Method, device and welding system for determining replacement of protective isolation parts

Abstract

The present application provides a method, device and welding system for determining the replacement of a protective isolator. The method includes: constructing a relationship between the brightness of a tracking image and the area of ​​welding slag attached to the protective isolator to obtain a target relationship, wherein the tracking image is an image taken by a camera when the laser tracks the weld; determining the initial welding slag area at least based on the target relationship and the initial brightness, wherein the initial brightness is the brightness of the first image captured after the protective isolator is replaced; determining the current welding slag area at least based on the target relationship and the current brightness; determining whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area. The method can quantitatively describe whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area, and thus can accurately determine whether the protective isolator needs to be replaced.

Description

Technical Field

[0001] The present application relates to the field of welding, and in particular, to a method, device, computer-readable storage medium, processor, and welding system for determining replacement of a protective isolation member. Background Art

[0002] In the prior art, during welding with a welding robot, when a line structured light module (which is a part of the welding robot, including a line laser and an industrial camera, with a filter in the same wavelength band as the line laser added in front of the industrial camera, so that during the imaging process of the industrial camera, only light in the same wavelength band as the line laser will be captured by the industrial camera) is used for weld tracking, a large amount of spatter will be generated during welding. Currently, in order to prevent the solder from splashing directly onto the filter, a glass is provided in front of the camera filter to block the solder from splashing directly onto the filter, which is called a protective isolation member.

[0003] Welding slag splash appears as point-like particles. When these point-like particles cover the protective isolation parts, the amount of light entering the industrial camera will be reduced, making the image darker and tending to be underexposed. Usually, when the camera is underexposed, the common method is to increase the camera exposure time to make the image brighter. However, this method will make the entire image very bright, and some places will even tend to be over-exposed, which will affect the extraction of image feature points and directly affect the quality of the weld.

[0004] At present, there are some methods in the prior art for determining whether the protective isolation member needs to be replaced. However, the accuracy of these methods is relatively poor. For example, multiple images taken by a camera are obtained, and whether a predetermined part is included in the image is used to determine whether the protective isolation member needs to be replaced. However, in fact, the predetermined part is easily acquired abnormally, that is, whether the predetermined part is included in the image is determined by multiple factors, and is not necessarily caused by a large amount of welding slag on the protective isolation member.

[0005] Therefore, there is an urgent need for a method that can accurately determine whether the protective isolation member needs to be replaced.

[0006] The above information disclosed in the background technology section is only used to enhance the understanding of the background technology of the technology described in this article. Therefore, the background technology may contain certain information that does not form the prior art known in this country for those skilled in the art. Summary of the invention

[0007] The main purpose of the present application is to provide a method, device, computer-readable storage medium, processor and welding system for determining replacement of a protective isolation member, so as to solve the problem in the prior art that it is difficult to accurately determine whether a protective isolation member needs to be replaced.

[0008] According to one aspect of an embodiment of the present invention, a method for determining replacement of a protective isolator is provided, wherein the protective isolator is arranged on one side of the incident light of the filter of the camera of the welding robot, the transmittance of the protective isolator is greater than or equal to 80%, and the welding robot also includes a laser, and the laser is used to track the weld, including: constructing a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator to obtain a target relationship, and the tracking image is an image taken by the camera when the laser tracks the weld; determining the initial welding slag area at least based on the target relationship and the initial brightness, and the initial brightness is the brightness of the first image captured by tracking the protective isolator after replacement; determining the current welding slag area at least based on the target relationship and the current brightness, and the current brightness is the brightness of the current tracking image; and determining whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area.

[0009] Optionally, a relationship between the brightness of the tracking image and the area of ​​slag attached to the protective isolation piece is constructed to obtain a target relationship, including: determining a target factor that affects the brightness of the tracking image, the target factor at least including the slag area and the exposure time; constructing a relationship between the brightness of the tracking image, the slag area and the exposure time to obtain a preliminary relationship; determining a value of a correlation coefficient of the exposure time; and determining an expression for the slag area based on the preliminary relationship and the value of the correlation coefficient to obtain the target relationship.

[0010] Optionally, the target factor also includes a noise factor, and a relationship between the brightness of the tracking image, the slag area and the exposure time is constructed to obtain a preliminary relationship, including: constructing a relationship between the brightness of the tracking image, the noise factor, the slag area and the exposure time to obtain the preliminary relationship.

[0011] Optionally, determining the correlation coefficient of the exposure time includes: obtaining the exposure time of an ideal situation and the brightness of the tracking image of the ideal situation, wherein the ideal situation is a situation where the noise factor is equal to 0 and the slag area is equal to 0; determining the correlation coefficient of the exposure time according to the exposure time of the ideal situation, the brightness of the tracking image of the ideal situation and the prepared relationship.

