Adjusting device for image acquisition device, welding robot system and control method thereof

Abstract

The present application provides an adjustment device for an image acquisition device, a welding robot system and a control method thereof. The adjustment device includes: a position adjustment mechanism, wherein a first motor is connected to a first end of a first transmission component, and a front surface of a sliding component is slidably mounted on the first transmission component; a first fixing mechanism, the first end of which is used to be connected to the image acquisition device; a horizontal adjustment mechanism, wherein a first end of a second motor is located on a back surface of the sliding component, a second end of the second motor is connected to a first end of a fixing member, and a second end of the fixing member is rotatably connected to a first end of the first fixing mechanism; a pitching adjustment mechanism, wherein a first end of a third motor is located on the back surface of the sliding component, a second end of the third motor is connected to a first end of a moving component, and a second end of the moving component has a track arranged along a first direction, and a second end of the first fixing mechanism is located in the track. The present application solves the problem that the molten pool camera needs to be manually adjusted during the welding process.

Description

Technical Field

[0001] The present application relates to the field of welding technology, and more particularly, to an adjustment device for an image acquisition device, a welding robot system, a control method thereof, a control device, and a welding system. Background Art

[0002] The molten pool camera is a special application of industrial cameras in the welding field, and is suitable for occasions such as on-line monitoring and image acquisition of molten pools in plasma welding, argon arc welding, gas shielded welding, and laser welding. Considering the harshness of the welding environment and the inconvenience of adjustment, the adaptive adjustment device of the molten pool camera is crucial for improving the welding efficiency and welding progress.

[0003] During the welding process of large-scale outdoor gas shielded welding, due to different welding fields, the thickness of the welding plate ranges from a few millimeters to several hundred millimeters. During the welding process, the welding wire undergoes dynamic transfer as the welding process progresses. Ordinary molten pool camera brackets mostly play a fixing role and cannot be adjusted during the welding process. If the imaging area shifts during the welding process, it is necessary to stop the arc for adjustment, which affects the welding speed and efficiency. Moreover, during the crawling process of the robot, it is inaccessible to humans, and the adjustment is difficult and the process is cumbersome.

[0004] The molten pool camera is mostly used for on-line monitoring in metal welding. Due to the particularity of the welding field, the welding working conditions and the structure on which the molten pool camera is mounted will be matched according to requirements and applicable occasions. Currently, most molten pool cameras on the market are sold with optical components, and there are no supporting installation brackets and adjustment brackets, or they are fixed brackets simply built according to temporary scenarios, with high adjustment difficulty and poor scene adaptability, and are not suitable for welding large-scale structural parts in outdoor gas shielded welding.

[0005] Therefore, it is necessary to manually adjust the position and angle of the molten pool camera of the welding robot during the welding process, which affects the welding efficiency and is an urgent problem to be solved at present. Summary of the Invention

[0006] The main object of the present application is to provide an adjustment device for an image acquisition device, a welding robot system, a control method thereof, a control device, and a welding system, so as to solve the problem that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during the welding process in the prior art, which affects the welding efficiency.

[0007] According to one aspect of the embodiments of the present invention, an adjustment device for an image acquisition device is provided, including: a position adjustment mechanism, including a first motor, a first transmission component, and a sliding component, the first motor is connected to the first end of the first transmission component, the sliding component has opposite front and back surfaces, the front surface of the sliding component is slidably mounted on the first transmission component, and the first motor rotates to drive the sliding component to move along the first transmission component; a first fixing mechanism, the first end of the first fixing mechanism is used to be connected to the image acquisition device; a horizontal adjustment mechanism, including a fixing member and a second motor, the first end of the second motor is located on the back surface of the sliding component, the second end of the second motor is connected to the first end of the fixing member, the second end of the fixing member is rotatably connected to the first end of the first fixing mechanism, and the second motor rotates to drive the image acquisition device to rotate in a first direction through the fixing member; a pitching adjustment mechanism, including a third motor and a moving component, the first end of the third motor is located on the back surface of the sliding component, the second end of the third motor is connected to the first end of the moving component, the second end of the moving component has a track arranged along the first direction, the second end of the first fixing mechanism is located in the track, and the third motor rotates to drive the moving component to move in a second direction, so that the first fixing mechanism drives the image acquisition device to rotate in the second direction, and the second direction is perpendicular to the first direction.

[0008] Optionally, the first fixing mechanism includes: a first fixing ring, which is used to be sleeved on the image acquisition device, and the axis of the first fixing ring is parallel to the optical axis of the image acquisition device; a second fixing ring, the outer wall of the second fixing ring is tangent to the outer wall of the first fixing ring, and the axis of the second fixing ring is perpendicular to the axis of the first fixing ring; a telescopic rod, the first end of the telescopic rod is connected to the outer wall of the second fixing ring, and the second end of the telescopic rod is the second end of the first fixing mechanism, and the telescopic rod is perpendicular to the axis of the second fixing ring.

[0009] Optionally, the fixing member includes: a first coupling, the first end of the first coupling is the first end of the fixing member; a support shaft, the first end of the support shaft is connected to the second end of the first coupling, the second end of the support shaft has a third fixing ring, and the third fixing ring and the second fixing ring are coaxial; a rotary damper, the rotary damper is the second end of the fixing member, and the second fixing ring and the third fixing ring are respectively sleeved on the rotary damper.

[0010] Optionally, the moving component includes: an inner sleeve fixed to the back surface of the sliding component and sleeved outside the second motor; an outer sleeve sleeved outside the inner sleeve, and the inner wall of the outer sleeve is slidably connected to the outer wall of the inner sleeve; the track is connected to the end of the outer sleeve away from the sliding component, and the track is an annular track; a fixed connection bracket, the first end of the fixed connection bracket is connected to the outer pipe wall of the outer sleeve; a second transmission component, the first end of the second transmission component is connected to the second end of the fixed connection bracket, and the second end of the second transmission component is the first end of the moving component. When the third motor rotates, the second transmission component moves along the second direction to drive the outer sleeve to move along the second direction through the fixed connection bracket.

[0011] Optionally, the first transmission component has a front surface and a back surface, and the sliding component is located on the front surface of the first transmission component. The adjustment device further includes: a second fixing mechanism including a first fixing plate and a second fixing plate connected thereto. The included angle between the first fixing plate and the second fixing plate is less than 90°. The surface of the first fixing plate away from the second fixing plate is used to connect to the crawling robot, and the surface of the second fixing plate away from the first fixing plate is connected to the back surface of the first transmission component.

[0012] Optionally, the position adjustment mechanism further includes: a second coupling, and the first motor and the first transmission component are connected through the second coupling.

[0013] According to another aspect of the embodiments of the present invention, there is also provided a welding robot, including: a crawling robot; an adjustment device of any one of the image acquisition devices, and the crawling robot is connected to the first transmission component of the adjustment device.

[0014] According to another aspect of the embodiments of the present invention, there is also provided a control method for the welding robot, including: obtaining a first image and / or a second image, a first distance, and a second distance collected by an image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire; when the difference between the first distance and the second distance is greater than a first preset value, controlling the first motor to operate according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value; when the first position is not within the first region and / or the second position is not within the second region, controlling the second motor and the third motor to operate according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0015] Optionally, there are multiple consecutive frames of the first image. Before controlling the second motor and the third motor to operate according to the first position and / or the second position, after obtaining the first image and / or the second image, the first distance, and the second distance collected by the image acquisition device, the method further includes: performing at least one of the following: processing the multiple consecutive frames of the first image by using the inter-frame difference method to obtain the position information of the end of the welding wire, and extracting the image of the molten pool from the second image by using the edge detection method to obtain the position information of the molten pool.

[0016] Optionally, controlling the second motor and the third motor to operate according to the first position and / or the second position includes: determining a third distance according to the first position, and / or determining a fourth distance according to the second position, where the third distance is the distance between the first position and the center point of the first image, and the fourth distance is the distance between the second position and the center point of the second image; performing coordinate transformation on the third distance and / or the fourth distance to obtain the pitch angle adjustment value and the yaw angle adjustment value of the image acquisition device; determining the rotation direction and the number of rotation turns of the second motor according to the yaw angle adjustment value, and determining the rotation direction and the number of rotation turns of the third motor according to the pitch angle adjustment value; controlling the second motor and the third motor to rotate the corresponding number of rotation turns in the corresponding rotation direction.

[0017] Optionally, obtaining the first image and / or the second image collected by the image acquisition device includes: determining the first image and / or the second image according to the current welding state, where, when the current welding state is before welding, the first image is obtained, and when the current welding state is during welding, the second image is obtained.

