CN217167072U - Robot welding and real-time monitoring system based on line laser and binocular vision - Google Patents
Robot welding and real-time monitoring system based on line laser and binocular vision Download PDFInfo
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- CN217167072U CN217167072U CN202123281593.8U CN202123281593U CN217167072U CN 217167072 U CN217167072 U CN 217167072U CN 202123281593 U CN202123281593 U CN 202123281593U CN 217167072 U CN217167072 U CN 217167072U
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- 238000003466 welding Methods 0.000 title claims abstract description 127
- 238000012544 monitoring process Methods 0.000 title claims abstract description 20
- 238000001931 thermography Methods 0.000 claims abstract description 27
- 238000001514 detection method Methods 0.000 claims abstract description 17
- 230000000007 visual effect Effects 0.000 claims abstract description 7
- 238000004891 communication Methods 0.000 claims abstract description 4
- 239000011521 glass Substances 0.000 claims description 3
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- 238000007789 sealing Methods 0.000 claims description 3
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- 230000007547 defect Effects 0.000 abstract description 10
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- 230000005611 electricity Effects 0.000 abstract 1
- 239000000284 extract Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 4
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- 238000010586 diagram Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
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Abstract
The utility model relates to a robot welding and real-time monitoring system based on line laser and binocular vision, including visual detection module, host computer, motion control module and welding module, wherein, visual detection module includes the line laser sensor and the binocular infrared thermal imaging camera that fix at holding pole support both ends and all be connected with host computer communication, and motion control module includes robot controller, reaches the six robots of being connected with its electricity; one end of the six-axis robot is fixedly connected with the base, and the other end of the six-axis robot is fixedly connected with the welding module; the welding module comprises a welding machine power supply and a welding gun, a positioning welding seam is detected through line laser, positioning accuracy is improved, binocular thermal infrared image detection is adopted, advantages of binocular detection and infrared detection are combined, molten pool characteristics in the welding process are extracted, welding defects are detected, welding is stopped timely under unqualified conditions, an alarm is given out, meanwhile, welding deviation is regulated and controlled in real time, and welding quality is improved.
Description
Technical Field
The utility model relates to a technical field is made to the robot intelligence, in particular to robot welding and real-time monitoring system based on line laser and two mesh vision.
Background
With the rapid development of modern industry, the application range of welding is more and more extensive, the quality of welding directly influences the quality and efficiency of the whole production, the welding quality is strictly controlled, and the method has important significance for improving and ensuring the product quality. Meanwhile, the automatic welding technology of the robot plays an increasingly important role in the intelligent manufacturing process.
Various defects such as air holes, slag inclusion, incomplete fusion, partial welding and the like are often generated in the welding process, the welding interface strength is reduced due to the defects, and potential safety hazards are generated, so that the method has great significance in detecting the welding defects and improving the welding quality. At present, a method of detecting after welding is generally adopted in production, so that the detection cost and the time cost are increased, and the production efficiency is greatly reduced.
SUMMERY OF THE UTILITY MODEL
In order to overcome prior art's shortcoming and not enough, the utility model provides a robot welding and real-time monitoring system based on line laser and two mesh vision.
Specifically, robot welding and real-time monitoring system based on line laser and binocular vision, include at least: visual detection module, host computer, motion control module and welding module.
The vision detection module comprises a line laser sensor and a binocular infrared thermal imaging camera which are fixed at two ends of the pole holding support and are in communication connection with an upper computer.
The motion control module comprises a robot controller and a six-axis robot electrically connected with the robot controller; one end of the six-axis robot is fixedly connected with the base, and the other end of the six-axis robot is fixedly connected with the welding module.
The welding module includes a welder power supply and a welding gun.
And the welding gun is connected and installed at the tail end of the robot through a flange.
Embrace pole support includes middle clamping part, bracing piece, first stiff end and second stiff end, the bracing piece is respectively through first stiff end and second stiff end and line laser sensor and two mesh infrared thermal imaging camera fixed connection.
The middle clamping part is two rectangular plates with semicircular grooves in the middle, through holes are formed in the positions, corresponding to the four corners, of the rectangular plates, the rectangular plates are fixed through screws, and the semicircular grooves in the fixed rectangular plates are circular.