[0012] Optionally, the initial welding slag area is determined at least based on the target relationship and the initial brightness, including: determining the initial welding slag area based on the target relationship, the initial brightness, the corresponding exposure time and the noise factor.

[0013] Optionally, the current welding slag area is determined at least based on the target relationship and the current brightness, including: determining the current welding slag area according to the target relationship, the current brightness, the corresponding exposure time and the noise factor.

[0014] Optionally, based on the size relationship between the initial welding slag area and the current welding slag area, determining whether the current protective isolation member needs to be replaced includes: calculating the ratio of the initial welding slag area to the current welding slag area; when the ratio is greater than or equal to a predetermined value, determining that the current protective isolation member does not need to be replaced; when the ratio is less than the predetermined value, determining that the current protective isolation member needs to be replaced.

[0015] According to another aspect of an embodiment of the present invention, a device for determining replacement of a protective isolator is also provided, wherein the protective isolator is arranged on one side of the incident light of the filter of the camera of the welding robot, the transmittance of the protective isolator is greater than or equal to 80%, and the welding robot also includes a laser, which is used to track the weld, including a construction unit, a first determination unit, a second determination unit and a third determination unit, wherein the construction unit is used to construct a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator to obtain a target relationship, and the tracking image is an image taken by the camera when the laser tracks the weld; the first determination unit is used to determine the initial welding slag area based on at least the target relationship and the initial brightness, and the initial brightness is the brightness of the first image captured by the tracking of the protective isolator after replacement; the second determination unit is used to determine the current welding slag area based on at least the target relationship and the current brightness, and the current brightness is the brightness of the current tracking image; the third determination unit is used to determine whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area.

[0016] According to another aspect of an embodiment of the present invention, a computer-readable storage medium is further provided, wherein the computer-readable storage medium includes a stored program, wherein the program executes any one of the methods described.

[0017] According to another aspect of an embodiment of the present invention, a processor is further provided, wherein the processor is used to run a program, wherein any one of the methods is executed when the program is run.

[0018] According to another aspect of an embodiment of the present invention, a welding system is also provided, comprising a welding robot, one or more processors, a memory, and one or more programs, wherein the one or more programs are stored in the memory and are configured to be executed by the one or more processors, and the one or more programs are used to execute any one of the described methods.

[0019] In an embodiment of the present invention, in the method for determining replacement of the protective isolator, first, a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator is constructed to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the weld; then, the initial welding slag area is determined at least according to the target relational expression and the initial brightness, wherein the initial brightness is the brightness of the first image taken by the tracking of the protective isolator after replacement; thereafter, the current welding slag area is determined at least according to the target relational expression and the current brightness, wherein the current brightness is the brightness of the current tracking image; finally, according to the size relationship between the initial welding slag area and the current welding slag area, it is determined whether the current protective isolator needs to be replaced. In the method for determining replacement of the protective isolator of the present application, the welding slag area is determined by constructing a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator, so that the welding slag area can be quantitatively described according to the size relationship between the initial welding slag area and the current welding slag area, thereby accurately determining whether the protective isolator needs to be replaced. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings constituting part of the present application are used to provide a further understanding of the present application. The exemplary embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0021] Figure 1 A flow chart showing a method for determining replacement of a protective isolation member according to an embodiment of the present application is shown;

[0022] Figure 2 A schematic diagram of a device for determining replacement of a protective isolation member according to an embodiment of the present application is shown. DETAILED DESCRIPTION

[0023] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0024] In order to enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of this application.

[0025] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0026] It should be understood that when an element (such as a layer, film, region, or substrate) is described as being "on" another element, the element may be directly on the other element, or there may be intermediate elements. Moreover, in the specification and claims, when an element is described as being "connected" to another element, the element may be "directly connected" to the other element, or "connected" to the other element through a third element.

[0027] As mentioned in the background technology, it is difficult to accurately determine whether the protective isolation member needs to be replaced in the prior art. In order to solve the above problem, in a typical embodiment of the present application, a method, device, computer-readable storage medium, processor and welding system for determining the replacement of a protective isolation member are provided.

[0028] According to an embodiment of the present application, a method for determining the replacement of a protective isolator is provided, wherein the protective isolator is arranged on the side of the incident light of the filter of the camera of the welding robot, that is, on the side of the filter away from the lens, that is, from the object side to the image side, the camera comprises a lens, a filter and a protective isolator in sequence, and the protective isolator is used to protect the filter, so that the projection of the protective isolator on a predetermined plane overlaps with the projection of the filter on the predetermined plane or the projection of the protective isolator on the predetermined plane covers the projection of the filter on the predetermined plane, and the predetermined plane is a plane parallel to the filter, and the transmittance of the protective isolator is greater than or equal to 80%, and the specific material may be glass or other materials with good light transmittance, and the welding robot also comprises a laser, and the laser is used to track the weld.