[0018] According to another aspect of the embodiments of the present invention, there is also provided a control device for the welding robot, including: an acquisition unit, configured to acquire the first image and / or the second image, the first distance, and the second distance collected by the image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire; a first control unit, configured to, when the difference between the first distance and the second distance is greater than a first preset value, control the operation of the first motor according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value; a second control unit, configured to, when the first position is not within the first region and / or the second position is not within the second region, control the operation of the second motor and the third motor according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0019] According to another aspect of the embodiments of the present invention, there is also provided a welding system, including the welding robot; the controller of the welding robot includes one or more processors, a memory, and one or more programs, where 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 include those for executing any one of the methods.

[0020] In the embodiments of the present invention, the adjustment device of the image acquisition device can realize the automatic adjustment of the spatial position of the image acquisition device through the operation of the first motor of the position adjustment mechanism, can realize the automatic adjustment of the yaw angle of the image acquisition device through the operation of the second motor of the horizontal adjustment mechanism; can realize the automatic adjustment of the pitch angle of the image acquisition device through the operation of the third motor of the pitch adjustment mechanism. The automatic adjustment of the position and angle of the image acquisition device is realized through the adjustment device of the present application, without manual adjustment, ensuring a relatively high welding efficiency of the welding robot, and solving the problem in the prior art that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during the welding process, affecting the welding efficiency. Brief Description of the Drawings

[0021] The accompanying drawings forming a part of this application are used to provide a further understanding of this application. The schematic embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation of this application. In the drawings:

[0022] Figure 1 shows a schematic structural diagram of an adjustment device of an image acquisition device according to an embodiment of this application;

[0023] Figure 2 shows a schematic structural diagram of a first fixing mechanism according to an embodiment of this application;

[0024] Figure 3 shows a schematic structural diagram of a telescopic rod according to an embodiment of this application;

[0025] Figure 4 shows a partial schematic structural diagram of a pitch adjustment mechanism according to an embodiment of this application;

[0026] Figure 5 shows a schematic structural diagram of a horizontal adjustment mechanism according to an embodiment of this application;

[0027] Figure 6 shows a schematic diagram of the positional relationship between an inner sleeve and a second motor according to an embodiment of this application;

[0028] Figure 7 shows a schematic structural diagram of a position adjustment mechanism according to an embodiment of this application;

[0029] Figure 8 shows a schematic flow diagram of a control method for a welding robot according to an embodiment of this application;

[0030] Figure 9 shows a schematic diagram of the positional relationship between an image acquisition device, its adjustment device and a base material according to an embodiment of this application;

[0031] Figure 10 shows a schematic block diagram of a control device of a welding robot according to an embodiment of this application.

[0032] Among them, the above-mentioned drawings include the following reference numerals:

[0033] 100. First motor; 101. First transmission assembly; 102. Sliding assembly; 103. First fixing mechanism; 104. Image acquisition device; 105. Fixing member; 106. Second motor; 107. Third motor; 108. Moving assembly; 109. Track; 110. First fixing ring; 111. Second fixing ring; 112. Telescopic rod; 113. First coupling; 114. Support shaft; 115. Rotary damper; 116. Inner sleeve; 117. Outer sleeve; 118. Fixed connection bracket; 119. Second transmission assembly; 120. First fixing plate; 121. Second fixing plate; 122. Second coupling; 123. Motor power cord. Detailed implementation manners

[0034] It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments may be combined with each other. The present application will be described in detail below with reference to the drawings and in combination with the embodiments.

[0035] In order to enable those skilled in the art to better understand the solution of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0036] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application are used to distinguish similar objects, and do not necessarily need to be used to describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so as to describe the embodiments of the present application here. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device including a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these process, method, product or device.

[0037] It should be understood that when a component (such as a layer, film, region, or substrate) is described as being "on" another component, the component can be directly on the other component, or there may also be an intermediate component. Moreover, in the specification and claims, when it is described that a component is "connected" to another component, the component can be "directly connected" to the other component, or "connected" to the other component through a third component.

[0038] As described in the background art, the molten pool camera of the welding robot in the prior art needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency. To solve the above problems, in a typical embodiment of the present application, an adjustment device for an image acquisition device, a welding robot system, its control method, a control device, and a welding system are provided.

[0039] According to a typical embodiment of the present application, there is provided an adjustment device for an image acquisition device as shown in Figure 1 The above adjustment device includes: a position adjustment mechanism, including a first motor 100, a first transmission component 101, and a sliding component 102. The first motor 100 is connected to the first end of the first transmission component 101. The sliding component 102 has opposite front and back surfaces. The front surface of the sliding component 102 is slidably mounted on the first transmission component 101. The rotation of the first motor 100 drives the sliding component 102 to move along the first transmission component 101; as shown in Figure 2 A first fixing mechanism 103, the first end of the first fixing mechanism 103 is used to connect to the image acquisition device 104; as shown in Figure 5 A horizontal adjustment mechanism, including a fixing member 105 and a second motor 106. The first end of the second motor 106 is located on the back surface of the sliding component 102. The second end of the second motor 106 is connected to the first end of the fixing member 105. The second end of the fixing member 105 is rotatably connected to the first end of the first fixing mechanism 103. The rotation of the second motor 106 drives the image acquisition device 104 to rotate in the first direction through the fixing member 105; a pitching adjustment mechanism, including a third motor 107 and a moving component 108. The first end of the third motor 107 is located on the back surface of the sliding component 102. The second end of the third motor 107 is connected to the first end of the moving component 108. The second end of the moving component 108 has a track 109 arranged along the first direction. The second end of the first fixing mechanism 103 is located in the track 109. The rotation of the third motor 107 drives the moving component 108 to move in the second direction, so that the first fixing mechanism 103 drives the image acquisition device 104 to rotate in the second direction, and the second direction is perpendicular to the first direction.

[0040] In the adjustment device of the above-mentioned image acquisition device, the image acquisition device is connected through the first fixing mechanism; the horizontal adjustment mechanism includes a fixing member and a second motor. By rotating the second motor, the fixing member is driven to rotate in the first direction, and then the image acquisition device is driven by the first fixing mechanism to rotate in the first direction, so as to adjust the yaw angle of the image acquisition device; the pitch adjustment mechanism includes a third motor and a moving component. By rotating the third motor, the moving component is driven to move in the second direction, and then the image acquisition device is driven by the first fixing mechanism to rotate in the second direction, so as to adjust the pitch angle of the image acquisition device; the position adjustment mechanism includes a first motor, a first transmission component and a sliding component. By rotating the first motor, the sliding component is driven to move along the first transmission component, and then the image acquisition device is driven to move, so as to adjust the position of the image acquisition device. Compared with the problem that the molten pool camera of the welding robot in the prior art needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency, in this application, by operating the first motor of the position adjustment mechanism, the automatic adjustment of the spatial position of the image acquisition device can be realized. By operating the second motor of the horizontal adjustment mechanism, the automatic adjustment of the yaw angle of the image acquisition device can be realized; by operating the third motor of the pitch adjustment mechanism, the automatic adjustment of the pitch angle of the image acquisition device can be realized. The adjustment device of this application realizes the automatic adjustment of the position and angle of the image acquisition device without manual adjustment, ensuring a high welding efficiency of the welding robot.

[0041] Moreover, the second end of the above-mentioned fixing member is rotatably connected to the first end of the above-mentioned first fixing mechanism, and the second end of the above-mentioned first fixing mechanism is located in the above-mentioned track. In this way, when the image acquisition device is driven to rotate in the above-mentioned second direction by operating the third motor, there will be no interference problem between the fixing member and the first fixing mechanism.

[0042] In the embodiment of this application, the above-mentioned first direction is the horizontal direction, and the above-mentioned second direction is the vertical direction. The above-mentioned image acquisition device is a molten pool camera.

[0043] In another specific embodiment, such as Figure 2As shown in the figure, the above-mentioned first fixing mechanism 103 includes: a first fixing ring 110 for sleeving on the above-mentioned image acquisition device 104, and the axis of the first fixing ring 110 is parallel to the optical axis of the image acquisition device 104; a second fixing ring 111, the outer wall of the outer ring of the second fixing ring 111 is tangent to the outer wall of the first fixing ring 110, and the axis of the second fixing ring 111 is perpendicular to the axis of the first fixing ring 110; a telescopic rod 112, the first end of the telescopic rod 112 is connected to the outer wall of the second fixing ring 111, the second end of the telescopic rod 112 is the second end of the first fixing mechanism 103, and the telescopic rod 112 is perpendicular to the axis of the second fixing ring 111. In the embodiment of the present application, the second end of the telescopic rod is located in the above-mentioned track. When the third motor rotates, it drives the moving component to move in the second direction to push or pull the telescopic rod up or down, thereby driving the image acquisition device to perform pitching adjustment. And, since the telescopic rod can be telescoped, during the rotation of the second motor to drive the second end of the telescopic rod to rotate along the track, the telescopic rod will not interfere with the track due to the change of the rotation radius, and the variable diameter movement of the second end of the telescopic rod can be realized, and further the effective automatic adjustment of the angle of the image acquisition device can be realized.

