A welding correction system

Abstract

The present invention is applicable to the field of welding technology, and provides a welding correction system, including an integrated vision module, a central control module, a welding module and a mobile module, to achieve high-precision welding. The vision module identifies the welding area, the central control module processes data and guides the welding module to perform welding, and the mobile module provides three-dimensional displacement. The system collects images, identifies features, determines welding quality and performs corrections, and uses an inverse kinematics algorithm to accurately plan the path of the robot arm. Therefore, the present invention can monitor the welding status in real time, intelligently correct errors, reduce manual intervention and downtime, thereby improving welding quality and production efficiency, and has a wide range of applications and high welding efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of welding, and in particular to a welding correction system. Background Art

[0002] In the field of welding technology, automated welding technology refers to the automation of the welding process by controlling various parameters in the welding process. It can reduce labor intensity and improve working conditions. Accurate path planning and welding quality control are the key to achieving efficient and high-quality welding.

[0003] Traditional welding systems usually rely on preset paths and limited feedback adjustment mechanisms, which makes it difficult to ensure welding consistency and accuracy when faced with complex or dynamically changing welding environments (for example, when welding a boiler to a pipeline, or welding a boiler to a lifting accessory, the welding effect directly affects the overall strength of the boiler, so higher welding accuracy is required). In addition, the existing system has limited ability to identify and correct errors during the welding process, and often requires manual intervention, which not only increases costs but also reduces production efficiency.

[0004] As is known from the above, the prior art obviously has inconveniences and defects in practical use, so it is necessary to improve it. A welding correction system is proposed to address the above problems. Summary of the invention

[0005] In view of the above-mentioned defects, the purpose of the present invention is to provide a welding correction system, which monitors the real-time status of automatic welding and performs repairs through the cooperation of a visual module, thereby providing a welding correction system.

[0006] In order to achieve the above-mentioned object, the present invention provides a welding correction system, comprising a visual module, wherein the visual module comprises a camera, and the visual module is used to identify a to-be-welded area and a welding area.

[0007] The central control module is used to receive the image input by the visual module. The central control module includes a computing unit for performing operations on data and programs, a storage unit for storing data, and a communication unit for transmitting data.

[0008] The welding module includes a welding device for welding in the area to be welded, and one end of the welding device is connected to the mechanical arm in the moving module.

[0009] The mobile module is used to provide three-dimensional movement displacement for the welding module. The mobile module includes a three-degree-of-freedom mechanical arm that enables the welding module to move. The mechanical arm includes a plurality of connecting rods.

[0010] According to a welding correction system of the present invention, the steps of using the welding correction system are as follows:

[0011] S1, the central control module receives the welding path planning data, and the welding module receives the coordinate data calculated by the central control module.

[0012] S2, the welding module obtains the actual coordinates of the welding robot arm and the relative rotation angle of the welding robot arm according to the coordinate data.

[0013] S3, the visual module collects welding images on the welding path, performs feature recognition on the welding images and determines the welding success rate and welding problem points in the path area.

[0014] S4, the central control module transmits the relative position coordinates of the welding problem points to the welding module, and the welding module performs secondary correction welding on the welding problem points.

[0015] According to a welding correction system of the present invention, the visual module photographs the area to be welded and the welding area, and the central control module obtains images img_1 and img_2 of the area to be welded G1 and the welding area G2.

[0016] According to a welding correction system of the present invention, the image img_2 is preprocessed to obtain the width w of the welding passing area G20 and the welding defect area G21. i , area i and shape k i The welding defect area is divided into grades, and the initial values ​​are set to w0, s0, k0. The grade of the identified welding defect area is judged, and the defect grade is set to , the defect levels are accumulated to obtain the total defect level of the welding area within period t, .

[0017] If the total defect level , the welding area is not treated.

[0018] If the total defect level , call the mobile module to perform repair welding on the welding area.

[0019] If the total defect level , shut down the welding module and check the initial value of the system vision module adjustment.

[0020] According to a welding correction system described in the present invention, the base coordinate system of the robot arm is O, the coordinate system of the welding module is E, the three joint angles of the robot arm are θ1, θ2, θ3, and the position P of the welding gun in the welding module is set to P=[x i ,y i ,z i ], d1, d2, d3 are the lengths of the connecting rods of the robot arm, x i ,yi ,z i is the coordinate of the welding gun in three-dimensional space.