[0029] Figure 1 FIG. 1 is a flow chart of a method for determining replacement of a protective isolation member according to an embodiment of the present application. Figure 1 As shown, the method comprises the following steps:

[0030] Step S101, constructing a relational expression between the brightness of a tracking image and the area of ​​welding slag attached to a protective isolation member to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the welding seam;

[0031] Step S102, determining an initial welding slag area at least according to a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured after the protective isolation element is replaced;

[0032] Step S103, determining the current welding slag area at least according to the target relationship and the current brightness, where the current brightness is the current brightness of the tracking image;

[0033] Step S104, determining whether the current protective isolation member needs to be replaced based on the relationship between the initial welding slag area and the current welding slag area.

[0034] In the above-mentioned method for determining replacement of the protective isolator, first, a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator is constructed to obtain a target relationship, and the above-mentioned tracking image is an image taken by the above-mentioned camera when the above-mentioned laser tracks the above-mentioned weld; then, the initial welding slag area is determined at least according to the target relationship and the initial brightness, and the above-mentioned initial brightness is the brightness of the first image taken by the above-mentioned protective isolator after replacement; thereafter, the current welding slag area is determined at least according to the above-mentioned target relationship and the current brightness, and the above-mentioned current brightness is the brightness of the current above-mentioned tracking image; finally, according to the size relationship between the above-mentioned initial welding slag area and the above-mentioned current welding slag area, it is determined whether the current above-mentioned protective isolator needs to be replaced. This method determines the welding slag area by constructing a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator, so that it can quantitatively describe whether the current protective isolator needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area, and then it can accurately determine whether the protective isolator needs to be replaced.

[0035] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0036] In one embodiment of the present application, a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolation member is constructed to obtain a target relationship, including: determining a target factor that affects the brightness of the above-mentioned tracking image, the above-mentioned target factor at least including the above-mentioned welding slag area and exposure time; constructing a relationship between the brightness of the above-mentioned tracking image, the above-mentioned welding slag area and the above-mentioned exposure time to obtain a preliminary relationship; determining the value of the correlation coefficient of the above-mentioned exposure time; according to the above-mentioned preliminary relationship and the value of the above-mentioned correlation coefficient, determining the expression of the above-mentioned welding slag area to obtain the above-mentioned target relationship. The brightness of the tracking image can be accurately determined by the welding slag area and exposure time target factors, and then the expression of the welding slag area can be accurately calculated, so that it can be more accurately determined whether the protective isolation member needs to be replaced.

[0037] Specifically, when the area of ​​welding slag attached to the protective isolation piece is the largest, that is, the amount of light entering the camera is close to 0, the image is completely black at this time, and the brightness of the tracking image is 0; when the area of ​​welding slag attached to the protective isolation piece is 0, the amount of light entering the camera at this time is not affected by any noise interference, and is only related to the aperture size of the current camera lens, and the aperture size of the camera lens belongs to the camera hardware part and will not change, that is, the brightness of the tracking image at this time is related to the current exposure time. The longer the exposure time, the brighter the image. When the image is completely white, the brightness is the maximum, and the exposure time at this time is T, T ≥ 1000ms. In an ideal situation, the brightness of the laser line part composed of the linear laser in the image is evenly distributed, and there is no additional noise interference. At this time, the image brightness is L, and the exposure time is M, M∈[0, T]. Therefore, under normal circumstances, the light intensity input to the camera remains unchanged, the exposure time is positively correlated with the brightness of the tracking image, and the welding slag area is negatively correlated with the brightness of the tracking image.

[0038] In order to make the calculation of the brightness of the tracking image more accurate, and thus more accurately determine whether the protective isolation piece needs to be replaced, in another embodiment of the present application, the target factor also includes a noise factor, and a relationship between the brightness of the tracking image, the slag area and the exposure time is constructed to obtain a preliminary relationship, including: constructing a relationship between the brightness of the tracking image, the noise factor, the slag area and the exposure time to obtain the preliminary relationship.

[0039] Specifically, the above-mentioned preparatory relation can be expressed as v=kt+bf+g, where v is the brightness of the tracking image, t is the exposure time, f is the slag area, k is the exposure time correlation coefficient and k>0, b is the slag area correlation coefficient and b<0, and g is the noise factor. In practical applications, the slag area generated during welding is related to the welding voltage and current at that time and the material of the base material and welding wire, that is, b is a constant. In addition, the above-mentioned noise factor g is an inertia constant between [0, 1].