[0044] In the actual application process, the above-mentioned first fixing ring, the second fixing ring and the telescopic rod are integrally formed structures.

[0045] According to another specific embodiment of the present application, as Figure 2 and Figure 3 shown, the above-mentioned telescopic rod is a spring rod with a spherical structure at one end. The spherical structure and the spring rod are connected by a spring, and the telescopic function is realized by the contraction and stretching of the spring. The spherical structure is the second end of the telescopic rod. As Figure 4 shown, the above-mentioned track 109 is an annular groove, and the spherical structure is clamped in the annular groove. When the second motor rotates, the spherical structure rotates in the annular groove.

[0046] Specifically, as Figure 5 shown, the above-mentioned fixing member 105 includes: a first coupling 113, the first end of the first coupling 113 is the first end of the fixing member 105; a support shaft 114, the first end of the support shaft 114 is connected to the second end of the first coupling 113, and the second end of the support shaft 114 has a third fixing ring, the third fixing ring and Figure 2is coaxial with the above-mentioned second fixing ring 111; a rotary damper 115, the rotary damper 115 is the second end of the above-mentioned fixing member, and the above-mentioned second fixing ring and the above-mentioned third fixing ring are respectively sleeved on the above-mentioned rotary damper. The second motor and the support shaft are connected by a first coupling. During the process that the second motor rotates to drive the support shaft to rotate in the first direction, the first coupling can play the functions of buffering, shock absorption and improving the dynamic performance of the shafting, so as to further realize the effect of automatically adjusting the yaw angle of the image acquisition device. When the second motor rotates, the rotational power will be transmitted to the support shaft through the first coupling, and the support shaft drives the entire image acquisition device to complete the adjustment of the horizontal angle through the fixing member.

[0047] In order to further ensure the stability of the above-mentioned horizontal adjustment mechanism, in the actual application process, the second end of the above-mentioned support shaft also has a fourth fixing ring. The above-mentioned third fixing ring and the above-mentioned fourth fixing ring are arranged in parallel. The above-mentioned second fixing ring is located between the above-mentioned third fixing ring and the above-mentioned fourth fixing ring, and the above-mentioned rotary damper sequentially passes through the above-mentioned third fixing ring, the above-mentioned second fixing ring and the above-mentioned fourth fixing ring.

[0048] In addition, as Figure 4 and Figure 6 shown, the above-mentioned moving component 108 includes: an inner sleeve 116, fixed on the back surface of the above-mentioned sliding component 102 and sleeved on Figure 5 the above-mentioned second motor 106 shown; an outer sleeve 117, sleeved on the outside of the above-mentioned inner sleeve 116, and the inner wall of the above-mentioned outer sleeve 117 is slidably connected to the outer wall of the above-mentioned inner sleeve 116; the above-mentioned track 109, connected to one end of the above-mentioned outer sleeve 117 away from the above-mentioned sliding component 102, and the above-mentioned track 109 is an annular track; a fixed connection bracket 118, the first end of the above-mentioned fixed connection bracket 118 is connected to the outer pipe wall of the above-mentioned outer sleeve 117; a second transmission component 119, the first end of the above-mentioned second transmission component 119 is connected to the second end of the above-mentioned fixed connection bracket 118, and the second end of the above-mentioned second transmission component 119 is the first end of the above-mentioned moving component 108. When the above-mentioned third motor 107 rotates, the above-mentioned second transmission component 119 moves in the above-mentioned second direction to drive the above-mentioned outer sleeve 117 to move in the above-mentioned second direction through the above-mentioned fixed connection bracket 118. In the above-mentioned embodiment, the inner sleeve can not only play the role of protecting the second motor, but also provide support for the movement of the outer sleeve in the second direction, ensuring that the outer sleeve can move relatively stably and controllably along the outer wall of the above-mentioned inner sleeve.

[0049] In the above embodiments, the second transmission assembly is a transmission assembly arranged along the second direction; the setting direction of the fixed connection bracket is perpendicular to the second transmission assembly, that is, the fixed connection bracket is a bracket arranged along the horizontal direction. The fixed connection bracket can be any feasible bracket structure in the prior art, such as a straight bracket, a Y-shaped bracket, an H-shaped bracket, etc.; the extending direction of the inner sleeve wall is the second direction.

[0050] In the actual application process, both the first transmission assembly and the second transmission assembly can be any suitable transmission assembly, such as a transmission lead screw, a transmission gear, a transmission belt, a transmission chain, a hydraulic transmission part, a turbine transmission part, a transmission ratchet, a transmission crank connecting rod, a transmission universal joint, a transmission coupling, etc.

[0051] When the third motor rotates, the second transmission assembly drives the fixed connection bracket and the outer sleeve to move. At this time, the outer sleeve moves along the axial direction of the inner sleeve, and the spherical structure is lifted in the track at the upper part of the outer sleeve. The telescopic rod is connected to the first fixing mechanism of the fixed image acquisition device, and the pitching adjustment of the image acquisition device is completed through the rotary damper. Considering the change of the rotation radius of the spherical structure in the track, the telescopic rod is used to complete the variable diameter movement to avoid the interference problem between the telescopic rod and the track during the pitching adjustment process.

[0052] To protect the third motor, the adjustment device of the present application further includes: a motor protection cover, which is sleeved outside the third motor.

[0053] It should be noted that, in order to further ensure the automatic adjustment of the pitching angle of the image acquisition device, when the pitching angle of the image acquisition device is 0, there is a preset distance between one end of the outer sleeve close to the sliding assembly and the back surface of the sliding assembly.

[0054] In other embodiments, the first transmission assembly has a front surface and a back surface, and the sliding assembly is located on the front surface of the first transmission assembly. As Figure 1 shown, the adjustment device further includes: a second fixing mechanism, including a connected first fixing plate 120 and a second fixing plate 121. The included angle between the first fixing plate 120 and the second fixing plate 121 is less than 90°. The surface of the first fixing plate 120 away from the second fixing plate 121 is used to connect with the crawling robot, and the surface of the second fixing plate 121 away from the first fixing plate 120 is connected to the back surface of the first transmission assembly. Through the above second fixing mechanism, the mechanical connection with the crawling robot is realized.

[0055] Generally, the above-mentioned adjustment device of the present application is fixed at the front end of the crawling robot. One end of the first fixing plate is connected to one end of the second fixing plate to realize the connection between the first fixing plate and the second fixing plate. Installation grooves are respectively provided on the first fixing plate and the second fixing plate, and the connection between the first fixing plate and the crawling robot and the connection between the second fixing plate and the first transmission assembly are realized through screws.

[0056] As Figure 7 shown, the above-mentioned position adjustment mechanism further includes: a second coupling 122, and the first motor 100 and the first transmission assembly 101 are connected through the second coupling 122. By connecting the first motor and the first transmission assembly through the second coupling, during the process that the first motor rotates to drive the sliding assembly to move along the first transmission assembly, the second coupling can play functions of buffering, shock absorption and improving the dynamic performance of the shafting, so as to further realize the automatic adjustment effect of the spatial position of the image acquisition device. In addition, when the first motor moves, power is transmitted to the sliding assembly through the second coupling and the first transmission assembly, and the sliding assembly drives the image acquisition device to move to complete the adjustment of its spatial position.

[0057] And, as Figure 1 shown, the above-mentioned adjustment device further includes: a motor power cord 123, which is located on the back surface of the sliding assembly 102 and is electrically connected to the first motor, the second motor and the third motor respectively, and is used to supply electrical energy to the first motor, the second motor and the third motor.

[0058] According to another typical embodiment of the present application, a welding robot is further provided, including: a crawling robot; an adjustment device for any one of the above-mentioned image acquisition devices, and the crawling robot is connected to the first transmission assembly of the adjustment device.

[0059] The above-mentioned welding robot includes a crawling robot and an adjustment device for any one of the above-mentioned image acquisition devices. By running the first motor of the position adjustment mechanism in the adjustment device, the automatic adjustment of the spatial position of the image acquisition device can be realized. By running the second motor of the red horizontal adjustment mechanism in the adjustment device, the automatic adjustment of the yaw angle of the image acquisition device can be realized; by running the third motor of the pitch adjustment mechanism in the adjustment device, the automatic adjustment of the pitch angle of the image acquisition device can be realized, realizing the automatic adjustment of the position and angle of the image acquisition device without manual adjustment, ensuring that the welding efficiency of the welding robot is relatively high, and effectively solving the problem that in the prior art, the molten pool camera of the welding robot needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency.

