TWI574003B - Device for detecting a three-dimensional image of welds and method for detecting the same - Google Patents
Device for detecting a three-dimensional image of welds and method for detecting the same Download PDFInfo
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Description
本發明係有關於一種銲道三維影像檢測裝置及其檢測方法,尤指一種可快速且準確的由銲道外觀判斷銲道品質優劣之銲道三維影像檢測裝置及其檢測方法。 The invention relates to a three-dimensional image detecting device for a bead and a detecting method thereof, in particular to a three-dimensional image detecting device for a bead which can quickly and accurately determine the quality of a bead from the appearance of a bead and a detecting method thereof.
按,銲接在建築、汽車、航太及機械工業等領域應用非常廣泛,然在銲接施工中有時會因為人員疏忽、技術不熟練或作業程序錯誤等因素,造成銲件品質不良情況,而銲件品質良窳係會嚴重影響到結構體強度與安全性。因此,當銲接完成後,係須進一步透過檢測方法,以對銲件之銲道等進行缺陷檢測,以確保銲件品質。 According to the welding, the application in the fields of construction, automobile, aerospace and machinery industry is very extensive. However, in the welding construction, the quality of the weldment is poor due to factors such as negligence, unskilled technology or incorrect operation procedures. The quality of the good quality will seriously affect the strength and safety of the structure. Therefore, after the welding is completed, it is necessary to further pass the detection method to perform defect detection on the weld bead of the weldment to ensure the quality of the weldment.
目前常用之銲接缺陷檢測方法有超音波檢測、量測動態電阻或量測電阻抗函數等,請參閱我國公告第I325496號之「銲道缺陷檢測之方法及其測試系統」,其主要於銲接後,將一電連接二電極之待測試銲件持續地通入交流電,並測量該等電極間於一預定時間內之一類比電流訊號及一類比電壓訊號,接著分別轉換該類比電流訊號及該類比電壓訊號為一數位電流函數及一數位電壓函數,然後將該數位電流函數及數位電壓函數分別轉換為一複數電流函數及一複數電壓函數。接著,將該複數電壓函數除以該複數電流函數得到一電阻抗函數,復將 該電阻抗函數轉換為一電阻抗波形,以顯示該待測試銲件之銲道缺陷。然,該我國公告第I325496號之「銲道缺陷檢測之方法及其測試系統」雖可對完成銲接之銲件進行銲道缺陷的偵測,但其檢測及運算過程皆過於繁瑣,不若採外觀檢查來得直接方便且迅速。 At present, the commonly used methods for detecting welding defects include ultrasonic detection, measuring dynamic resistance or measuring electrical impedance function. Please refer to the "Method and Test System for Weld Defect Detection" of China No. I325496, which is mainly after welding. And a weldment to be tested electrically connected to the two electrodes is continuously connected to the alternating current, and an analog current signal and a analog voltage signal are measured between the electrodes for a predetermined time, and then the analog current signal and the analogy are respectively converted. The voltage signal is a digital current function and a digital voltage function, and then the digital current function and the digital voltage function are respectively converted into a complex current function and a complex voltage function. Then, dividing the complex voltage function by the complex current function to obtain an electrical impedance function, The electrical impedance function is converted to an electrical impedance waveform to indicate a weld bead defect of the weldment to be tested. However, the "Method and Test System for Weld Defect Detection" of the No. I325496 of China can detect the weld bead defects of the welded parts, but the detection and calculation process is too cumbersome. Visual inspection is straightforward and quick.
由銲道外觀即可得知銲件的強度,不良的銲道外觀,造成應力集中使銲件強度減弱,而凹陷的銲道形狀會使銲道斷面面積減少,導致銲件損壞,另過於凸起的銲道形狀產生較大的集中應力,減少疲勞壽命等。美國銲接學會(American Welding Society)更明確將各種填角銲之銲道外觀列出圖表,請參閱第六圖所示,並整理出兩種優良品、兩種尚可接受及六種不良品之銲道形狀,其圖(a)及圖(b)所示者為理想之填角銲外形,而圖(c)及圖(d)所示者為可接受之填角銲外形,另圖(e)~圖(j)所示者則為六種不良品之銲道外觀,依序為喉深不足、銲道過凸、銲蝕、搭疊、腳長不足及熔接不足等外觀形狀。然,銲道外觀檢查方式雖極為簡便又有明確規範可供遵循,但現有外觀檢查主要係使用銲道樣板規比測,該樣板規一次僅能量測極短長度,故得分段進行量測,而無法快速及全面檢測,另運用個人之經驗判斷銲道之好壞,則易造成檢測誤差及不客觀性等缺失。 The strength of the weldment can be known from the appearance of the weld bead, the appearance of the bad weld bead, the stress concentration will weaken the strength of the weldment, and the shape of the weld bead will reduce the cross-sectional area of the weld bead, resulting in damage to the weldment, and too The raised bead shape produces a large concentrated stress, reducing fatigue life and the like. The American Welding Society has more clearly listed the appearance of the fillet welds of various fillet welds. Please refer to Figure 6 and sort out two good products, two acceptable and six defective products. The shape of the bead is shown in (a) and (b) as the ideal fillet weld profile, while those shown in (c) and (d) are acceptable fillet weld profiles. e) ~ Figure (j) shows the appearance of the weld bead of the six defective products, which are in the form of appearances such as insufficient throat depth, over-bending of the weld bead, welding, overlap, insufficient length of the foot and insufficient welding. However, although the appearance inspection method of the weld bead is extremely simple and has clear specifications to be followed, the existing visual inspection is mainly based on the use of the weld bead sample gauge. The specimen gauge is only energy-measured at a very short length, so the segmentation amount is obtained. Testing, but not fast and comprehensive testing, and using personal experience to judge the quality of the weld bead, it is easy to cause detection errors and non-objectivity and other missing.