[0040] In another embodiment of the present application, determining the correlation coefficient of the exposure time includes: obtaining the exposure time of an ideal situation and the brightness of the tracking image of the ideal situation, wherein the ideal situation is a situation where the noise factor is equal to 0 and the slag area is equal to 0; determining the correlation coefficient of the exposure time according to the exposure time of the ideal situation, the brightness of the tracking image of the ideal situation and the preparatory relationship. The correlation coefficient of the exposure time can be further accurately calculated by the exposure time of the ideal situation, the brightness of the tracking image of the ideal situation and the preparatory relationship, and then the expression of the slag area can be quantitatively described.

[0041] Specifically, in the above ideal situation, the noise factor g is 0 and the slag area f is 0. In this ideal situation, the brightness of the tracking image is L and the exposure time is M. Substituting into the above preliminary relationship v = kt + bf + g, the exposure time correlation coefficient k = L / M can be obtained. At this time, the target relationship is In the above target relationship, ideally, the brightness L of the tracking image, the exposure time M, the slag area correlation coefficient b, and the noise factor g are all constants. For the convenience of calculation, the slag area correlation coefficient β can be set to -1 / b, and the above target relationship can be written as

[0042] More specifically, the value of the exposure time correlation coefficient k=L / M is related to the hardware parameters of the camera itself, such as the target surface size, the aperture size of the lens, etc. Therefore, under the same environmental conditions, the value of k remains unchanged, and k can be set equal to the constant a. In addition, the noise factor g is an inertial constant between [0, 1]. For the convenience of calculation, g=0 can be set. Therefore, in practical applications, the above target relationship can be written as f=(at-v)β, where a=L / M.

[0043] In another embodiment of the present application, the initial slag area is determined at least according to the target relationship and the initial brightness, including: determining the initial slag area according to the target relationship, the initial brightness, the corresponding exposure time and the noise factor. The initial slag area can be determined more accurately by combining the initial brightness, exposure time, noise factor and the target relationship.

[0044] In another embodiment of the present application, the current welding slag area is determined at least according to the target relationship and the current brightness, including: determining the current welding slag area according to the target relationship, the current brightness, the corresponding exposure time and the noise factor. Similarly, the current welding slag area can be more accurately determined by the initial brightness, exposure time, noise factor and target relationship.

[0045] In actual applications, the calculation method of the above initial brightness and the above current brightness can be the mean method, the variance method, etc. In order to make the calculation result more accurate, the calculation method of the above initial brightness and the above current brightness needs to be consistent, and the above exposure time can be obtained in real time through the camera's own driver software. In addition, in actual working conditions, many welds have traces of manual polishing, and the polished plates are prone to mirror reflection for line structured light. If the camera takes such an image, it will have a great interference with the calculation of the initial welding slag area and the current welding slag area. Therefore, when obtaining tracking images, try to avoid places that are manually polished or places with low mirror reflection.

[0046] In another embodiment of the present application, determining whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area includes: calculating the ratio of the initial welding slag area to the current welding slag area; when the ratio is greater than or equal to a predetermined value, determining that the current protective isolator does not need to be replaced; when the ratio is less than the predetermined value, determining that the current protective isolator needs to be replaced. By calculating the ratio of the initial welding slag area to the current welding slag area, it is possible to more accurately and quantitatively determine whether the protective isolator needs to be replaced.

[0047] In a specific embodiment of the present application, the ratio of the initial welding slag area f0 to the current welding slag area f1 is represented by λ, and the predetermined value can be 0.5. λ represents the similarity between the current protective isolation member and the initial protective isolation member. As the welding time increases, f1≥f0. If λ=1, it means that the welding slag area attached to the current protective isolation member is consistent with the initial one and does not need to be replaced; if 1>λ≥0.5, it means that the welding slag area attached to the current protective isolation member has not reached the threshold value for replacing the protective isolation member and does not need to be replaced; if λ<0.5, it means that the welding slag area attached to the current protective isolation member has reached the threshold value for replacing the protective isolation member and can be output to the system interaction interface to remind the replacement of the protective isolation member.

[0048] The embodiment of the present application also provides a device for determining the replacement of a protective spacer. It should be noted that the device for determining the replacement of a protective spacer in the embodiment of the present application can be used to execute the method for determining the replacement of a protective spacer provided in the embodiment of the present application. The following is an introduction to the device for determining the replacement of a protective spacer provided in the embodiment of the present application. The above-mentioned protective spacer is arranged on the side of the incident light of the filter of the camera of the welding robot, that is, it is arranged on the side of the filter away from the lens, that is, from the object side to the image side. The camera includes a lens, a filter and a protective spacer in sequence. The protective spacer is used to protect the filter. Therefore, the projection of the protective spacer on the predetermined plane overlaps with the projection of the filter on the predetermined plane or the projection of the protective spacer on the predetermined plane covers the projection of the filter on the predetermined plane. The predetermined plane is a plane parallel to the filter. The transmittance of the above-mentioned protective spacer is greater than or equal to 80%. The specific material can be glass or other materials with good light transmittance. The above-mentioned welding robot also includes a laser, which is used to track the weld.