[0060] According to another typical embodiment of the present application, a control method for the above-mentioned welding robot is further provided.

[0061] Figure 8 is a flowchart of the control method of the welding robot according to the above embodiments of the present application. As Figure 8 shown, the method includes the following steps:

[0062] Step S101, obtaining a first image and / or a second image, a first distance, and a second distance collected by an image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire;

[0063] Since the adjustment of the shooting angle of the image acquisition device mainly includes two aspects, one is the recognition of the position of the end of the welding wire and the other is the recognition of the position of the molten pool. Therefore, in the above embodiments, by obtaining at least one of the first image and the second image, the distance between the image acquisition device and the end of the welding wire, and the preset object distance, it is convenient to subsequently determine whether the spatial position and shooting angle of the image acquisition device meet the welding requirements based on the obtained information, and automatically adjust the spatial position or shooting angle of the image acquisition device that does not meet the welding requirements.

[0064] In a specific embodiment, obtaining the first image and / or the second image collected by the image acquisition device includes: determining the first image and / or the second image according to the current welding state, where, when the current welding state is before welding, obtaining the first image, and when the current welding state is during welding, obtaining the second image. Since the recognition of the position of the end of the welding wire is relatively accurate before welding, and the recognition of the molten pool image is relatively accurate during welding, therefore, determining whether to obtain the first image or the second image according to the different states of welding can further ensure that the angle adjustment value of the image acquisition device is determined more accurately based on the first image or the second image and the image acquisition device is adjusted, thereby further ensuring that the angle of the adjusted image acquisition device is relatively accurate.

[0065] Of course, obtaining the first image and / or the second image collected by the image acquisition device is not limited to the above method. In another embodiment, obtaining the first image and / or the second image collected by the image acquisition device includes: determining the first image and / or the second image according to the current welding state, where, when the current welding state is before welding, obtaining the first image, and when the current welding state is during welding, obtaining the second image and the first image.

[0066] To further ensure obtaining the position information of the wire end and the position information of the molten pool simply, quickly, and accurately, according to another specific embodiment of the present application, the above first image has multiple consecutive frames. Before controlling the operation of the second motor and the third motor according to the above first position and / or the above second position, after acquiring the first image and / or the second image, the first distance, and the second distance collected by the image acquisition device, the method further includes: performing at least one of the following: processing the multiple consecutive frames of the first image by using the inter-frame difference method to obtain the position information of the wire end, and extracting the image of the molten pool from the second image by using the edge detection method to obtain the position information of the molten pool.

[0067] Before welding, it is necessary to rely on the swing of the welding torch to judge whether the set process parameters are reasonable. The position of the welding wire is different in different image frames. By subtracting the corresponding pixel points of different frames through the inter-frame difference method and judging the absolute value of the gray difference, when the absolute value exceeds a certain threshold, it can be judged as a moving target, thus realizing the function of welding wire detection.

[0068] Since the moving distance of the welding torch is short and the movement is fast, the position of the welding wire end of the welding torch in adjacent frame images varies greatly. The present application uses the three-frame difference method to identify the welding wire end of the welding torch. Denote the images of the (n + 2)-th frame, the (n + 1)-th frame, and the n-th frame in the image sequence collected by the image acquisition device as f n+2 , f n+1 and f n , and denote the gray values of the corresponding pixel points of the three frames as f n+2 (x, y), f n+1 (x, y) and f n (x, y). Subtract the corresponding pixel points of f n+2 from those of f n+1 , and subtract the corresponding pixel points of f n+1 from those of f n to obtain the difference images f2 and f1. Subtract the corresponding pixel points of the difference images f2 and f1 to obtain the image f0, and then perform threshold processing and connectivity analysis to finally extract the position information of the wire end.

[0069] During the swing of the welding wire, the recognition of the end position will show a certain degree of fluctuation, and there will be errors when recognizing the geometric center position of the swing of the wire end. The recognition of the welding wire can be used for the rough adjustment of the angle of the molten pool image acquisition device before welding. At the beginning of welding, the molten pool presents rich contour information in the observation of the image acquisition device due to its own radiation, and the angle can be finely adjusted further through the geometric center of the molten pool on the basis of the recognition of the welding wire.

[0070] During the welding process, the pixel level difference between the molten pool and the surrounding environment grayscale image is obvious. The edge contour of the molten pool can be extracted through edge detection, and then the geometric center of the molten pool can be calculated to observe in real time whether the area where the molten pool is located deviates from the interval set by the image acquisition device.

[0071] Of course, the method for obtaining the end of the welding wire as described above is not limited to the above-mentioned inter-frame difference method, and the position information of the end of the welding wire can also be determined by means of image segmentation and edge acquisition, etc. The method for obtaining the image of the molten pool is not limited to the above-mentioned edge detection method, and the image of the molten pool can also be obtained by any other suitable image processing method.

[0072] Step S102, when the difference between the first distance and the second distance is greater than the first preset value, control the first motor to operate according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value;

[0073] In a specific embodiment, controlling the first motor to operate according to the difference to adjust the difference includes: determining the rotation direction and the number of rotation turns of the first motor according to the difference; controlling the first motor to operate in the rotation direction and the number of rotation turns so that the adjusted difference is less than or equal to the first preset value.

[0074] In the actual application process, the first distance can be set according to the focal length of the image acquisition device; the second distance can be obtained through a sensor installed on the image acquisition device, such as a ranging sensor. Of course, the second distance can also be obtained through other means. In one embodiment, the specific implementation manner for obtaining the second distance is as follows:

[0075] As Figure 9 shown, the ranging sensor on the image acquisition device measures the distance l from the fixed point C (i.e., the position of the sliding assembly) of the graphic acquisition device to the starting point A of the stroke of the first transmission assembly AC , then the distance l from the fixed position C of the image acquisition device to the end F of the welding wire CF is:

[0076] l CF =l AB -l AC +l BF

[0077] Since the installation height l CD (that is, the distance from the center of the image acquisition device to the first transmission assembly) of the image acquisition device is certain, the distance l from the image acquisition device to the end F of the welding wire DF is:

[0078]

[0079] Then the direction and the number of turns n in which the first motor should rotate can be obtained by the following formula:

[0080] Δl = l o -l DF

[0081]

[0082] where l AB represents the effective stroke of the first transmission assembly, l BF represents the distance from the end point B of the first transmission assembly to the end F of the above-mentioned welding wire, l DE represents the distance from the image acquisition device to the welded base material, l DF represents the distance between the image acquisition device and the end of the welding wire, Δl represents the difference between the actual position and the pre-input position of the image acquisition device, and l o represents the preset object distance of the above-mentioned image acquisition device. If Δl ≥ 0, it means that the actual position is less than the preset position, and the first motor needs to rotate counterclockwise to adjust the position; if Δl < 0, the first motor needs to rotate forward. n represents the number of turns required for the image acquisition device to reach the pre-input position, and P h is the lead of the first transmission assembly.

[0083] Step S103, in the case where the first position is not within the first area and / or the second position is not within the second area, control the second motor and the third motor to operate according to the above-mentioned first position and / or the above-mentioned second position, so as to adjust the above-mentioned first position and / or the above-mentioned second position, so that the adjusted first position is within the first area and / or the adjusted second position is within the second area, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0084] It should be noted that the above embodiments include three cases, specifically: First, when the first position is not within the first region, the second motor and the third motor are controlled to operate according to the above first position to adjust the first position so that the adjusted first position is within the first region. Second, when the second position is not within the second region, the second motor and the third motor are controlled to operate according to the above second position to adjust the second position so that the adjusted second position is within the second region. When the first position is not within the first region and the second position is not within the second region, the second motor and the third motor are controlled to operate according to the above first position and the above second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and the adjusted second position is within the second region.

[0085] In order to further realize the automatic adjustment of the angle of the image acquisition device, in another specific embodiment of the present application, controlling the second motor and the third motor to operate according to the above first position and / or the above second position includes: determining a third distance according to the above first position, and / or determining a fourth distance according to the above second position, where the third distance is the distance between the first position and the center point of the first image, and the fourth distance is the distance between the second position and the center point of the second image; performing coordinate transformation on the third distance and / or the fourth distance to obtain the pitch angle adjustment value and the yaw angle adjustment value of the image acquisition device; determining the rotation direction and the number of rotation turns of the second motor according to the yaw angle adjustment value, and determining the rotation direction and the number of rotation turns of the third motor according to the pitch angle adjustment value; controlling the second motor and the third motor to rotate the corresponding number of rotation turns in the corresponding rotation direction.