緣是,本發明人有鑑於現有銲道外觀檢測方式,於實施上仍有上述諸多缺失,乃藉其多年於相關領域的製造及設計經驗和知識的輔佐,並經多方巧思,研創出本發明。 Therefore, the present inventors have many of the above-mentioned shortcomings in the implementation of the existing weld bead appearance detection methods, and have been assisted by many years of ingenuity in research and design experience and knowledge. invention.
本發明係有關於一種銲道三維影像檢測裝置及其檢測方法,其主要目的係為了提供一種可快速且準確的由銲道外觀判斷銲道品質優劣之銲道三維影像檢測裝置及其檢測方法。 The invention relates to a bead three-dimensional image detecting device and a detecting method thereof, and the main purpose thereof is to provide a bead three-dimensional image detecting device capable of quickly and accurately determining the quality of a bead from the appearance of a bead and a detecting method thereof.
為了達到上述實施目的,本發明人乃研擬如下銲道三維影像檢測裝置,係包含:一移動單元,係設有水平向移動組件,該水平向移動組件係包含直行軌道,並於該直行軌道上方設置有一基座,且於該基座底部組設有軌道輪,以使該軌道輪與該直行軌道對應銜接,另使該軌道輪處組設有位移動力源,又於該水平向移動組件上組設有垂直向移動組件,且於該垂直向移動組件組設高度調整動力源,另於該垂直向移動組件上設置有工作台;一影像擷取單元,係設置於該工作台上,乃包含有水平向旋轉組件、垂直向旋轉組件及攝像機,係使該水平向旋轉組件與該工作台相組設,又使該垂直向旋轉組件組設於該水平向旋轉組件上,另使該攝像機組設於該垂直向旋轉組件上,且使該水平向旋轉組件及垂直向旋轉組件各組接有角度調整器;一圖案投射單元,係設有一特徵投影部件,並於該特徵投影部件相鄰處設有一紅外線光源,且使該圖案投射單元與移動單元相連結;一控制單元,係主要包含有微處理器、操作暨顯示器及資料儲存元件,並使該操作暨顯示器及資料儲存元件與該微處理器相耦接,且於該資料儲存元件儲存有檢測程式模組,該檢測程式模組係至少包含有點雲處理程式及CAD軟體程式,又於該資料儲存元件儲存有美國銲接學會規範之銲道形狀資料,另使該控制單元以有線或無線其中之一,與該移動單元其水平向移動組件之位移動力源、垂直向移動組件之高度調整動力源、該影像擷取單元之攝像機及其水平向旋轉組件與垂直向旋轉組件組接之角度調整器,以及該圖案投射單元其紅外線光源相連結。 In order to achieve the above-mentioned implementation, the inventors have developed the following three-dimensional image detecting device for a bead, comprising: a mobile unit having a horizontal moving component, the horizontal moving component comprising a straight track, and the straight track A pedestal is arranged on the top, and a track wheel is arranged at the bottom of the pedestal to connect the track wheel with the straight track, and the track wheel is provided with a displacement power source and moves in the horizontal direction. The component is provided with a vertical moving component, and the vertical moving component is set with a height adjusting power source, and the vertical moving component is provided with a working platform; an image capturing unit is disposed on the working platform. The invention comprises a horizontal rotating component, a vertical rotating component and a camera, wherein the horizontal rotating component is assembled with the working table, and the vertical rotating component is assembled on the horizontal rotating component, and The camera assembly is disposed on the vertical rotating component, and the horizontal rotating component and the vertical rotating component are respectively connected with an angle adjuster; a pattern projection unit is provided a feature projection component, and an infrared light source is disposed adjacent to the feature projection component, and the pattern projection unit is coupled to the mobile unit; a control unit mainly includes a microprocessor, an operation and a display, and a data storage component. And the operation and display device and the data storage component are coupled to the microprocessor, and the data storage component stores a detection program module, the detection program module includes at least a cloud processing program and a CAD software program, and The data storage component stores the shape of the weld bead of the American Society of Welding Society, and the control unit is one of wired or wireless, and the displacement power source and the vertical moving component of the horizontal moving component of the mobile unit. The height adjustment power source, the camera of the image capturing unit and the angle adjuster of the horizontal rotation component and the vertical rotation component, and the infrared light source of the pattern projection unit are connected.
如上所述之銲道三維影像檢測裝置,其中,該移動單元之垂直向移動組件係為一垂直設置於該基座上之立桿,該立桿係由內管及外管套接組成,並於該內管及外管間組設有該高度調整動力源,又使該立桿其外管底端組接於該基座,另該內管上端組設有該工作台。 The three-dimensional image detecting device for a bead as described above, wherein the vertical moving component of the moving unit is a vertical rod vertically disposed on the base, and the vertical rod is composed of an inner tube and an outer tube sleeve, and The height adjustment power source is disposed between the inner tube and the outer tube, and the bottom end of the outer tube of the pole is assembled to the base, and the upper end of the inner tube is provided with the table.