[0049] Figure 2 Schematic diagram of a device for determining replacement of a protective isolation member according to an embodiment of the present application. Figure 2 As shown, the device comprises:

[0050] A construction unit 10 is used to construct a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolation member to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the welding seam;

[0051] A first determination unit 20, configured to determine an initial welding slag area based at least on a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured after the protective isolation element is replaced;

[0052] A second determination unit 30, configured to determine a current welding slag area at least according to the target relationship and current brightness, wherein the current brightness is the current brightness of the tracking image;

[0053] The third determination unit 40 is used to determine whether the current protective isolation member needs to be replaced according to the relationship between the initial welding slag area and the current welding slag area.

[0054] In the above-mentioned device for determining replacement of the protective isolator, a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator is constructed by a construction unit to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the weld; then the initial welding slag area is determined by a first determination unit at least according to the target relational expression and the initial brightness, wherein the initial brightness is the brightness of the first image taken after the protective isolator is replaced; then the current welding slag area is determined by a second determination unit at least according to the target relational expression and the current brightness, wherein the current brightness is the brightness of the current tracking image; finally, the third determination unit determines whether the current protective isolator needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area. The device determines the welding slag area by constructing a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator, thereby being able to quantitatively describe whether the current protective isolator needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area, thereby being able to accurately determine whether the protective isolator needs to be replaced.

[0055] In one embodiment of the present application, the construction unit includes a first determination module, a construction module, a second determination module and a third determination module, wherein the first determination module is used to determine the target factor affecting the brightness of the tracking image, and the target factor at least includes the slag area and the exposure time; the construction module is used to construct a relationship between the brightness of the tracking image, the slag area and the exposure time, and obtain a preliminary relationship; the second determination module is used to determine the value of the correlation coefficient of the exposure time; the third determination module is used to determine the expression of the slag area according to the preliminary relationship and the value of the correlation coefficient, and obtain the target relationship. The brightness of the tracking image can be accurately determined by the slag area and exposure time target factors, and then the expression of the slag area can be accurately calculated.

[0056] Specifically, when the area of ​​welding slag attached to the protective isolation piece is the largest, that is, the amount of light entering the camera is close to 0, the image is completely black at this time, and the brightness of the tracking image is 0; when the area of ​​welding slag attached to the protective isolation piece is 0, the amount of light entering the camera at this time is not affected by any noise interference, and is only related to the aperture size of the current camera lens, and the aperture size of the camera lens belongs to the camera hardware part and will not change, that is, the brightness of the tracking image at this time is related to the current exposure time. The longer the exposure time, the brighter the image. When the image is completely white, the brightness is the maximum, and the exposure time at this time is T, T ≥ 1000ms. In an ideal situation, the brightness of the laser line part composed of the linear laser in the image is evenly distributed, and there is no additional noise interference. At this time, the image brightness is L, and the exposure time is M, M∈[0, T]. Therefore, under normal circumstances, the light intensity input to the camera remains unchanged, the exposure time is positively correlated with the brightness of the tracking image, and the welding slag area is negatively correlated with the brightness of the tracking image.

[0057] In order to make the calculation of the brightness of the tracking image more accurate, and thus more accurately determine whether the protective isolation piece needs to be replaced, in another embodiment of the present application, the target factor also includes a noise factor, and the construction module includes a construction submodule, which is used to construct a relationship between the brightness of the tracking image, the noise factor, the welding slag area and the exposure time to obtain the preliminary relationship.

[0058] Specifically, the above-mentioned preparatory relation can be expressed as v=kt+bf+g, where v is the brightness of the tracking image, t is the exposure time, f is the slag area, k is the exposure time correlation coefficient and k>0, b is the slag area correlation coefficient and b<0, and g is the noise factor. In practical applications, the slag area generated during welding is related to the welding voltage and current at that time and the material of the base material and welding wire, that is, b is a constant. In addition, the above-mentioned noise factor g is an inertia constant between [0, 1].