[0086] The above first region and the second region may be the same region, both of which are observation regions.

[0087] The geometric center position of the wire swing at the left and right extreme ends can be obtained by the frame difference method. It is judged whether the area where it is located is in the observation area according to the pixel coordinates. If it exceeds, the horizontal distance and the vertical distance from the geometric center point to the center of the observation area are calculated at this time, and the pitch adjustment value and the horizontal adjustment value in the world coordinate system are calculated through coordinate system transformation to complete the angle adjustment of the image acquisition device.

[0088] The geometric center position of the molten pool contour can be obtained by the edge detection method. According to the pixel coordinates, it is judged whether the area is within the observation area. If it exceeds, the horizontal distance and vertical distance from the geometric center point to the center of the observation area are calculated at this time. Through coordinate system transformation, the pitch adjustment value and horizontal adjustment value in the world coordinate system are calculated to complete the fine adjustment of the angle of the image acquisition device.

[0089] The specific implementation method of coordinate transformation for the above third distance and / or the above fourth distance is as follows:

[0090] The relationship between the swing center of the wire end or the center position of the molten pool in the pixel coordinate system and the world coordinate system is obtained by the following formula. The distance of the world coordinate system after obtaining is used to realize the angle adjustment through the number of turns of the motor shafts of the second motor and the third motor.

[0091]

[0092] Among them, dx and dy respectively represent the width and height of each pixel point in the pixel coordinate system; u0 and v0 respectively represent the horizontal and vertical coordinates of the origin of the image coordinate system in the pixel coordinate system; R and T respectively represent the transformation matrix from the world coordinate system to the camera coordinate system; f represents the focal length; the subscript w represents the world coordinate system; the subscript c represents the camera coordinate system; xoy represents the image coordinate system; uv is the pixel coordinate system; Z c is the Z-axis of the camera coordinate axis.

[0093] In this application, according to different welding states during welding, the observation targets are respectively identified. Before welding, the geometric center position of the wire end swing is identified by relying on the frame difference method. During welding, the geometric center position of the molten pool is identified by edge detection. The difference between the pixel coordinates in the observation field of view and the actual position is compared, and the adjusted parameters are fed back to the motor driver to complete the adaptive adjustment of the image acquisition angle of the image acquisition device. During the multi-layer and multi-pass welding process, the image acquisition device can adjust the observation angle in real time according to the movement of the welding torch wire. When the crawling robot has a pose offset, it can also realize the function of centering the observation target. The automatic adjustment of the image acquisition device is realized during the non-stop welding and long-distance climbing of the crawling robot, reducing manual intervention, improving the welding efficiency and welding progress, and realizing intelligent and automatic adjustment.

[0094] In addition, when the first motor, the second motor, and the third motor do not receive control commands, they will not rotate. The self-locking function of the angle adjustment is realized by the first motor, the second motor, and the third motor.

[0095] In the above control method of the welding robot, first, a first distance representing a preset object distance and a second distance representing the distance between the image acquisition device and the end of the welding wire are obtained by the image acquisition device, and a first image including the end of the welding wire and / or a second image including the molten pool are also obtained; then, when the difference between the first distance and the second distance is greater than a first preset value, the first motor is controlled to operate according to the difference to adjust the difference, so as to adjust the spatial position of the image acquisition device; and, when the first position is not within the first region and / or the second position is not within the second region, the second motor and the third motor are controlled to operate according to the first position and / or the second position to adjust the first position and / or the second position, so as to adjust the yaw angle and / or the pitch angle of the image acquisition device, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image. Compared with the problem in the prior art that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during the welding process, which affects the welding efficiency, in the above method of the present application, the first motor is controlled to operate according to the actual distance between the image acquisition device and the end of the welding wire and the preset object distance, so as to automatically adjust the spatial position of the image acquisition device, and the second motor and the third motor are controlled to operate according to the position of the center point of the end of the welding wire and / or the center line point of the molten pool in the image to automatically adjust the yaw angle and the pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements, without stopping the welding robot during the welding process for manual adjustment of the image acquisition device, and ensuring that the welding efficiency of the welding robot is relatively high.

[0096] It should be noted that the steps shown in the flowchart of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and although the logical order is shown in the flowchart, in some cases, the steps shown or described can be executed in a different order than here.

[0097] The embodiment of the present application also provides a control device for the above welding robot. It should be noted that the control device for the above welding robot in the embodiment of the present application can be used to execute the control method for the above welding robot provided by the embodiment of the present application. The following introduces the control device for the above welding robot provided by the embodiment of the present application.

[0098] Figure 10 is a schematic diagram of the control device for the above welding robot according to the embodiment of the present application. As Figure 10 shown, the device includes:

[0099] An acquisition unit 10 is configured to acquire a first image and / or a second image, a first distance, and a second distance collected by an image acquisition device, where the first image is an image including the end of a welding wire, the second image is an image including a molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire;

[0100] Since the adjustment of the shooting angle of the image acquisition device mainly includes two aspects, one is the recognition of the position of the end of the welding wire and the other is the recognition of the position of the molten pool. Therefore, in the above embodiments, by acquiring at least one of the first image and the second image, the distance between the image acquisition device and the end of the welding wire, and the preset object distance, it is convenient to subsequently determine whether the spatial position and shooting angle of the image acquisition device meet the welding requirements based on the acquired information, and automatically adjust the spatial position or shooting angle of the image acquisition device that does not meet the welding requirements.

[0101] In a specific embodiment, the acquisition unit includes: a first determination module, configured to determine the first image and / or the second image according to the current welding state. Wherein, when the current welding state is before welding, the first image is acquired; when the current welding state is during welding, the second image is acquired. Since the recognition of the position of the end of the welding wire is relatively accurate before welding, and the recognition of the molten pool image is relatively accurate during welding, therefore, determining whether to acquire the first image or the second image according to the different states of welding can further ensure that the angle adjustment value of the image acquisition device is determined more accurately based on the first image or the second image, and the image acquisition device is adjusted, thereby further ensuring that the angle of the adjusted image acquisition device is relatively accurate.

[0102] Of course, acquiring the first image and / or the second image collected by the image acquisition device is not limited to the above method. In another embodiment, the acquisition unit may further include: a second determination module, configured to determine the first image and / or the second image according to the current welding state. Wherein, when the current welding state is before welding, the first image is acquired; when the current welding state is during welding, the second image and the first image are acquired.

[0103] To further ensure obtaining the position information of the wire end and the position information of the molten pool simply, quickly, and accurately, according to another specific embodiment of the present application, the above first image has multiple consecutive frames, and the above device further includes: an execution unit, configured to perform at least one of the following after obtaining the first image and / or the second image, the first distance, and the second distance collected by the image acquisition device and before controlling the operation of the second motor and the third motor according to the above first position and / or the above second position: processing the multiple consecutive frames of the above first image by using the inter-frame difference method to obtain the position information of the wire end, and extracting the image of the molten pool from the above second image by using the edge detection method to obtain the position information of the molten pool.

[0104] Before welding, it is necessary to rely on the swing of the welding torch to judge whether the set process parameters are reasonable. The position of the welding wire is different in different image frames. By subtracting the corresponding pixel points of different frames through the inter-frame difference method and judging the absolute value of the gray difference, when the absolute value exceeds a certain threshold, it can be judged as a moving target, thus realizing the function of welding wire detection.

[0105] Since the moving distance of the welding torch is short and the movement is fast, the position of the welding wire end on adjacent frame images varies greatly. The present application uses the three-frame difference method to identify the welding wire end of the welding torch. Denote the images of the (n + 2)-th frame, the (n + 1)-th frame, and the n-th frame in the image sequence collected by the image acquisition device as f n+2 , f n+1 and f n , and denote the gray values of the corresponding pixel points of the three frames as f n+2 (x, y), f n+1 (x, y), and f n (x, y). Subtract the corresponding pixel points of f n+2 and f n+1 respectively, and subtract the corresponding pixel points of f n+1 and f n to obtain the difference images f2 and f1. Subtract the corresponding pixel points of the difference images f2 and f1 to obtain the image f0, and then perform threshold processing and connectivity analysis to finally extract the position information of the welding wire end.

[0106] During the swing of the welding wire, the recognition of the end position will show a certain degree of fluctuation, and there will be errors when recognizing the geometric center position of the swing of the welding wire end. The welding wire recognition can be used for the rough adjustment of the angle of the molten pool image acquisition device before welding. At the beginning of welding, the molten pool presents rich contour information in the observation of the image acquisition device due to its own radiation, and the angle can be finely adjusted further through the geometric center of the molten pool on the basis of the welding wire recognition.