[0021]

[0022]

[0023]

[0024] According to a welding correction system of the present invention, the calculated joint angles θ1, θ2, θ3 at the position P, the rotation angle of the three-degree-of-freedom manipulator is:

[0025] .

[0026] , .

[0027] .

[0028] According to the welding correction system described in the present invention, the kinematic model of the robot arm is represented by a homogeneous transformation matrix, and the transformation of each joint can be expressed as ,in is the rotation matrix, and each change vector is .

[0029] The present invention provides a welding correction system, which has the following beneficial effects:

[0030] The welding route is planned through external input. Through the integrated kinematic algorithm and joint space interpolation technology, the system can accurately calculate and plan the path for the robot arm to reach each welding point, thus improving the welding accuracy.

[0031] The visual module set on the system takes the welded image within a unit time, and continues to identify the welded image and monitor the welding status to ensure real-time monitoring and quality control of the welding process;

[0032] The central control module analyzes the welding deviations detected by the vision module and adjusts the welding parameters and robot arm paths to achieve intelligent error correction, reducing manual intervention and downtime in production. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the overall structure of the present invention; DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0035] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0036] In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0037] See also Figure 1 The present invention provides a welding correction system, including a visual module, wherein the visual module includes a camera, and the visual module is used to identify the area to be welded and the welding area, and photograph the area to be welded and the welding area through the camera, and the camera photographs the area to be welded and the welding area in units of period t.

[0038] The central control module is used to receive the image input by the visual module. The central control module includes a computing unit for performing operations on data and programs, a storage unit for storing data, and a communication unit for transmitting data.

[0039] The welding module includes welding equipment for welding in the area to be welded, a welding gun is selected as the welding equipment for welding in the area to be welded, and one end of the welding equipment is connected to the mechanical arm in the mobile module.

[0040] The mobile module is used to provide three-dimensional movement displacement for the welding module. The mobile module includes a plurality of three-degree-of-freedom mechanical arms that enable the welding module to move, and the mechanical arms include a plurality of connecting rods.

[0041] The specific steps of the welding correction system are as follows:

[0042] S1. The central control module receives the welding path planning data, and the welding module receives the coordinate data calculated by the central control module.

[0043] S2. The welding module obtains the actual coordinates of the welding robot arm and the relative rotation angle of the welding robot arm according to the coordinate data.

[0044] S3. The visual module collects welding images on the welding path, performs feature recognition on the welding images, and determines the welding success rate and welding problem points in the path area.

[0045] S4. The central control module transmits the relative position coordinates of the welding problem points to the welding module, and the welding module performs secondary correction welding on the welding problem points.

[0046] Furthermore, a dedicated welding 3D camera (such as Tracer P series) is used to photograph the area to be welded and the welding area, and the central control module obtains images img_1 and img_2 of the area to be welded G1 and the welding area G2.

[0047] Furthermore, the images img_1 and img_2 are preprocessed to eliminate noise and enhance features. The preprocessing steps include filtering, binarization, edge detection and other operations to highlight the features of the welding area and reduce interference factors in the image. The above-mentioned preprocessing of the image img_2 obtains the welding through area G20 and the welding defect area G21. The means of preprocessing the image and distinguishing between the welding and non-welding areas are conventional technical means in the field and will not be repeated here.

[0048] Preferably, the preprocessing of the image img_2 obtains the width w of the welding through area G20 and the welding defect area G21 i , area i and shape k i The welding defect area is divided into grades, and the initial values ​​are set to w0, s0, k0. The grade of the identified welding defect area is judged, and the defect grade is set to , the defect levels are accumulated to obtain the total defect level of the welding area within period t, ,

[0049] If the total defect level , no treatment is done on the welding area;

[0050] If the total defect level , call the mobile module to perform repair welding on the welding area;

[0051] If the total defect level , shut down the welding module and check the initial value of the system vision module adjustment.

[0052] Furthermore, the base coordinate system of the robot is set to O, and the coordinate system of the end effector is set to E. The three joint angles of the robot are θ1, θ2, and θ3 respectively, and the position P of the welding gun is set to P=[x i ,y i ,z i ], d1, d2, d3 are the lengths of the connecting rods of the robot arm.