如上所述之銲道三維影像檢測裝置,其中,該影像擷取單元其水平向旋轉組件係包含有一第一框體,並使該第一框體組接有第一樞軸,且使該第一樞軸與該工作台垂直樞接,又使該第一樞軸端部組設有該角度調整器,另該垂直向旋轉組件係包含有一第二框體,乃使該第二框體設於該第一框體間,且使該第二框體與第一框體以一第二樞軸水平穿設樞接,並使該第二樞軸端部組設有該角度調整器,另使該攝像機組設於該第二框體上。 The three-dimensional image detecting device of the bead according to the above aspect, wherein the horizontally rotating component of the image capturing unit comprises a first frame, and the first frame is coupled to the first pivot, and the first a pivotal shaft is vertically pivoted to the table, and the first pivot end is provided with the angle adjuster, and the vertical rotating component comprises a second frame, so that the second frame is provided Between the first frame body, the second frame body and the first frame body are pivotally connected by a second pivot horizontally, and the second pivot end portion is provided with the angle adjuster, and The camera is assembled on the second frame.
如上所述之銲道三維影像檢測裝置,其中,該攝像機係設有左鏡頭及右鏡頭。 The bead three-dimensional image detecting device as described above, wherein the camera is provided with a left lens and a right lens.
如上所述之銲道三維影像檢測裝置,其中,該圖案投射單元係設置在該移動單元之工作台上。 The bead three-dimensional image detecting device as described above, wherein the pattern projection unit is disposed on a table of the moving unit.
本發明人係進一步研擬如下銲道三維影像檢測方法,其實施步驟係包含:A.定點調校:係先於一定點由控制單元驅使移動單元,以將一組設於移動單元之影像擷取單元其攝像機調整至拍攝到欲檢測之鋼構件及其銲道之位置處;B.特徵圖案投影:繼由控制單元驅使一圖案投射單元其紅外線光源發出紅外線,以透過其特徵投影部件將特徵圖案投射於該鋼構件及其銲道上; C.移動攝影鏡頭:續由控制單元驅使組設於移動單元上之影像擷取單元行進,並以時間差移動攝像機方式,使攝像機其鏡頭沿著該鋼構件及其銲道擷取連續分段不同角度的多重重疊影像;D.三角測量法演算:將由攝像機擷取到之多重重疊影像由控制單元之微處理器以三角測量法演算三維深度,及以不同時間擷取兩相鄰影像,利用圖案投射單元所投射出紅外線特徵圖案之影像計算基線,並進行其距離之計算;E.影像排序及特徵點偵測:再由控制單元之微處理器將該鋼構件及其銲道影像進行影像排序及特徵點對應,找出對應之間的基礎矩陣,以建立圖像之間的匹配關係;F.重建銲道三維點雲模型:又由控制單元之微處理器通過圖像之間的特徵匹配或區域相似性匹配,建構該鋼構件及其銲道的三維點雲資料;G.銲道外觀尺寸比對:續控制單元之微處理器利用銲道剖斷面重建該銲道曲面,再由該銲道三維點雲資料進行銲道外觀檢測,並與其內鍵之美國銲接學會(AWS)規範之銲道形狀進行比對,以檢測出該銲道其銲接品質優劣。 The inventor further develops the following method for detecting the three-dimensional image of the bead. The implementation steps include: A. Fixed point adjustment: the mobile unit is driven by the control unit before a certain point to set a group of images set on the mobile unit. The camera is adjusted to the position where the steel member to be inspected and its bead are photographed; B. feature pattern projection: following the control unit driving a pattern projection unit whose infrared light source emits infrared rays to transmit features through its characteristic projection unit a pattern projected onto the steel member and its weld bead; C. Moving Photographic Lens: Continued by the control unit to drive the image capturing unit set on the mobile unit to travel, and move the camera mode by time difference, so that the lens of the camera is continuously segmented along the steel member and its bead. Multiple overlapping images of angles; D. Triangulation calculus: the multiple overlapping images captured by the camera are calculated by the microprocessor of the control unit to calculate the three-dimensional depth by triangulation, and to capture two adjacent images at different times, using patterns The projection unit projects the image of the infrared characteristic pattern to calculate the baseline, and calculates the distance; E. Image sorting and feature point detection: the image of the steel member and its bead image is imaged by the microprocessor of the control unit. Corresponding to the feature points, find the basic matrix between the corresponding ones to establish the matching relationship between the images; F. Reconstruct the three-dimensional point cloud model of the bead: the matching between the images by the microprocessor of the control unit Or regional similarity matching, constructing the three-dimensional point cloud data of the steel member and its weld bead; G. Comparison of the dimensions of the bead appearance: continued use of the microprocessor of the control unit The bead profile is reconstructed from the weld bead section, and the weld bead appearance is detected by the bead 3D point cloud data, and compared with the shape of the inner weld of the American Welding Society (AWS) specification to detect the weld bead. The welding quality of the weld bead is good or bad.