[0107] During the welding process, the pixel level difference between the molten pool and the surrounding environment grayscale image is obvious. The edge contour of the molten pool can be extracted through edge detection, and then the geometric center of the molten pool can be calculated to observe in real time whether the area where the molten pool is located deviates from the interval set by the image acquisition device.

[0108] Of course, the method for obtaining the end of the above-mentioned welding wire is not limited to the above-mentioned inter-frame difference method, and the position information of the end of the welding wire can also be determined by means of image segmentation and edge acquisition. The method for obtaining the image of the molten pool is not limited to the above-mentioned edge detection method, and the image of the molten pool can also be obtained by using any other suitable image processing method.

[0109] The first control unit 20 is configured to, when the difference between the first distance and the second distance is greater than a first preset value, control the first motor to operate according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value.

[0110] In a specific embodiment, the first control unit includes: a third determination module for determining the rotation direction and the number of rotation turns of the first motor according to the difference; a first control module for controlling the first motor to operate in the rotation direction and the number of rotation turns so that the adjusted difference is less than or equal to the first preset value.

[0111] In the actual application process, the first distance can be set according to the focal length of the image acquisition device; the second distance can be obtained through a sensor installed on the image acquisition device, such as a ranging sensor. Of course, the second distance can also be obtained through other means. In one embodiment, the specific implementation manner for obtaining the second distance is as follows:

[0112] As Figure 9 shown, the distance l measured by the ranging sensor on the image acquisition device from the fixed point C (i.e., the position of the sliding component) of the graphic acquisition device to the starting point A of the stroke of the first transmission component AC , then the distance l from the fixed position C of the image acquisition device to the end F of the above-mentioned welding wire CF is:

[0113] l CF = l AB - l AC + l BF

[0114] Since the installation height l CD (that is, the distance from the center of the image acquisition device to the first transmission component) of the image acquisition device is certain, the distance l from the image acquisition device to the end F of the above-mentioned welding wire DF :

[0115]

[0116] Then the direction and the number of turns n that the first motor should rotate can be obtained by the following formula:

[0117] Δl = l o -l DF

[0118] n = Δl / P h

[0119] Wherein, l AB represents the effective stroke of the first transmission component, l BF represents the distance from the end point B of the first transmission component to the end F of the above-mentioned welding wire, l DE represents the distance from the image acquisition device to the welded base material, l DF represents the distance between the image acquisition device and the end of the welding wire, Δl represents the difference between the actual position and the pre-input position of the image acquisition device, l o represents the preset object distance of the above-mentioned image acquisition device. If Δl ≥ 0, it means that the actual position is less than the preset position, and the first motor needs to rotate counterclockwise to adjust the position; if Δl < 0, the first motor needs to rotate forward. n represents the number of turns that the image acquisition device needs to rotate to reach the pre-input position, and P h is the lead of the first transmission component.

[0120] The second control unit 30 is configured to control the operation of the second motor and the third motor according to the above-mentioned first position and / or the above-mentioned second position when the first position is not within the first region and / or the second position is not within the second region, so as to adjust the above-mentioned first position and / or the above-mentioned second position, so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, wherein the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0121] It should be noted that the above embodiments include three cases, specifically: First, when the first position is not within the first region, the second motor and the third motor are controlled to operate according to the above first position to adjust the first position so that the adjusted first position is within the first region. Second, when the second position is not within the second region, the second motor and the third motor are controlled to operate according to the above second position to adjust the second position so that the adjusted second position is within the second region. When the first position is not within the first region and the second position is not within the second region, the second motor and the third motor are controlled to operate according to the above first position and the above second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and the adjusted second position is within the second region.

[0122] In order to further realize the automatic adjustment of the angle of the image acquisition device, in another specific embodiment of the present application, the second control unit includes: a fourth determination module for determining a third distance according to the above first position and / or determining a fourth distance according to the above second position, where the third distance is the distance between the first position and the center point of the first image, and the fourth distance is the distance between the second position and the center point of the second image; a transformation module for performing coordinate transformation on the third distance and / or the fourth distance to obtain the pitch angle adjustment value and the yaw angle adjustment value of the image acquisition device; a fifth determination module for determining the rotation direction and the number of rotation turns of the second motor according to the above yaw angle adjustment value, and determining the rotation direction and the number of rotation turns of the third motor according to the above pitch angle adjustment value; a second control module for controlling the second motor and the third motor to rotate the corresponding number of rotation turns in the corresponding rotation direction.

[0123] The above first region and the second region may be the same region, both being the observation region.

[0124] From the inter-frame difference method, the geometric center position of the welding wire swinging at the left and right extremes can be obtained. According to the pixel coordinates, it is judged whether the area is in the observation area. If it exceeds, the horizontal distance and the vertical distance from the geometric center point to the center of the observation area are calculated, and the pitch adjustment value and the horizontal adjustment value in the world coordinate system are calculated through coordinate system transformation to complete the angle adjustment of the image acquisition device.

[0125] The geometric center position of the molten pool contour can be obtained by the edge detection method. According to the pixel coordinates, it is judged whether the area is within the observation area. If it exceeds, the horizontal distance and vertical distance from the geometric center point to the center of the observation area are calculated at this time. Through coordinate system transformation, the pitch adjustment value and horizontal adjustment value in the world coordinate system are calculated to complete the fine adjustment of the angle of the image acquisition device.

[0126] The specific implementation method of coordinate transformation for the above third distance and / or the above fourth distance is as follows:

[0127] The relationship between the swing center of the wire end or the center position of the molten pool in the pixel coordinate system and the world coordinate system is obtained by the following formula. The distance of the world coordinate system after obtaining is used to realize the angle adjustment through the number of turns of the motor shafts of the second motor and the third motor.

[0128]

[0129] Among them, dx and dy respectively represent the width and height of each pixel point in the pixel coordinate system; u0 and v0 respectively represent the horizontal and vertical coordinates of the origin of the image coordinate system in the pixel coordinate system; R and T respectively represent the transformation matrix from the world coordinate system to the camera coordinate system; f represents the focal length; the subscript w represents the world coordinate system; the subscript c represents the camera coordinate system; xoy represents the image coordinate system; uv is the pixel coordinate system; Z c is the Z-axis of the camera coordinate axis.

[0130] In this application, according to different welding states during welding, the observation targets are respectively identified. Before welding, the geometric center position of the wire end swing is identified by relying on the frame difference method. During welding, the geometric center position of the molten pool is identified by edge detection. The difference between the pixel coordinates in the observation field of view and the actual position is compared, and the adjusted parameters are fed back to the motor driver to complete the adaptive adjustment of the image acquisition angle of the image acquisition device. During the multi-layer and multi-pass welding process, the image acquisition device can adjust the observation angle in real time according to the movement of the welding torch wire. When the crawling robot has a pose offset, it can also realize the function of centering the observation target. The automatic adjustment of the image acquisition device is realized during the non-stop welding and long-distance climbing of the crawling robot, reducing manual intervention, improving the welding efficiency and welding progress, and realizing intelligent and automatic adjustment.

[0131] In addition, when the first motor, the second motor, and the third motor do not receive control instructions, they will not rotate. The self-locking function of the angle adjustment is realized by the first motor, the second motor, and the third motor.

[0132] In the control device of the above-mentioned welding robot, the acquisition unit is used to acquire the first distance representing the preset object distance collected by the image acquisition device, the second distance representing the distance between the image acquisition device and the end of the welding wire, and also acquire the first image including the end of the welding wire and / or the second image including the molten pool; when the difference between the first distance and the second distance is greater than the first preset value, the first control unit controls the operation of the first motor according to the difference to adjust the difference, so as to realize the adjustment of the spatial position of the image acquisition device; when the first position is not located in the first area and / or the second position is not located in the second area, the second control unit controls the operation of the second motor and the third motor according to the first position and / or the second position to adjust the first position and / or the second position, so as to realize the adjustment of the yaw angle and / or pitch angle of the image acquisition device, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image. Compared with the problem that the molten pool camera of the welding robot in the prior art needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency, the above-mentioned device of the present application controls the operation of the first motor according to the actual distance between the image acquisition device and the end of the welding wire and the preset object distance, realizes the automatic adjustment of the spatial position of the image acquisition device, and controls the operation of the second motor and the third motor according to the position of the center point of the end of the welding wire and / or the center line point of the molten pool in the image to automatically adjust the yaw angle and pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements, without stopping the welding robot during the welding process for manual adjustment of the image acquisition device, and ensuring that the welding efficiency of the welding robot is relatively high.