The included angle between the middle clamping part and the welding gun is 90 degrees.
And image acquisition cards are arranged in the line laser sensor and the binocular infrared thermal imaging camera.
And the upper computer is respectively electrically connected with the robot controller and the welding machine power supply.
The line laser sensor further includes: the laser welding device comprises a closed outer box, a laser emitter and a camera, wherein the laser emitter and the camera are arranged in the outer box, sealing protective glass is arranged below the outer box, and a baffle is additionally arranged on one side, close to the welding gun, of the outer box.
The binocular infrared thermal imaging cameras are 2 and symmetrically fixed on two sides of the second fixed end.
The binocular infrared thermal imaging camera focus point and the welding gun are the same focus point.
The upper computer is respectively connected with the robot controller and the welding machine power supply, the motion track and the motion speed of the robot are controlled through the robot controller, and the welding start and stop, the welding current and the welding voltage are controlled through the welding machine power supply.
In the technical scheme, the line laser sensor is used for collecting the welding seam image of the workpiece and transmitting the welding seam image to the upper computer through the image collecting card. The binocular thermal infrared imager camera is used for collecting an infrared image of a molten pool in the welding process and transmitting the infrared image to the upper computer through the image collecting card.
In the technical scheme, the upper computer processes and analyzes the image acquired by the line laser sensor, extracts the characteristic points of the welding line, calculates the position coordinates of the welding line, plans the motion track of the robot and guides the welding gun to move.
In the technical scheme, a closed-loop control system is formed by a binocular infrared thermal imaging camera, an upper computer, a robot and a welding machine, and welding quality is monitored in real time. The upper computer processes and analyzes the image acquired by the binocular infrared thermal imaging camera, extracts the characteristic information of the molten pool, detects whether welding defects exist or not, and stops welding and gives an alarm in time if serious defects exist. Meanwhile, whether welding deviation exists or not is detected, if yes, welding parameters are regulated and controlled in real time, and welding deviation is reduced.
The utility model discloses compare in prior art's beneficial effect and be: the robot welding and real-time monitoring system adopts the linear laser to detect and position the welding line, improves the positioning precision of the welding line, thereby improving the welding quality, and simultaneously adopts a mode of synchronously scanning, positioning and welding, thereby improving the working efficiency. On the basis, a welding quality closed-loop detection control scheme is introduced, binocular infrared thermography detection is adopted, the advantages of binocular detection and infrared detection are combined, molten pool characteristics in the welding process are extracted, welding defects are detected, welding is stopped in time for unqualified conditions, and an alarm is given. Meanwhile, welding deviation is regulated and controlled in real time, and welding quality is improved.
Drawings
Fig. 1 is a block diagram of the robot welding and real-time monitoring system of the present invention.
Fig. 2 is a schematic structural diagram of the robot welding device of the present invention.
Fig. 3 is a schematic view of a vision inspection module according to an embodiment of the present invention.
Wherein, 1-a visual detection module; 11-line laser sensor; 110-a closed outer box; 111-a laser transmitter; 112-a camera; 113-sealing protective glass; 114-a baffle; 12-binocular infrared thermography camera; 2-an upper computer; 3-a motion control module; 31-a robot controller; 32-six axis robot; 33-a base; 4-welding the module; 41-welder power supply; 42-a welding gun; 5-holding pole support; 51-an intermediate clamp; 511-semicircular groove; 52-a support bar; 53-a first fixed end; 54-second fixed end.
Detailed Description
The following describes the robot welding and real-time monitoring system based on line laser and binocular vision in further detail with reference to the specific embodiments and the accompanying drawings.
As shown in fig. 1-3, the utility model provides a robot welding and real-time monitoring system based on line laser and binocular vision includes at least: the device comprises a visual detection module 1, an upper computer 2, a motion control module 3 and a welding module 4.
The vision detection module 1 comprises a line laser sensor 11 and a binocular infrared thermal imaging camera 12 which are fixed at two ends of a pole holding support 5 and are in communication connection with an upper computer 2.
The motion control module 3 comprises a robot controller 31 and a six-axis robot 32 electrically connected with the robot controller; one end of the six-axis robot 32 is fixedly connected with the base 33, and the other end of the six-axis robot is fixedly connected with the welding module 4.