如上所述之銲道三維影像檢測方法,其中,該重建銲道三維點雲模型步驟後係進一步進行點雲資料處理,以將點雲資料縮減與點雲資料平滑化、雜訊點濾除及點雲資料座標重整,再進行銲道外觀尺寸比對步驟。 The three-dimensional image detecting method for the bead as described above, wherein the step of reconstructing the three-dimensional point cloud model of the bead is further processed by the point cloud data to reduce the point cloud data and smooth the point cloud data, and filter the noise point and The point cloud data coordinates are re-formed, and then the bead appearance size comparison step is performed.
如上所述之銲道三維影像檢測方法,其中,該移動攝影鏡頭之步驟中,該攝像機其鏡頭係對該鋼構件及其銲道進行前、後及上、下角度之影像擷取。 The method for detecting a three-dimensional image of a bead as described above, wherein in the step of moving the photographing lens, the lens of the camera is imaged by the front, back, and up and down angles of the steel member and the bead thereof.
如上所述之銲道三維影像檢測方法,其中,該移動攝影鏡頭之步驟中,每一影像與相鄰影像其重疊係以至少50%以上為最佳。 In the method of detecting a three-dimensional image of a bead as described above, in the step of moving the photographic lens, it is preferable that at least 50% of each of the images overlap with the adjacent image.
(1)‧‧‧移動單元 (1)‧‧‧Mobile units
(11)‧‧‧直行軌道 (11) ‧ ‧ straight track
(12)‧‧‧基座 (12) ‧ ‧ pedestal
(121)‧‧‧軌道輪 (121)‧‧‧ Track wheel
(122)‧‧‧位移動力源 (122)‧‧‧ Displacement power source
(13)‧‧‧立桿 (13) ‧‧‧ pole
(131)‧‧‧內管 (131) ‧ ‧ inner management
(132)‧‧‧外管 (132)‧‧‧External management
(14)‧‧‧工作台 (14) ‧‧‧ Workbench
(2)‧‧‧影像擷取單元 (2) ‧‧‧Image capture unit
(21)‧‧‧第一框體 (21)‧‧‧First frame
(22)‧‧‧第一樞軸 (22)‧‧‧First pivot
(23)‧‧‧第二框體 (23) ‧‧‧Second frame
(24)‧‧‧第二樞軸 (24) ‧‧‧Second pivot
(25)‧‧‧角度調整器 (25)‧‧‧Angle adjuster
(26)‧‧‧攝像機 (26)‧‧‧Camera
(261)‧‧‧鏡頭 (261)‧‧‧ lens
(3)‧‧‧圖案投射單元 (3) ‧‧‧ pattern projection unit
(31)‧‧‧特徵投影部件 (31)‧‧‧Feature projection parts
(4)‧‧‧控制單元 (4) ‧‧‧Control unit
(41)‧‧‧微處理器 (41)‧‧‧Microprocessor
(42)‧‧‧操作暨顯示器 (42)‧‧‧Operation & Display
(43)‧‧‧資料儲存元件 (43) ‧‧‧Data storage components
(5)‧‧‧鋼構件 (5) ‧‧‧Steel components
(51)‧‧‧銲道 (51)‧‧‧weld
第一圖:本發明之立體圖 First picture: perspective view of the invention
第二圖:本發明之流程圖 Second figure: flow chart of the present invention
第三圖:本發明之影像掃描成像示意圖 Third: Schematic diagram of image scanning imaging of the present invention
第四圖:本發明之影像掃描三維點雲三角測量示意圖 Fourth picture: schematic diagram of three-dimensional point cloud triangulation of image scanning of the present invention
第五圖:本發明之CAD建構銲道斷面圖 Figure 5: Sectional view of the CAD construction weld bead of the present invention
第六圖:現有之美國銲接學會(AWS)各種填角銲之銲道外觀規範圖 Figure 6: Existing American Welding Society (AWS) fillet welds
而為令本發明之技術手段及其所能達成之效果,能夠有更完整且清楚的揭露,茲詳細說明如下,請一併參閱揭露之圖式及圖號:首先,請參閱第一圖所示,為本發明之銲道三維影像檢測裝置,係主要由移動單元(1)、影像擷取單元(2)、圖案投射單元(3)及控制單元(4)所組成;其中:該移動單元(1),係包含有水平向移動組件,該水平向移動組件係包含直行軌道(11),並於該直行軌道(11)上方設置有一基座(12),且於該基座(12)底部兩側組設有軌道輪(121),以使該軌道輪(121)與該直行軌道(11)對應銜接,又使該軌道輪(121)組設有位移動力源(122),另設有垂直向移動組件,該垂直向移動組件係為垂直組設於該基座(12)上之立桿(13),該立桿(13)係由內管(131)及外管(132)套接組成,並於內管(131)及外管(132)間組設有高度調整動力源, 以使該立桿(13)可上、下伸縮調整,並使該立桿(13)其外管(132)底端組接於基座(12)上,而於該內管(131)上端係組設有工作台(14); 該影像擷取單元(2),係設置於該工作台(14)上,乃包含有水平向旋轉組件及垂直向旋轉組件,該水平向旋轉組件係包含有一第一框體(21),並使該第一框體(21)與該工作台(14)以第一樞軸(22)垂直樞接,以使該第一框體(21)可相對工作台(14)做水平方向旋轉,且使與該第一樞軸(22)端部組設有角度調整器,又於該第一框體(21)間設有該垂直向旋轉組件,該垂直向旋轉組件係包含有一第二框體(23),且使該第二框體(23)與第一框體(21)以第二樞軸(24)水平穿設樞接,以使該第二框體(22)可相對第一框體(21)做垂直方向旋轉,且於穿設該第二框體(23)之第二樞軸(24)端部組設有角度調整器(25),另於該第二框體(23)上組設有攝像機(26),該攝像機(26)係可為紅外線攝像機(26)或數位照相機等,並於該攝像機(26)設有左、右兩鏡頭(261); 該圖案投射單元(3),係設置在工作台(14)上,而與影像擷取單元(2)相隔一定距離,乃設有一特徵投影部件(31),並於該特徵投影部件(31)相鄰處設有一紅外線光源,該紅外線光源可由紅外線攝像機(26)發出,以藉由紅外線光源將特徵投影部件(31)投射在待量測之鋼構件(5)其銲道(51)上; 該控制單元(4),係可為電腦或手機等,乃包含有微處理器(41)、操作暨顯示器(42)及資料儲存元件(43)等,並使該操作暨顯示器(42)及資料儲存元件(43)與該微處理器(41) 相耦接,且於該資料儲存元件(43)儲存有檢測程式模組,該檢測程式模組係至少包含有點雲處理程式及CAD軟體程式等,又於該資料儲存元件(43)儲存有美國銲接學會(American Welding Society)規範之銲道形狀資料,另使該控制單元(4)以有線或無線其中之一,與該移動單元(1)其軌道輪(121)組設之位移動力源(122)、立桿(13)組設之高度調整動力源、影像擷取單元(2)之攝像機(26)及其第一樞軸(22)、第二樞軸(24)端部組設之角度調整器(25),以及圖案投射單元(3)其紅外線光源等相連結。 