[0133] The control device of the above-mentioned welding robot includes a processor and a memory. The acquisition unit, the first control unit, the second control unit, etc. are all stored in the memory as program units, and the processor executes the program units stored in the memory to realize corresponding functions.

[0134] The processor contains a kernel, and the kernel retrieves the corresponding program units from the memory. One or more kernels can be set, and by adjusting the kernel parameters, the problem that the molten pool camera of the welding robot in the prior art needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency, can be solved.

[0135] The memory may include non-permanent memory in a computer-readable medium, forms such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash memory (flash RAM), and the memory includes at least one storage chip.

[0136] An embodiment of the present invention provides a computer-readable storage medium, on which a program is stored, and when the program is executed by a processor, the control method of the welding robot described above is implemented.

[0137] An embodiment of the present invention provides a processor, and the above-mentioned processor is used to run a program. Among them, when the above-mentioned program runs, the control method of the welding robot described above is executed.

[0138] An embodiment of the present invention provides a device, which includes a processor, a memory, and a program stored on the memory and executable on the processor. When the processor executes the program, at least the following steps are implemented:

[0139] Step S101, obtaining a first image and / or a second image, a first distance, and a second distance collected by an image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire;

[0140] Step S102, when the difference between the first distance and the second distance is greater than a first preset value, controlling the first motor to run according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value;

[0141] Step S103, when the first position is not located in the first area and / or the second position is not located in the second area, controlling the second motor and the third motor to run according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is located in the first area and / or the adjusted second position is located in the second area, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0142] The device in this article can be a server, a PC, a PAD, a mobile phone, etc.

[0143] The present application also provides a computer program product, which, when executed on a data processing device, is adapted to execute a program initialized with at least the following method steps:

[0144] Step S101, obtaining a first image and / or a second image, a first distance, and a second distance collected by an image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire;

[0145] Step S102, when the difference between the first distance and the second distance is greater than a first preset value, control the first motor to run according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value;

[0146] Step S103, when the first position is not within the first region and / or the second position is not within the second region, control the second motor and the third motor to run according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, where the first position is the position of the center point of the wire end in the first image, and the second position is the position of the center point of the molten pool in the second image.

[0147] According to another typical embodiment of the present application, a welding system is further provided, including the above-mentioned welding robot; a controller of the above-mentioned welding robot, including one or more processors, a memory, and one or more programs, where 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 include those for executing any one of the above-mentioned methods.

[0148] The above-mentioned welding system includes the above-mentioned welding robot and its controller. The controller is used to execute any one of the above-mentioned methods. This method controls the first motor to run according to the actual distance between the image acquisition device and the wire end and the preset object distance to automatically adjust the spatial position of the image acquisition device. According to the position of the center point of the wire end and / or the center line point of the molten pool in the image, it controls the second motor and the third motor to run to automatically adjust the yaw angle and pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements. There is no need to stop the welding robot during the welding process for manual adjustment of the graphic acquisition device, ensuring a high welding efficiency of the welding robot, and effectively solving the problem in the prior art that the molten pool camera of the welding robot needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency, ensuring a high welding efficiency and a high degree of automation of the welding system.

[0149] In the above embodiments of the present invention, the descriptions of the various embodiments have their own focuses. For parts not detailed in a certain embodiment, reference may be made to the relevant descriptions of other embodiments.

[0150] In several embodiments provided in the present application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are merely illustrative. For example, the above division of units can be a logical function division. In actual implementation, there can be other division methods. 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 couplings or direct couplings or communication connections shown or discussed with each other can be through some interfaces. The indirect couplings or communication connections of units or modules can be in electrical or other forms.

[0151] The units described above as separate components may or may not be physically separated. The components shown as units may or may not be physical units, that is, they can be located in one place or distributed to multiple units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0152] In addition, in each embodiment of the present invention, the functional units can be integrated in a processing unit, or each unit can exist physically alone, or two or more units can be integrated in one unit. The above integrated units can be implemented in the form of hardware or in the form of software functional units.

[0153] If the above 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 such an understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which can be a personal computer, a server or a network device, etc.) to execute all or part of the steps of the methods in each embodiment of the present invention. The foregoing storage medium includes: various media such as USB flash drives, read-only memories (ROMs), random access memories (RAMs), mobile hard disks, magnetic disks or optical discs that can store program codes.

[0154] From the above description, it can be seen that the above embodiments of the present application achieve the following technical effects:

[0155] 1) In the adjustment device of the above-mentioned image acquisition device of the present application, the image acquisition device is connected through the first fixing mechanism; the horizontal adjustment mechanism includes a fixing member and a second motor. By rotating the second motor, the fixing member is driven to rotate in the first direction, and then the image acquisition device is driven by the first fixing mechanism to rotate in the first direction, realizing the adjustment of the yaw angle of the image acquisition device; the pitch adjustment mechanism includes a third motor and a moving component. By rotating the third motor, the moving component is driven to move in the second direction, and then the image acquisition device is driven by the first fixing mechanism to rotate in the second direction, realizing the adjustment of the pitch angle of the image acquisition device; the position adjustment mechanism includes a first motor, a first transmission component, and a sliding component. By rotating the first motor, the sliding component is driven to move along the first transmission component, and then the image acquisition device is driven to move, realizing the adjustment of the position of the image acquisition device. Compared with the problem in the prior art that the molten pool camera of the welding robot needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency, in the present application, by operating the first motor of the position adjustment mechanism, the automatic adjustment of the spatial position of the image acquisition device can be realized. By operating the second motor of the horizontal adjustment mechanism, the automatic adjustment of the yaw angle of the image acquisition device can be realized; by operating the third motor of the pitch adjustment mechanism, the automatic adjustment of the pitch angle of the image acquisition device can be realized. Through the adjustment device of the present application, the automatic adjustment of the position and angle of the image acquisition device is realized, without manual adjustment, ensuring a relatively high welding efficiency of the welding robot.

[0156] 2) The above-mentioned welding robot of the present application includes a crawling robot and the adjustment device of any one of the above-mentioned image acquisition devices. By operating the first motor of the position adjustment mechanism in the adjustment device, the automatic adjustment of the spatial position of the image acquisition device can be realized. By operating the second motor of the horizontal adjustment mechanism in the adjustment device, the automatic adjustment of the yaw angle of the image acquisition device can be realized; by operating the third motor of the pitch adjustment mechanism in the adjustment device, the automatic adjustment of the pitch angle of the image acquisition device can be realized, realizing the automatic adjustment of the position and angle of the image acquisition device, without manual adjustment, ensuring a relatively high welding efficiency of the welding robot, and effectively solving the problem in the prior art that the molten pool camera of the welding robot needs to be manually adjusted in position and angle during the welding process, which affects the welding efficiency.

[0157] 3) In the control method of the welding robot of the present application, first, a first distance representing a preset object distance and a second distance representing the distance between the image acquisition device and the end of the welding wire are obtained by the image acquisition device, and a first image including the end of the welding wire and / or a second image including the molten pool are also obtained. Then, when the difference between the first distance and the second distance is greater than a first preset value, the first motor is controlled to operate according to the difference to adjust the difference, so as to adjust the spatial position of the image acquisition device. And when the first position is not within the first region and / or the second position is not within the second region, the second motor and the third motor are controlled to operate according to the first position and / or the second position to adjust the first position and / or the second position, so as to adjust the yaw angle and / or the pitch angle of the image acquisition device, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image. Compared with the problem in the prior art that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during the welding process, which affects the welding efficiency, in the above method of the present application, the first motor is controlled to operate according to the actual distance between the image acquisition device and the end of the welding wire and the preset object distance to automatically adjust the spatial position of the image acquisition device, and the second motor and the third motor are controlled to operate according to the position of the center point of the end of the welding wire and / or the center line point of the molten pool in the image to automatically adjust the yaw angle and the pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements, without stopping the welding robot during the welding process for manual adjustment of the graphic acquisition device, and ensuring a high welding efficiency of the welding robot.

[0158] 4) In the control device of the welding robot described above in the present application, a first distance representing a preset object distance and a second distance representing the distance between the image acquisition device and the end of the welding wire are obtained by an acquisition unit, and a first image including the end of the welding wire and / or a second image including the molten pool are also obtained; when the difference between the first distance and the second distance is greater than a first preset value, a first control unit controls the operation of the first motor according to the difference to adjust the difference, so as to adjust the spatial position of the image acquisition device; when the first position is not within the first region and / or the second position is not within the second region, a second control unit controls the operation of the second motor and the third motor according to the first position and / or the second position to adjust the first position and / or the second position, so as to adjust the yaw angle and / or pitch angle of the image acquisition device, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image. Compared with the problem in the prior art that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during welding, which affects the welding efficiency, in the above device of the present application, the operation of the first motor is controlled according to the actual distance between the image acquisition device and the end of the welding wire and the preset object distance, so as to automatically adjust the spatial position of the image acquisition device, and the operation of the second motor and the third motor is controlled according to the position of the center point of the end of the welding wire and / or the center line point of the molten pool in the image to automatically adjust the yaw angle and pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements, without the need to stop the welding robot during welding for manual adjustment of the image acquisition device, ensuring that the welding efficiency of the welding robot is relatively high.