[0059] In another embodiment of the present application, the second determination module includes an acquisition submodule and a determination submodule, wherein the acquisition submodule is used to acquire the exposure time of an ideal situation and the brightness of the tracking image of the ideal situation, wherein the ideal situation is a situation where the noise factor is equal to 0 and the slag area is equal to 0; the determination submodule determines the correlation coefficient of the exposure time according to the exposure time of the ideal situation, the brightness of the tracking image of the ideal situation and the preparatory relationship. The correlation coefficient of the exposure time can be further accurately calculated through the exposure time of the ideal situation, the brightness of the tracking image of the ideal situation and the preparatory relationship, and then the expression of the slag area can be quantitatively described.

[0060] Specifically, in the above ideal situation, the noise factor g is 0 and the slag area f is 0. In this ideal situation, the brightness of the tracking image is L and the exposure time is M. Substituting into the above preliminary relationship v = kt + bf + g, the exposure time correlation coefficient k = L / M can be obtained. At this time, the target relationship is In the above target relationship, ideally, the brightness L of the tracking image, the exposure time M, the slag area correlation coefficient b, and the noise factor g are all constants. For the convenience of calculation, the slag area correlation coefficient β can be set to -1 / b, and the above target relationship can be written as

[0061] More specifically, the value of the exposure time correlation coefficient k=L / M is related to the hardware parameters of the camera itself, such as the target surface size, the aperture size of the lens, etc. Therefore, under the same environmental conditions, the value of k remains unchanged, and k can be set equal to the constant a. In addition, the noise factor g is an inertial constant between [0, 1]. For the convenience of calculation, g=0 can be set. Therefore, in practical applications, the above target relationship can be written as f=(at-v)β, where a=L / M.

[0062] In another embodiment of the present application, the first determination unit includes a fourth determination module, and the fourth determination module is used to determine the initial welding slag area according to the target relationship, the initial brightness, the corresponding exposure time and the noise factor. The initial welding slag area can be determined more accurately by combining the initial brightness, exposure time, noise factor and target relationship.

[0063] In another embodiment of the present application, the second determination unit includes a fifth determination module, and the fifth determination module is used to determine the current welding slag area according to the target relationship, the current brightness, the corresponding exposure time and the noise factor. Similarly, the current welding slag area can be more accurately determined by the initial brightness, exposure time, noise factor and target relationship.

[0064] In actual applications, the calculation method of the above initial brightness and the above current brightness can be the mean method, the variance method, etc. In order to make the calculation result more accurate, the calculation method of the above initial brightness and the above current brightness needs to be consistent, and the above exposure time can be obtained in real time through the camera's own driver software. In addition, in actual working conditions, many welds have traces of manual polishing, and the polished plates are prone to mirror reflection for line structured light. If the camera takes such an image, it will have a great interference with the calculation of the initial welding slag area and the current welding slag area. Therefore, when obtaining tracking images, try to avoid places that are manually polished or places with low mirror reflection.

[0065] In another embodiment of the present application, the third determination unit includes a calculation module, a sixth determination module and a seventh determination module. The calculation module is used to calculate the ratio of the initial welding slag area to the current welding slag area; the sixth determination module is used to determine that there is no need to replace the current protective isolation member when the ratio is greater than or equal to a predetermined value; the seventh determination module is used to determine that the current protective isolation member needs to be replaced when the ratio is less than the predetermined value. By calculating the ratio of the initial welding slag area to the current welding slag area, it is possible to more accurately and quantitatively determine whether the protective isolation member needs to be replaced.

[0066] In a specific embodiment of the present application, the ratio of the initial welding slag area f0 to the current welding slag area f1 is represented by λ, and the predetermined value can be 0.5. λ represents the similarity between the current protective isolation member and the initial protective isolation member. As the welding time increases, f1≥f0. If λ=1, it means that the welding slag area attached to the current protective isolation member is consistent with the initial one and does not need to be replaced; if 1>λ≥0.5, it means that the welding slag area attached to the current protective isolation member has not reached the threshold value for replacing the protective isolation member and does not need to be replaced; if λ<0.5, it means that the welding slag area attached to the current protective isolation member has reached the threshold value for replacing the protective isolation member and can be output to the system interaction interface to remind the replacement of the protective isolation member.

[0067] The above-mentioned determination device for replacing the protective isolation component includes a processor and a memory. The above-mentioned construction unit, the first determination unit, the second determination unit and the third determination unit are all stored in the memory as program units, and the processor executes the above-mentioned program units stored in the memory to realize the corresponding functions.

[0068] The processor includes a kernel, which retrieves the corresponding program unit from the memory. One or more kernels can be set, and the problem of the difficulty in accurately determining whether the protective isolation component needs to be replaced in the prior art is solved by adjusting kernel parameters.

[0069] The memory may include non-permanent memory in a computer-readable medium, random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM, and the memory includes at least one memory chip.