In order to make the technical means of the present invention and the effects thereof can be more completely and clearly disclosed, the details are as follows. Please refer to the disclosed drawings and drawings: First, please refer to the first figure. The present invention is a three-dimensional image detecting device for a bead of the present invention, which is mainly composed of a mobile unit (1), an image capturing unit (2), a pattern projection unit (3) and a control unit (4); wherein: the mobile unit (1) comprising a horizontal moving component, the horizontal moving component comprising a straight track (11), and a base (12) disposed above the straight track (11), and the base (12) A rail wheel (121) is arranged on both sides of the bottom portion, so that the rail wheel (121) is coupled with the straight rail (11), and the rail wheel (121) is provided with a displacement power source (122). A vertical moving component is disposed, the vertical moving component is a vertical pole (13) vertically disposed on the base (12), and the vertical pole (13) is composed of an inner tube (131) and an outer tube (132) The sleeve is composed of a height-adjusting power source between the inner tube (131) and the outer tube (132). So that the upright (13) can be adjusted up and down, and the bottom end of the outer tube (132) of the upright (13) is assembled on the base (12), and the upper end of the inner tube (131) The department has a workbench (14); The image capturing unit (2) is disposed on the working table (14) and includes a horizontal rotating component and a vertical rotating component, wherein the horizontal rotating component comprises a first frame (21), and The first frame body (21) and the table (14) are vertically pivoted with the first pivot (22) so that the first frame body (21) can be rotated horizontally relative to the table (14). And providing an angle adjuster to the end of the first pivot (22), and the vertical rotating component is further disposed between the first frame (21), the vertical rotating component includes a second frame a body (23), and the second frame body (23) and the first frame body (21) are horizontally pivoted with the second pivot (24) so that the second frame body (22) is relatively a frame body (21) is rotated in a vertical direction, and an angle adjuster (25) is disposed at an end portion of the second pivot shaft (24) through which the second frame body (23) is disposed, and the second frame body is further disposed (23) The upper group is provided with a camera (26), which can be an infrared camera (26) or a digital camera, and the camera (26) is provided with left and right lenses (261); The pattern projection unit (3) is disposed on the table (14) and spaced apart from the image capturing unit (2) by a feature projection member (31), and the feature projection member (31) An infrared light source is disposed adjacent to the infrared light source, and the infrared light source (26) is projected by the infrared light source to project the feature projection member (31) on the weld bead (51) of the steel member (5) to be measured; The control unit (4) can be a computer or a mobile phone, etc., and includes a microprocessor (41), an operation and display (42), and a data storage component (43), and the operation and display (42) and Data storage component (43) and the microprocessor (41) Coupled in the data storage component (43), the detection program module stores at least a cloud processing program and a CAD software program, and the US data storage component (43) stores the US The shape information of the weld bead specified by the American Welding Society, and the displacement power source of the control unit (4), which is wired or wireless, and the track unit (1) of the mobile unit (1) (122), the height adjustment power source of the vertical pole (13), the camera (26) of the image capturing unit (2), and the first pivot (22) and the second pivot (24) end assembly The angle adjuster (25) and the pattern projection unit (3) are connected by an infrared light source or the like.