[0053] Among them, x i ,y i ,z i is the coordinate of the welding gun in three-dimensional space,

[0054]

[0055]

[0056] .

[0057] Calculate the vector from the origin to the target point , then the vector Length .

[0058] Inverse kinematics is used to calculate the joint angles θ1, θ2, θ3 according to the target position P. For a three-degree-of-freedom robotic arm,

[0059]

[0060] , ,

[0061] .

[0062] The kinematic model of the entire robotic arm can be represented by a homogeneous transformation matrix. The transformation of each joint can be expressed as, ,in is the rotation matrix, and each change vector is .

[0063] The corresponding rotation matrices of each joint, about the x-axis rotation, y-axis rotation, and z-axis rotation are,

[0064] ,

[0065] ,

[0066] .

[0067] The central control module is used through the above rotation matrix to realize the welding process in three-dimensional coordinates by the welding gun through the robot arm.

[0068] Furthermore, the central control module or sub-control module and electrical integration are composed of various operators and chips, and are built using the CPU central processing unit system architecture. The communication system is also integrated into the electrical centralized system. The communication module further uses 4G / 5G / GPRS / WIFI / LORA / NB IOT / BIU / ZIGBEE wireless communication and CAN / 485 / Ethernet wired communication bus to send commands, report data, receive commands, transmit information, voice interpretation, networking, etc., and interfaces are reserved to accommodate new communication modules and other communication modules in the future.

[0069] Of course, the present invention may have many other embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art may make various corresponding changes and modifications based on the present invention, but these corresponding changes and modifications should all fall within the scope of protection of the claims attached to the present invention.

Claims

1. A welding correction system, characterized in that: include: A visual module, the visual module comprising a camera, and the visual module is used to identify the area to be welded and the welding area; A central control module, used to receive the image input by the visual module, the central control module includes a computing unit for computing data and programs, a storage unit for storing data, and a communication unit for transmitting data; A welding module, wherein the welding module includes a welding device for welding in the area to be welded, and one end of the welding device is connected to a mechanical arm in the moving module; A mobile module, the mobile module is used to provide three-dimensional movement displacement for the welding module, the mobile module includes a three-degree-of-freedom mechanical arm that enables the welding module to move, and the mechanical arm includes a plurality of connecting rods; The steps for using the welding correction system are as follows: S1, the central control module receives the welding path planning data, and the welding module receives the coordinate data calculated by the central control module; S2, the welding module obtains the actual coordinates of the welding robot arm and the relative rotation angle of the welding robot arm according to the coordinate data; S3, the visual module collects welding images on the welding path, performs feature recognition on the welding images and determines the welding success rate and welding problem points in the path area; S4, the central control module transmits the relative position coordinates of the welding problem point to the welding module, and the welding module performs secondary correction welding on the welding problem point; The visual module takes pictures of the area to be welded and the welding area, and the central control module obtains images img_1 and img_2 of the area to be welded G1 and the welding area G2; According to the width wi, area si and shape ki of the welding pass area G20 and the welding defect area G21 obtained by preprocessing the image img_2, the welding defect area is classified into grades, and the initial values ​​are set to w0, s0, k0. The grade of the identified welding defect area is judged, and the defect grade is set to , the defect levels are accumulated to obtain the total defect level of the welding area within period t, , If the total defect level , no treatment is done on the welding area; If the total defect level , call the mobile module to perform repair welding on the welding area; If the total defect level , shut down the welding module and check the initial value of the system vision module adjustment.

2. The welding correction system according to claim 1, characterized in that: The base coordinate system of the robot arm is O, the coordinate system of the welding module is E, the three joint angles of the robot arm are θ1, θ2, θ3, the position P of the welding gun in the welding module is set to P=[xi,yi,zi], d1, d2, d3 are the lengths of the connecting rods of the robot arm, xi,yi,zi are the coordinates of the welding gun in three-dimensional space, ， ， 。 3. The welding correction system according to claim 2, characterized in that: According to the position P, the joint angles θ1, θ2, θ3 are calculated. The rotation angle of the three-degree-of-freedom robot arm is, ， ， ， 。 4. The welding correction system according to claim 3, characterized in that: The kinematic model of the robot arm is represented by a homogeneous transformation matrix, and the transformation of each joint can be expressed as: ， in is the rotation matrix, and each change vector is .

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