laser imaging and a part of outliers exist in the welding process:
The intersection point of the two linear equations is obtained, and the position of the weld joint can be obtained, as shown in fig. 2, the cross is the position of the weld joint.
As shown in fig. 3: when the welding object is not positioned, a gap appears in the welding line, the welding process is limited, and when the width of the welding line is larger than a certain threshold value, the welding effect cannot meet the requirement, so that the width of the welding line is measured, and the upper computer controls the motion system to automatically perform 'gun jump' arc collection according to the preset threshold value. The width of the weld is the distance from the intersection point (weld location) to the adjacent straight line end in the figure.
The line laser vision sensor needs to calibrate a trigonometric mathematical model in advance, calibration parameters are transmitted into an upper computer, and the upper computer calculates the physical distance of the welding seam based on the three-dimensional coordinate of the line laser vision sensor and the width of the welding seam according to the pixel value of the welding seam position calculated before.
The coordinate of the triaxial rectangular motion system is based on the tool coordinate system, so that the conversion relation between the world coordinate system of the line laser vision sensor and the tool coordinate system, namely 'hand-eye calibration', needs to be calculated. As shown in fig. 4: calculating and storing three-dimensional coordinates of a welding point in the current image, marking the welding point on a welding object, controlling a motion system to move a welding gun tip to a marked position, storing coordinates in a tool coordinate system where the current welding gun tip is located as shown in fig. 5, and calculating a conversion relation from a world coordinate system to the tool coordinate, namely a 'hand-eye calibration' matrix by combining the three-dimensional coordinates of the welding point.
The upper computer combines a 'hand-eye calibration' matrix, three-dimensional points of a weld joint and the width of the weld joint of a world coordinate are converted into tool coordinates, the tool coordinates are sent to the motion system, the motion system is connected with all coordinate points in a linear interpolation mode, a welding gun is controlled to perform motion welding, arc is automatically drawn out through 'gun jump', and automatic and intelligent welding is achieved.
The line laser vision sensor calibration is only needed to be carried out when the line laser generator and the industrial camera are assembled for the first time, and the line laser generator and the industrial camera are not needed to be calibrated again in the subsequent use as long as the positions of the line laser generator and the industrial camera are not changed; the 'hand-eye calibration' only needs to be carried out when the line laser vision sensor and the welding gun are installed for the first time, and calibration is not needed again as long as the positions of the line laser vision sensor and the welding gun are not changed in the subsequent use.
The utility model discloses a real-time welding seam tracking system of right angle welding robot line laser not only can solve the not enough of present teaching welding robot existence, can also measure the width of welding seam in real time, when the welding seam width is greater than the width that the robot can be welded, realizes automatic "jump rifle" arc-receiving, is mended by the manual work of next procedure and welds, realizes automatic, intelligent welding.
It is to be understood that the above-described embodiments of the present invention are merely examples provided for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. Not all embodiments are exhaustive. All obvious changes or variations led out by the technical scheme of the utility model are still in the protection scope of the utility model.
Claims (8)
1. The utility model provides a real-time welding seam tracking system of right angle welding robot line laser which characterized in that: it comprises a base (1), a three-axis right-angle motion module (2), a digital welding machine (3), a control cabinet (4), an upper computer (5), a wire feeder (6), a welding gun (7), a line laser vision sensor (8) and an anti-collision device (9), wherein the base (1) is installed on an X-axis (21) of the three-axis right-angle motion module (2), Yc-axes (22) and Yw-axes (23) of the three-axis right-angle motion module (2) are parallel to each other, installed on the base (1) and vertical to the X-axis (21), Zc-axes (24) and Zw-axes (25) of the three-axis right-angle motion module (2) are respectively installed on the top ends of the Yc-axes (22) and the Yw-axes (23) and vertical to the horizontal plane, the welding gun (7) is installed on the Zw-axes (25), the line laser vision sensor (8) is arranged on the Zc-axes (24), the digital welding machine (3) is, be provided with switch board (4), host computer (5), send silk machine (6) on base (1), host computer (5) are respectively connecting wire laser visual sensor (8) and switch board (4) through data line and power cord, triaxial right angle motion module (2), digital welding machine (3), send silk machine (6) are connected respectively through data line and power cord in switch board (4), welder (7) are connected through the power cord in digital welding machine (3).
2. The line laser real-time weld tracking system of the right-angle welding robot according to claim 1, characterized in that: line laser visual sensor (8) are including line laser generator (81), industry camera (82), light filter (83), installation base (84) and shell (85), install on ZC axle (24) installation base (84), shell (85) are installed on installation base (84), and the inside at shell (85) is installed in laser generator (81), industry camera (82), install on industry camera (82) light filter (83).
3. The line laser real-time weld tracking system of the right-angle welding robot according to claim 1, characterized in that: and an anti-collision device (9) is arranged between the welding gun (7) and the Zw shaft (25).
4. The line laser real-time weld tracking system of the right-angle welding robot according to claim 3, characterized in that: buffer stop (9) are including forward anticollision board (91), reverse anticollision board (92), first proximity switch (93), second proximity switch (94), dust cover (95), rotary disk (96), locking hand wheel (97), the side at reverse anticollision board (92) is installed to forward anticollision board (91) vertically, locking hand wheel (97) are installed welder (7) on forward anticollision board (91), one side that forward anticollision board (91) are close to the welding end of welder (7) is provided with first proximity switch (93), be provided with dust cover (95) on first proximity switch (93), second proximity switch (94) set up on reverse anticollision board (92) and relative with the position of forward anticollision board (91), rotary disk (96) are installed between forward anticollision board (91), reverse anticollision board (92) and respectively with forward anticollision board (91), The reverse anti-collision plates (92) are perpendicular to each other, the rotating disc (96) is installed on the Z axis through bolts, and the first proximity switch (93) and the second proximity switch (94) are connected with the upper computer (5) through data lines and power lines.
5. The line laser real-time weld tracking system of the right-angle welding robot according to claim 1, characterized in that: the unipolar length scope of Yc axle (22), Yw axle (23), ZC axle (24), Zw axle (25) of triaxial right angle motion module (2) is 100-500mm and the bearing is more than or equal to 30 kilograms, X axle (21) length scope is 1-20m and the bearing is more than or equal to 100 kilograms, the functioning speed of X axle (21), Yc axle (22), Yw axle (23), Zc axle (24), Zw axle (25) of triaxial right angle motion module (2) is 0-500 mm/s.
6. The line laser real-time weld tracking system of the right-angle welding robot according to claim 1, characterized in that: the wire feeder (6) is a 1.2mm or 1.6mm double-pressure wire feeder.
7. The line laser real-time weld tracking system of the right-angle welding robot according to claim 2, characterized in that: the line laser generator (81) is a semiconductor laser, the wavelength of the output light beam of the line laser generator (81) is 0.36-1 micron, the output light beam is in a fan shape, the output light spot is a straight line, and the output light power is more than or equal to 5 mW.
8. The line laser real-time weld tracking system of the right-angle welding robot according to claim 2, characterized in that: the industrial camera (82) has a resolution greater than or equal to 640x480 pixels and a frame rate greater than or equal to 30 frames/second.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115106617A (en) * | 2022-06-30 | 2022-09-27 | 中国水利水电夹江水工机械有限公司 | Scanning and tracking method for long weld joint in narrow space |
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2019
- 2019-04-09 CN CN201920467826.7U patent/CN210548751U/en active Active
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115106617A (en) * | 2022-06-30 | 2022-09-27 | 中国水利水电夹江水工机械有限公司 | Scanning and tracking method for long weld joint in narrow space |
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