據此,當本發明之銲道三維影像檢測裝置進行鋼構件(5)其銲道(51)缺陷檢測時,係將移動單元(1)之直行軌道(11)設置為與欲檢測之鋼構件(5)其銲道(51)相互平行方向,再由該控制單元(4)處控制移動單元(1)、影像擷取單元(2)及圖案投射單元(3)進行銲道(51)外觀掃描量測,並進行程式分析與銲道(51)比對等作業,其實施步驟係包含,請一併參閱第二圖所示:A.定點調校:係先於一定點處由控制單元(4)之微處理器(41)調整其移動單元(1)之立桿(13)伸縮高度,及調節影像擷取單元(2)其攝像機(26)之垂直方向旋轉及水平方向旋轉角度,以使攝像機(26)拍攝到欲檢測之鋼構件(5)及其銲道(51)位置處;B.特徵圖案投影:請一併參閱第三圖所示,繼由控制單元(4)驅使圖案投射單元(3)其紅外線光源發出紅外線,以透過其特徵投影部件(31)將呈點或線狀之特徵圖案投射而出,以將特徵圖案投射於鋼構件(5)及其銲道(51)上; C.移動攝影鏡頭:續由控制單元(4)操作該移動單元(1)其軌道輪(121)處組設之位移動力源(122)作動,以驅使組設於移動單元(1)其基座(12)上之影像擷取單元(2)於直行軌道(11)行進,並以時間差移動攝像機(26)方式,使攝像機(26)其左、右鏡頭(261)沿著鋼構件(5)及其銲道(51)擷取連續分段不同角度的多重重疊影像,其每一影像與相鄰影像以重疊至少50%以上為最佳; D.三角測量法演算:請一併參閱第四圖所示,由攝像機(26)擷取到的多重重疊影像係傳輸至控制單元(4),以由控制單元(4)之微處理器(41)經檢測程式模組以三角測量法演算三維深度,及以不同時間擷取兩鄰影像,利用圖案投射單元(3)所投射出紅外線特徵圖案之影像計算基線,並進行其距離之計算; E.影像排序及特徵點偵測:再由控制單元(4)之微處理器(41)經檢測程式模組由擷取到的鋼構件(5)及其銲道(51)影像進行影像排序及特徵點對應,找出對應之間的基礎矩陣,以建立圖像之間的匹配關係; F.重建銲道三維點雲模型:又由控制單元(4)之微處理器(41)經檢測程式模組重建鋼構件(5)及其銲道(51)三維點雲模型,通過圖像之間的特徵匹配或區域相似性匹配,建構鋼構件(5)及其銲道(51)的三維點雲資料; G.點雲資料處理:繼由控制單元(4)之微處理器(41)經檢測程式模組進行點雲資料縮減與點雲資料平滑化、雜訊點濾除及點雲資料座標重整等作業; H.銲道外觀尺寸比對:請一併參閱第五圖所示,續由控制單元(4)之微處理器(41)經檢測程式模組,進行銲道(51)剖斷面以重建銲道(51)曲面,再由銲道(51)三維點雲資料進行銲道(51)外觀檢測,並與其資料儲存元件(43)儲存之美國銲接學會(AWS)規範之銲道形狀資料進行比對〔如第六圖所示〕,以達到檢測出該銲道(51)銲接品質優劣之效果者。 Accordingly, when the bead three-dimensional image detecting device of the present invention performs the detection of the weld bead (51) defect of the steel member (5), the straight track (11) of the moving unit (1) is set to be the steel member to be inspected. (5) The weld bead (51) is parallel to each other, and then the control unit (4) controls the moving unit (1), the image capturing unit (2) and the pattern projection unit (3) to perform the appearance of the bead (51). Scanning measurement, and program analysis and bead (51) comparison operations, the implementation steps are included, please refer to the second figure: A. Fixed point adjustment: the control unit is before a certain point (4) The microprocessor (41) adjusts the telescopic height of the upright (13) of the moving unit (1), and adjusts the vertical rotation and the horizontal rotation angle of the camera (26) of the image capturing unit (2), To enable the camera (26) to capture the position of the steel member (5) and its weld bead (51) to be inspected; B. Feature pattern projection: Please refer to the third figure, followed by the control unit (4) The pattern projection unit (3) emits infrared rays from the infrared light source to project a point or line feature pattern through the feature projection member (31) to display the feature map Projecting the steel member (5) and the bead (51); C. Moving Photographic Lens: Continued operation of the mobile unit (1) by the control unit (4) to operate the displacement power source (122) at the track wheel (121) to drive the group to the mobile unit (1) The image capturing unit (2) on the base (12) travels on the straight track (11) and moves the camera (26) with a time difference so that the camera (26) has its left and right lenses (261) along the steel member ( 5) and the bead (51) draws multiple overlapping images of different angles in a continuous segment, and each image and the adjacent image overlap at least 50% is optimal; D. Triangulation calculus: Please refer to the fourth figure together, the multiple overlapping images captured by the camera (26) are transmitted to the control unit (4) to be controlled by the microprocessor of the control unit (4). 41) The detection program module calculates the three-dimensional depth by triangulation, and extracts the two adjacent images at different times, calculates the baseline by using the image of the infrared characteristic pattern projected by the pattern projection unit (3), and calculates the distance; E. Image sorting and feature point detection: the microprocessor (41) of the control unit (4) performs image sorting by the captured steel component (5) and its weld bead (51) image through the detection program module. And corresponding to the feature points, find the basic matrix between the corresponding ones to establish a matching relationship between the images; F. Reconstructing the bead 3D point cloud model: The microprocessor (41) of the control unit (4) reconstructs the steel component (5) and its bead (51) 3D point cloud model through the detection program module, and passes the image. The three-dimensional point cloud data of the steel member (5) and its bead (51) are constructed by feature matching or regional similarity matching; G. Point cloud data processing: following the microprocessor (41) of the control unit (4) through the detection program module for point cloud data reduction and point cloud data smoothing, noise point filtering and point cloud data coordinate reorganization Waiting for work; H. Appearance size comparison of the bead: Please refer to the fifth figure as shown in the figure. Continued by the microprocessor (41) of the control unit (4) through the test program module, the weld bead (51) is sectioned to reconstruct The bead (51) curved surface is then subjected to the appearance inspection of the bead (51) by the bead (51) three-dimensional point cloud data, and the shape information of the weld bead of the American Welding Society (AWS) specification stored with the data storage component (43). The comparison (as shown in the sixth figure) is to achieve the effect of detecting the quality of the weld bead (51).