[0070] An embodiment of the present invention provides a computer-readable storage medium having a program stored thereon, and when the program is executed by a processor, the method for determining replacement of the protective isolation component is implemented.

[0071] An embodiment of the present invention provides a processor, and the processor is used to run a program, wherein the method for determining replacement of the protective isolation component is executed when the program is running.

[0072] An embodiment of the present invention provides a device, the device including a processor, a memory, and a program stored in the memory and executable on the processor, and when the processor executes the program, at least the following steps are implemented:

[0073] Step S101, constructing a relational expression between the brightness of a tracking image and the area of ​​welding slag attached to a protective isolation member to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the welding seam;

[0074] Step S102, determining an initial welding slag area at least according to a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured after the protective isolation element is replaced;

[0075] Step S103, determining the current welding slag area at least according to the target relationship and the current brightness, where the current brightness is the current brightness of the tracking image;

[0076] Step S104, determining whether the current protective isolation member needs to be replaced based on the relationship between the initial welding slag area and the current welding slag area.

[0077] The devices in this article can be servers, PCs, PADs, mobile phones, etc.

[0078] The present application also provides a computer program product, which, when executed on a data processing device, is suitable for executing a program for initializing at least the following method steps:

[0079] Step S101, constructing a relational expression between the brightness of a tracking image and the area of ​​welding slag attached to a protective isolation member to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the welding seam;

[0080] Step S102, determining an initial welding slag area at least according to a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured after the protective isolation element is replaced;

[0081] Step S103, determining the current welding slag area at least according to the target relationship and the current brightness, where the current brightness is the current brightness of the tracking image;

[0082] Step S104, determining whether the current protective isolation member needs to be replaced based on the relationship between the initial welding slag area and the current welding slag area.

[0083] In another typical embodiment of the present application, a welding system is also provided, including a welding robot, one or more processors, a memory and one or more programs, wherein the one or more programs are stored in the one or more memories and are configured to be executed by the one or more processors, and the one or more programs are used to execute any one of the above methods.

[0084] One or more programs included in the above-mentioned welding system are used to execute any of the above-mentioned methods for determining the replacement of the protective isolation member. The method determines the welding slag area by constructing a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolation member. Therefore, whether the current protective isolation member needs to be replaced can be quantitatively described based on the relationship between the initial welding slag area and the current welding slag area, thereby accurately determining whether the protective isolation member needs to be replaced.

[0085] In the above embodiments of the present invention, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0086] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are only schematic. For example, the division of the above-mentioned units can be a logical function division. There may be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of units or modules, which can be electrical or other forms.

[0087] The units described above as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple units. Some or all of the units may be selected according to actual needs to achieve the purpose of the present embodiment.

[0088] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0089] If the above-mentioned integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for a computer device (which can be a personal computer, a server or a network device, etc.) to perform all or part of the steps of the above-mentioned methods of each embodiment of the present invention. The aforementioned storage medium includes: U disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), mobile hard disk, magnetic disk or optical disk and other media that can store program codes.

[0090] From the above description, it can be seen that the above embodiments of the present application achieve the following technical effects:

[0091] 1) In the method for determining replacement of the protective isolator of the present application, first, a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator is constructed to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the weld; then, the initial welding slag area is determined at least according to the target relational expression and the initial brightness, wherein the initial brightness is the brightness of the first image taken after the protective isolator is replaced; thereafter, the current welding slag area is determined at least according to the target relational expression and the current brightness, wherein the current brightness is the brightness of the current tracking image; finally, according to the size relationship between the initial welding slag area and the current welding slag area, it is determined whether the current protective isolator needs to be replaced. This method determines the welding slag area by constructing a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator, thereby being able to quantitatively describe whether the current protective isolator needs to be replaced based on the size relationship between the initial welding slag area and the current welding slag area, thereby being able to accurately determine whether the protective isolator needs to be replaced.

[0092] 2) In the device for determining replacement of the protective isolator of the present application, a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator is constructed by a construction unit to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the weld; then the initial welding slag area is determined by a first determination unit at least according to the target relational expression and the initial brightness, wherein the initial brightness is the brightness of the first image taken by the protective isolator after replacement; then the current welding slag area is determined by a second determination unit at least according to the target relational expression and the current brightness, wherein the current brightness is the brightness of the current tracking image; finally, the third determination unit is used to determine whether the current protective isolator needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area. The device determines the welding slag area by constructing a relational expression between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolator, thereby being able to quantitatively describe whether the current protective isolator needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area, thereby being able to accurately determine whether the protective isolator needs to be replaced.