[0159] 5) The welding system described above in the present application includes the above welding robot and its controller, and the controller is used to execute any one of the above methods. This method controls the operation of the first motor according to the actual distance between the image acquisition device and the end of the welding wire and the preset object distance to automatically adjust the spatial position of the image acquisition device, and controls the operation of the second motor and the third motor according to the position of the center point of the end of the welding wire and / or the center line point of the molten pool in the image to automatically adjust the yaw angle and pitch angle of the image acquisition device, ensuring that the spatial position and angle of the adjusted image acquisition device meet the welding requirements, without the need to stop the welding robot during welding for manual adjustment of the image acquisition device, ensuring that the welding efficiency of the welding robot is relatively high, effectively solving the problem in the prior art that the position and angle of the molten pool camera of the welding robot need to be manually adjusted during welding, which affects the welding efficiency, ensuring that the welding efficiency of the welding system is relatively high and the degree of automation is relatively high.

[0160] The above are only the preferred embodiments of the present application and are not intended to limit the present application. For those skilled in the art, various modifications and changes can be made to the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included within the protection scope of the present application.

Claims

1. An adjustment device for an image acquisition device, characterized in that, Comprising: A position adjusting mechanism, including a first motor, a first lead screw assembly, and a sliding assembly. The first motor is connected to the first end of the first lead screw assembly. The sliding assembly has opposite front and back surfaces. The front surface of the sliding assembly is slidably mounted on the first lead screw assembly. The first motor rotates to drive the sliding assembly to move along the first lead screw assembly; A first fixing mechanism, the first end of which is used to connect to the image acquisition device; A horizontal adjusting mechanism, including a fixing member and a second motor. The first end of the second motor is located on the back surface of the sliding assembly. The second end of the second motor is connected to the first end of the fixing member. The second end of the fixing member is rotatably connected to the first end of the first fixing mechanism. The second motor rotates to drive the image acquisition device to rotate in a first direction through the fixing member; A pitching adjusting mechanism, including a third motor and a moving assembly. The first end of the third motor is located on the back surface of the sliding assembly. The second end of the third motor is connected to the first end of the moving assembly. The second end of the moving assembly has a track arranged along the first direction. The second end of the first fixing mechanism is located in the track. The third motor rotates to drive the moving assembly to move in a second direction, so that the first fixing mechanism drives the image acquisition device to rotate in the second direction. The second direction is perpendicular to the first direction; The moving assembly includes: An inner sleeve, fixed to the back surface of the sliding assembly and sleeved outside the second motor; An outer sleeve, sleeved outside the inner sleeve, and the inner wall of the outer sleeve is slidably connected to the outer wall of the inner sleeve; The track, connected to the end of the outer sleeve away from the sliding assembly. The track is an annular track; A fixed connection bracket, the first end of which is connected to the outer pipe wall of the outer sleeve; A second lead screw assembly, the first end of the second lead screw assembly is connected to the second end of the fixed connection bracket. The second end of the second lead screw assembly is the first end of the moving assembly. When the third motor rotates, the second lead screw assembly moves in the second direction to drive the outer sleeve to move in the second direction through the fixed connection bracket.

2. The adjustment device according to claim 1, characterized in that, The first fixing mechanism includes: A first fixing ring, used to be sleeved on the image acquisition device. The axis of the first fixing ring is parallel to the optical axis of the image acquisition device; A second fixing ring, the outer wall of the second fixing ring is tangent to the outer wall of the first fixing ring. The axis of the second fixing ring is perpendicular to the axis of the first fixing ring; An expansion link, the first end of the expansion link is connected to the outer wall of the second fixing ring. The second end of the expansion link is the second end of the first fixing mechanism. The expansion link is perpendicular to the axis of the second fixing ring.

3. The adjustment device according to claim 2, characterized in that, The fixing member includes: A first coupling, the first end of which is the first end of the fixing member; A support shaft, the first end of the support shaft is connected to the second end of the first coupling, the second end of the support shaft has a third fixing ring, and the third fixing ring and the second fixing ring are coaxial; A rotary damper, the rotary damper is the second end of the fixing member, and the second fixing ring and the third fixing ring are respectively sleeved on the rotary damper.

4. The adjustment device according to any one of claims 1 to 3, characterized in that, The first lead screw assembly has a front side and a back side, the sliding assembly is located on the front side of the first lead screw assembly, and the adjusting device further includes: A second fixing mechanism, including a connected first fixing plate and a second fixing plate, the included angle between the first fixing plate and the second fixing plate is less than 90°, the surface of the first fixing plate away from the second fixing plate is used to connect with the crawling robot, and the surface of the second fixing plate away from the first fixing plate is connected to the back side of the first lead screw assembly.

5. The adjustment device according to any one of claims 1 to 3, characterized in that The position adjusting mechanism further includes: A second coupling, the first motor and the first lead screw assembly are connected through the second coupling.

6. A welding robot, characterized in that, Including: A crawling robot; The adjusting device of the image acquisition device according to any one of claims 1 to 5, the crawling robot is connected to the first lead screw assembly of the adjusting device.

7. A control method for a welding robot according to claim 6, characterized in that, Including: Obtaining a first image and / or a second image, a first distance, and a second distance collected by the image acquisition device, wherein the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire; When the difference between the first distance and the second distance is greater than a first preset value, controlling the first motor to operate according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value; When the first position is not within the first region and / or the second position is not within the second region, controlling the second motor and the third motor to operate according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, wherein the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

8. The method according to claim 7, wherein There are multiple consecutive frames of the first image. Before controlling the second motor and the third motor to operate according to the first position and / or the second position, after obtaining the first image and / or the second image, the first distance, and the second distance collected by the image acquisition device, the method further includes: Performing at least one of the following: processing the multiple consecutive frames of the first image by using the inter-frame difference method to obtain the position information of the end of the welding wire, and extracting the image of the molten pool from the second image by using the edge detection method to obtain the position information of the molten pool.

9. The method according to claim 7, characterized in that, Controlling the second motor and the third motor to operate according to the first position and / or the second position includes: Determine a third distance based on the first position, and / or determine a fourth distance based on the second position, where the third distance is the distance between the first position and the center point of the first image, and the fourth distance is the distance between the second position and the center point of the second image; Perform coordinate transformation on the third distance and / or the fourth distance to obtain a pitch angle adjustment value and a yaw angle adjustment value of the image acquisition device; Determine the rotation direction and the number of rotation turns of the second motor according to the yaw angle adjustment value, and determine the rotation direction and the number of rotation turns of the third motor according to the pitch angle adjustment value; Control the second motor and the third motor to rotate the corresponding number of rotation turns in the corresponding rotation direction.

10. The method according to any one of claims 7 to 9, characterized in that Obtain the first image and / or the second image acquired by the image acquisition device, including: Determine the first image and / or the second image according to the current welding state, where, when the current welding state is before welding, obtain the first image, and when the current welding state is during welding, obtain the second image.

11. The control device of the welding robot according to claim 6, characterized in that, Comprising: An acquisition unit, configured to acquire the first image and / or the second image, the first distance, and the second distance acquired by the image acquisition device, where the first image is an image including the end of the welding wire, the second image is an image including the molten pool, the first distance is a preset object distance, and the second distance is the distance between the image acquisition device and the end of the welding wire; A first control unit, configured to, when the difference between the first distance and the second distance is greater than a first preset value, control the first motor to operate according to the difference to adjust the difference so that the adjusted difference is less than or equal to the first preset value; A second control unit, configured to, when the first position is not within the first region and / or the second position is not within the second region, control the second motor and the third motor to operate according to the first position and / or the second position to adjust the first position and / or the second position so that the adjusted first position is within the first region and / or the adjusted second position is within the second region, where the first position is the position of the center point of the end of the welding wire in the first image, and the second position is the position of the center point of the molten pool in the second image.

12. A welding system, characterized in that, Comprising: The welding robot according to claim 6; The controller of the welding robot, including one or more processors, a memory, and one or more programs, where 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 include methods for executing any one of claims 7 to 10.

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