藉此,本發明運用3D影像式掃描技術,引入特徵投影部件(31),透過紅外線直接投射其特徵投影部件(31)之特徵圖案於鋼構件(5)上,藉由從攝像機(26)對鋼構件(5)擷取連續性影像資料,進行銲道(51)表面外形量測,利用影像擷取單元(2)設置於該工作台(14)上之第一框體(21)及第二框體(23)可相對工作台(14)做垂直向旋轉及水平向旋轉,以不同角度進行連續影像掃瞄,並藉其下移動單元(1)之可上、下伸縮調整之立桿(13),以進行鋼構件(5)其銲道(51)上、下方向軌跡運行錄影掃瞄,待影像判識掃瞄擷取與鋼構件(5)及其銲道(51)不同影像深度,即予進行鋼構件(5)及其銲道(51)下一斷面錄影掃瞄,再利用移動單元(1)與鋼構件(5)及其銲道(51)呈平行位置設置之直行軌道(11),沿著鋼構件(5)分段連續進行鋼構件(5)及其銲道(51)前、後及上、下不同角度的多幅影像計算鋼構件(5)包含銲道(51)整體三維點雲資訊。繼之,將量測得之銲道(51)表面影像資料,進行3D點雲座標數據轉換及前處理,由量測獲得之銲道(51)表面之點雲資料,係先經點雲資料預處理,以進行點雲資料縮減與點雲資料平滑化、雜訊點濾除及點雲資料座標重整等,再依設定間距建立銲道(51)之斷面數值模型,經程式優 化數值資料,以此建構銲道(51)CAD模型,隨之,將量測獲得之銲道(51)外觀,利用銲道(51)剖斷面技巧重建銲道(51)曲面,再由微處理器(41)依據美國銲接學會(AWS)銲接規範,比對優劣外形及尺寸大小,以判別銲道(51)之品質,由等間距剖斷面點雲資料設定母材部份、銲道(51)表面部份及銲道(51)根部,再根據美國銲接學會(AWS)規範以判別銲道(51)外觀之合格與不合格部位,並在CAD軟體上顯示出母材部位、合格銲道(51)部位、不合格銲道(51)部位,並計算其體積變化及標準差分析,由結果可系統化的對整個銲道(51)做快速且準確之外觀優劣判斷效果。 Therefore, the present invention uses the 3D image scanning technology to introduce a feature projection component (31), and directly projects the feature pattern of the feature projection component (31) on the steel component (5) through the infrared ray, by pairing from the camera (26). The steel member (5) takes continuous image data, performs surface profile measurement of the bead (51), and uses the image capturing unit (2) to mount the first frame (21) and the first part on the table (14) The two frames (23) can be rotated vertically and horizontally with respect to the table (14) to perform continuous image scanning at different angles, and the upper and lower telescopic adjustment poles of the moving unit (1) (13), to perform a video scan on the upper and lower trajectories of the weld bead (51) of the steel member (5), and the image recognition scan is different from the steel member (5) and the weld bead (51). Depth, that is, the steel member (5) and its bead (51) are scanned in the next section, and the moving unit (1) is placed in parallel with the steel member (5) and its bead (51). Straight track (11), along the steel member (5), continuously carry out multiple images of steel members (5) and their weld bead (51) at different angles before, after and up and down. (51) the overall three-dimensional point cloud information. Following this, the surface image data of the weld bead (51) will be measured, and the 3D point cloud coordinate data conversion and pre-processing will be performed. The point cloud data on the surface of the weld bead (51) obtained by the measurement is the first point cloud data. Pre-processing, for point cloud data reduction and point cloud data smoothing, noise point filtering and point cloud data coordinate reorganization, etc., and then establish a cross-section numerical model of the bead (51) according to the set spacing. The numerical data is used to construct the CAD model of the weld bead (51). Subsequently, the appearance of the weld bead (51) obtained by measurement is measured, and the weld bead (51) surface is reconstructed by the weld bead (51) section technique, and then The microprocessor (41) according to the American Welding Society (AWS) welding specification, compares the superior and inferior shape and size, to determine the quality of the weld bead (51), and set the base material portion by the equidistant cross-section point cloud data. The surface portion of the road (51) and the root of the weld bead (51) are determined according to the American Welding Society (AWS) specification to determine the qualified and unqualified parts of the appearance of the weld bead (51), and the base material portion is displayed on the CAD software. Qualified weld bead (51) and unqualified weld bead (51), and calculate the volume change and standard deviation analysis. The result can be systematically and quickly judged the effect of the appearance and quality of the entire weld bead (51).