[0093] 3) In the welding system of the present application, one or more programs included are used to execute any of the above-mentioned methods for determining the replacement of the protective isolation member. The method determines the welding slag area by constructing a relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolation member. Therefore, whether the current protective isolation member needs to be replaced can be quantitatively described based on the relationship between the initial welding slag area and the current welding slag area, thereby accurately determining whether the protective isolation member needs to be replaced.

[0094] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method for determining replacement of a protective isolation member, characterized in that: The protective isolator is arranged on a side of the incident light of the filter of the camera of the welding robot, and the light transmittance of the protective isolator is greater than or equal to 80%. The welding robot also includes a laser, and the laser is used to track the weld, including: Constructing a relational expression between the brightness of a tracking image and the area of ​​welding slag attached to a protective isolation member to obtain a target relational expression, wherein the tracking image is an image captured by the camera when the laser is tracking the weld; Determining an initial welding slag area at least according to a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured by tracking after the protective isolation element is replaced; Determine the current welding slag area at least according to the target relationship and the current brightness, wherein the current brightness is the current brightness of the tracking image; According to the size relationship between the initial welding slag area and the current welding slag area, it is determined whether the current protective isolation member needs to be replaced.

2. The method according to claim 1, characterized in that The relationship between the brightness of the tracking image and the area of ​​the welding slag attached to the protective isolation member is constructed to obtain the target relationship, including: Determine a target factor affecting the brightness of the tracking image, wherein the target factor includes at least the welding slag area and the exposure time; Constructing a relational expression among the brightness of the tracking image, the welding slag area and the exposure time to obtain a preliminary relational expression; Determining a value of a correlation coefficient of the exposure time; According to the preliminary relational expression and the value of the correlation coefficient, the expression of the welding slag area is determined to obtain the target relational expression.

3. The method according to claim 2, characterized in that The target factor also includes a noise factor, and a relationship between the brightness of the tracking image, the welding slag area and the exposure time is constructed to obtain a preliminary relationship, including: A relationship between the brightness of the tracking image, the noise factor, the slag area and the exposure time is constructed to obtain the preliminary relationship.

4. The method according to claim 2, characterized in that: Determining the correlation coefficient of the exposure time includes: Acquire an ideal exposure time and the brightness of the tracking image in the ideal situation, wherein the ideal situation is a situation where the noise factor is equal to 0 and the welding slag area is equal to 0; A correlation coefficient of the exposure time is determined according to the exposure time in the ideal situation, the brightness of the tracking image in the ideal situation, and the preliminary relationship.

5. The method according to claim 3, characterized in that: Determine the initial slag area based on at least the target relationship and the initial brightness, including: The initial slag area is determined according to the target relationship, the initial brightness, the corresponding exposure time and the noise factor.

6. The method according to claim 3, characterized in that Determining the current welding slag area at least according to the target relationship and the current brightness includes: The current welding slag area is determined according to the target relationship, the current brightness, the corresponding exposure time and the noise factor.

7. The method according to any one of claims 1 to 4, characterized in that Determining whether the current protective isolation member needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area includes: Calculating the ratio of the initial welding slag area to the current welding slag area; When the ratio is greater than or equal to a predetermined value, determining that there is no need to replace the current protective isolation element; When the ratio is less than the predetermined value, it is determined that the current protective isolation element needs to be replaced.

8. A device for determining replacement of a protective isolation member, characterized in that: The protective isolator is arranged on a side of the incident light of the filter of the camera of the welding robot, and the light transmittance of the protective isolator is greater than or equal to 80%. The welding robot also includes a laser, and the laser is used to track the weld, including: A construction unit, used to construct a relational expression between the brightness of a tracking image and the area of ​​welding slag attached to the protective isolation member to obtain a target relational expression, wherein the tracking image is an image taken by the camera when the laser tracks the weld; A first determination unit, configured to determine an initial welding slag area based at least on a target relationship and an initial brightness, wherein the initial brightness is the brightness of a first image captured by tracking after the protective isolation element is replaced; A second determination unit, configured to determine a current welding slag area at least according to the target relationship and a current brightness, wherein the current brightness is a current brightness of the tracking image; The third determination unit is used to determine whether the current protective isolation member needs to be replaced according to the size relationship between the initial welding slag area and the current welding slag area.

9. A computer-readable storage medium, characterized in that: The computer-readable storage medium includes a stored program, wherein the program executes the method of any one of claims 1 to 7.

10. A processor, characterized in that: The processor is used to run a program, wherein the program executes the method according to any one of claims 1 to 7 when running.

11. A welding system, characterized in that: include: A welding robot, one or more processors, a memory, and one or more programs, wherein the one or more programs are stored in the memory and are configured to be executed by the one or more processors, and the one or more programs are used to execute the method described in any one of claims 1 to 7.

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