The welding module 4 includes a welder power supply 41 and a welding gun 42.
Wherein the welding gun 42 is mounted at the end of the robot by flange connection.
Further, hold pole support 5 and include middle clamping part 51, bracing piece 52, first stiff end 53 and second stiff end 54, bracing piece 52 respectively through first stiff end 53 and second stiff end 54 with line laser sensor 11 and binocular infrared thermal imaging camera 12 fixed connection. Preferably, the line laser sensor 11 and the binocular infrared thermal imaging camera 12 acquire an image of a weld with laser stripes and an infrared thermal imaging image of a weld puddle, respectively, at a sampling rate of 30 frames per second.
Further, the middle clamping part 51 is two rectangular plates with a semicircular groove 511 in the middle, through holes are formed in the corresponding positions of four corners of each rectangular plate, the rectangular plates are fixed by screws, and the semicircular groove 511 in the fixed rectangular plates is circular.
Wherein the angle between the middle clamping part 51 and the welding gun 42 is 90 degrees.
Further, image acquisition cards are arranged in the line laser sensor 11 and the binocular infrared thermal imaging camera 12.
Further, the upper computer 2 is electrically connected with the robot controller 31 and the welder power supply 41 respectively. The movement track and the movement speed of the robot 32 are controlled by the robot controller 31, and the welding start and stop, the welding current and the welding voltage are controlled by the welder power supply 41. Preferably, the upper computer 2 processes and analyzes the image acquired by the line laser sensor 11, extracts the weld feature points, calculates the position coordinates of the weld, plans the motion track of the robot 32, and guides the welding gun 42 to move.
Further, the upper computer 2 also processes and analyzes the image acquired by the binocular infrared thermal imaging camera 12, extracts the characteristic information of the molten pool, detects the welding defect, and regulates and controls the welding deviation in real time through the welding machine power supply 41 and the robot controller 31.
The line laser sensor 11 further includes: the welding torch includes a sealed outer box 110, a laser emitter 111 and a camera 112 provided in the outer box 110, a seal cover glass 113 provided below the outer box 110, and a baffle plate 114 provided on a side of the outer box 110 adjacent to the welding torch 42.
The binocular infrared thermal imaging cameras 12 are 2 and symmetrically fixed on two sides of the second fixed end 54.
The focus point of the binocular infrared thermal imaging camera 12 and the welding gun 42 are the same focus point.
As another preferred embodiment, in the specific implementation process of this embodiment, first, the line laser sensor 11 and the binocular infrared thermal imaging camera 12 are calibrated respectively.
Further, hand-eye calibration between the line laser sensor 11 and the robot 32 and between the binocular infrared thermal imaging camera 12 and the robot 32 are respectively performed.
Further, the line laser sensor 11 is guided to reach the upper part of the starting point of the welding line of the workpiece, the welding line image with the line laser stripes is collected through the line laser sensor 11, and then the welding line image is sent to the upper computer 2 through the image collecting card 13.
Further, the upper computer 2 processes the acquired image, extracts the characteristic points of the weld joint, and calculates the three-dimensional coordinates of the characteristic points of the weld joint.
Further, the guide line laser sensor 11 moves along the direction of the weld joint, the weld joint is continuously scanned, the upper computer 2 establishes a coordinate point cloud of the weld joint, and the welding track of the robot 32 is planned.
Further, when the welding gun 42 is moved above the weld start point, the robot 32 is controlled to start welding.
Further, in the welding process, the line laser sensor 11 continuously scans the welding seam, the upper computer 2 extracts the characteristic points of the welding seam, and the welding track is planned until the welding task is completed.
Further, during the welding process, a welding pool image is acquired through the binocular infrared thermal imaging camera 12 and then sent to the upper computer 2 through the image acquisition card 13.
Further, the upper computer 2 processes the collected molten pool image, extracts characteristic information of the molten pool, detects whether welding defects exist, and stops welding in time and gives an alarm if serious defects exist. Meanwhile, whether welding deviation exists is detected, if the welding deviation exists, welding parameters are adjusted in real time, welding deviation is reduced, and welding quality is improved.
In the description of the present invention, it is to be understood that the terms such as "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore, should not be construed as limiting the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or to implicitly indicate the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically limited otherwise.