前述之實施例或圖式並非限定本發明之銲道三維影像檢測裝置及其檢測方法實施樣態,凡所屬技術領域中具有通常知識者所為之適當變化或修飾,皆應視為不脫離本發明之銲道三維影像檢測裝置及其檢測方法專利範疇。 The foregoing embodiments or drawings are not intended to limit the three-dimensional image detecting device of the bead of the present invention and the method for detecting the same, and any suitable changes or modifications of those skilled in the art should be considered as not departing from the present invention. The patent field of the bead 3D image detecting device and its detecting method.
綜上所述,本發明之實施例確能達到所預期功效,又其所揭露之具體構造,不僅未曾見諸於同類產品中,亦未曾公開於申請前,誠已完全符合專利法之規定與要求,爰依法提出發明專利之申請,懇請惠予審查,並賜准專利,則實感德便。 In summary, the embodiments of the present invention can achieve the expected functions, and the specific structures disclosed therein have not been seen in the same products, nor have they been disclosed before the application, and have fully complied with the provisions of the Patent Law. It is required that if an application for a patent for invention is filed in accordance with the law, and if the application is granted, the patent will be granted.
(1)‧‧‧移動單元 (1)‧‧‧Mobile units
(11)‧‧‧直行軌道 (11) ‧ ‧ straight track
(12)‧‧‧基座 (12) ‧ ‧ pedestal
(121)‧‧‧軌道輪 (121)‧‧‧ Track wheel
(122)‧‧‧位移動力源 (122)‧‧‧ Displacement power source
(13)‧‧‧立桿 (13) ‧‧‧ pole
(131)‧‧‧內管 (131) ‧ ‧ inner management
(132)‧‧‧外管 (132)‧‧‧External management
(14)‧‧‧工作台 (14) ‧‧‧ Workbench
(2)‧‧‧影像擷取單元 (2) ‧‧‧Image capture unit
(21)‧‧‧第一框體 (21)‧‧‧First frame
(22)‧‧‧第一樞軸 (22)‧‧‧First pivot
(23)‧‧‧第二框體 (23) ‧‧‧Second frame
(24)‧‧‧第二樞軸 (24) ‧‧‧Second pivot
(25)‧‧‧角度調整器 (25)‧‧‧Angle adjuster
(26)‧‧‧攝像機 (26)‧‧‧Camera
(261)‧‧‧鏡頭 (261)‧‧‧ lens
(3)‧‧‧圖案投射單元 (3) ‧‧‧ pattern projection unit
(31)‧‧‧特徵投影部件 (31)‧‧‧Feature projection parts
(4)‧‧‧控制單元 (4) ‧‧‧Control unit
(41)‧‧‧微處理器 (41)‧‧‧Microprocessor
(42)‧‧‧操作暨顯示器 (42)‧‧‧Operation & Display
(43)‧‧‧資料儲存元件 (43) ‧‧‧Data storage components
(5)‧‧‧鋼構件 (5) ‧‧‧Steel components
(51)‧‧‧銲道 (51)‧‧‧weld
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TW104116194A TWI574003B (en) | 2015-05-21 | 2015-05-21 | Device for detecting a three-dimensional image of welds and method for detecting the same |
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TWI689869B (en) * | 2018-12-28 | 2020-04-01 | 致茂電子股份有限公司 | Image inspection method |
TWI731443B (en) * | 2018-10-18 | 2021-06-21 | 美商賽博光學股份有限公司 | Point cloud merging for determining dimensional information of a surface |
TWI762047B (en) * | 2020-11-26 | 2022-04-21 | 樹德科技大學 | Image-based weld bead defect detection method and the device |
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TWI689723B (en) * | 2019-02-01 | 2020-04-01 | 中國鋼鐵股份有限公司 | Method for extracting dent on surface of object |
TWI742391B (en) * | 2019-06-25 | 2021-10-11 | 林聖傑 | Three-dimensional image surface defect detection system |
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TW201245705A (en) * | 2011-01-13 | 2012-11-16 | Omron Tateisi Electronics Co | Method for inspection of soldering, soldering inspection machine and substrate inspection system |
CN103191958A (en) * | 2013-04-08 | 2013-07-10 | 郑州轻工业学院 | Optical detection method for plate material forming and springback |
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US5481085A (en) * | 1994-09-09 | 1996-01-02 | University Of Kentucky Research Foundation | Apparatus and method for measuring 3-D weld pool shape |
TW201245705A (en) * | 2011-01-13 | 2012-11-16 | Omron Tateisi Electronics Co | Method for inspection of soldering, soldering inspection machine and substrate inspection system |
TW201439499A (en) * | 2013-03-27 | 2014-10-16 | 尼康股份有限公司 | Shape measurement device, structure production system, shape measurement method, structure production method, and shape measurement program |
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TWI731443B (en) * | 2018-10-18 | 2021-06-21 | 美商賽博光學股份有限公司 | Point cloud merging for determining dimensional information of a surface |
TWI689869B (en) * | 2018-12-28 | 2020-04-01 | 致茂電子股份有限公司 | Image inspection method |
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TWI762047B (en) * | 2020-11-26 | 2022-04-21 | 樹德科技大學 | Image-based weld bead defect detection method and the device |
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