While the invention has been described in conjunction with the specific embodiments set forth above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims.
The above-mentioned embodiments only represent some embodiments of the present invention, and the description thereof is specific and detailed, but not to be construed as limiting the scope of the present invention. It should be noted that, for those skilled in the art, without departing from the concept of the present invention, several variations and modifications can be made, which all fall within the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the appended claims.
Claims (10)
1. The utility model provides a robot welding and real-time monitoring system based on line laser and binocular vision which characterized in that includes at least: the device comprises a visual detection module (1), an upper computer (2), a motion control module (3) and a welding module (4);
the visual detection module (1) comprises a line laser sensor (11) and a binocular infrared thermal imaging camera (12), wherein the line laser sensor (11) and the binocular infrared thermal imaging camera (12) are fixed at two ends of the holding pole bracket (5) and are in communication connection with the upper computer (2);
the motion control module (3) comprises a robot controller (31) and a six-axis robot (32) electrically connected with the robot controller; one end of the six-axis robot (32) is fixedly connected with the base (33), and the other end of the six-axis robot is fixedly connected with the welding module (4);
the welding module (4) includes a welder power supply (41) and a welding gun (42).
2. The line laser and binocular vision based robotic welding and real-time monitoring system of claim 1, wherein the welding gun (42) is mounted at a robot end by a flange connection.
3. The line laser and binocular vision based robot welding and real-time monitoring system according to claim 2, wherein the holding pole bracket (5) comprises a middle clamping portion (51), a supporting rod (52), a first fixing end (53) and a second fixing end (54), and the supporting rod (52) is fixedly connected with the line laser sensor (11) and the binocular infrared thermal imaging camera (12) through the first fixing end (53) and the second fixing end (54), respectively.
4. The robot welding and real-time monitoring system based on line laser and binocular vision according to claim 3, wherein the middle clamping portion (51) is two rectangular plates with a semicircular groove (511) in the middle, through holes are formed in the rectangular plates at corresponding positions of four corners, the rectangular plates are fixed by screws, and the semicircular groove (511) in the fixed rectangular plates is circular.
5. The line laser and binocular vision based robotic welding and real-time monitoring system according to claim 4, wherein the intermediate clamp (51) is angled 90 ° from the welding gun (42).
6. The robot welding and real-time monitoring system based on line laser and binocular vision according to claim 5, wherein image acquisition cards are provided in both the line laser sensor (11) and the binocular infrared thermal imaging camera (12).
7. The line laser and binocular vision based robot welding and real-time monitoring system according to claim 6, wherein the upper computer (2) is electrically connected with a robot controller (31) and a welder power supply (41), respectively.
8. The line laser and binocular vision based robotic welding and real-time monitoring system according to claim 7, wherein the line laser sensor (11) further comprises: the welding gun comprises a sealed outer box (110), a laser emitter (111) and a camera (112) which are arranged in the outer box (110), wherein a sealing protective glass (113) is arranged below the outer box (110), and a baffle (114) is additionally arranged on one surface, close to the welding gun (42), of the outer box (110).
9. The line laser and binocular vision based robotic welding and real-time monitoring system of claim 8, wherein the binocular infrared thermal imaging cameras (12) are 2, symmetrically fixed on both sides of the second fixed end (54).
10. The line-laser and binocular vision based robotic welding and real-time monitoring system of claim 9, wherein a focus point of the binocular infrared thermal imaging camera (12) and the welding gun (42) are the same focus point.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202123281593.8U CN217167072U (en) | 2021-12-24 | 2021-12-24 | Robot welding and real-time monitoring system based on line laser and binocular vision |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202123281593.8U CN217167072U (en) | 2021-12-24 | 2021-12-24 | Robot welding and real-time monitoring system based on line laser and binocular vision |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115106674A (en) * | 2022-08-25 | 2022-09-27 | 江苏华强模具科技有限公司 | Welding seam quality detection device for laser welding operation |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115106674A (en) * | 2022-08-25 | 2022-09-27 | 江苏华强模具科技有限公司 | Welding seam quality detection device for laser welding operation |
| CN115106674B (en) * | 2022-08-25 | 2022-11-29 | 江苏华强模具科技有限公司 | Welding seam quality detection device for laser welding operation |
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Granted publication date: 20220812 |