Device for adjusting vision of welding robot and adjusting method thereof

Abstract

The invention relates to a device for adjusting vision of a welding robot and an adjusting method of the device, and belongs to the technical field of welding robos.The device comprises a detection table and a six-axis mechanical arm, a rotary positioning shaft is rotatably arranged on the detection table, and a positioning structure for positioning a to-be-detected part is arranged on the rotary positioning shaft; the fixed end of the six-axis mechanical arm is connected to the detection table, and a detection camera is clamped at the free end of the six-axis mechanical arm; a control system is further included. The shaft mechanical arm and the detection camera are combined with the control system, full-automatic detection of weld defects of products machined by the welding robot is achieved, the labor intensity is relieved, the detection efficiency and accuracy are greatly improved, and the situations of missing detection and false detection are reduced; the six-axis mechanical arm can drive the detection camera to move in a full range on the circumferential side of the rotary positioning shaft, all-directional and multi-angle shooting of the to-be-detected part is achieved in combination with rotation of the rotary positioning shaft, detection dead angles are effectively avoided, and detection comprehensiveness is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of welding robots, and in particular relates to a device for adjusting the vision of a welding robot and an adjustment method thereof. Background Art

[0002] Welding, also known as fusion, is a manufacturing process and technology that uses heating, high temperature or high pressure to join metals or other thermoplastic materials such as plastics. There are many sources of energy for modern welding, including gas flame, arc, laser, electron beam, friction and ultrasound. Welding technology is mostly used in factories, but now welding can also be carried out in a variety of environments, such as outdoors, underwater and in space. When performing welding operations, it may bring dangers to the operator, such as burns, visual impairment, inhalation of toxic gases, etc. In the existing technology, in order to protect the operator and to improve welding efficiency, welding robots have begun to replace manual welding work. Welding robots are intelligent machines that can work semi-autonomously or fully autonomously. They are highly flexible automated machines with basic characteristics such as perception, decision-making, and execution, so that they can assist or even replace humans to complete welding work, so as to improve work efficiency and quality, and assist or replace human work.

[0003] In actual production, due to the influence of the production environment or human factors, defects such as pores, cracks, burn-through, and lack of fusion are prone to occur in the weld part, which greatly reduces the quality of the product and may cause safety problems in production. For this reason, it is necessary to detect defects such as welds on products processed by welding robots. The existing technology for detecting products processed by welding robots is through manual detection, which has a large workload, is prone to errors, and is prone to missed detection; or through camera detection, the detection angle is not comprehensive and blind spots are prone to appear. Summary of the invention

[0004] In order to solve the above-mentioned problems existing in the prior art, the present invention provides a device for adjusting the vision of a welding robot and an adjustment method thereof, which solves the problems that the detection means for welding robot processing products in the prior art are manual detection, which has a large workload, is prone to errors, and is prone to missed detections; or detection by camera, which has the problem of incomplete detection angles and blind spots.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] In the first aspect, an embodiment of the present invention is a device for adjusting the vision of a welding robot, comprising a detection table and a six-axis robotic arm, wherein a rotation positioning shaft is rotatably provided on the detection table, and a positioning structure for positioning a component to be detected is provided on the rotation positioning shaft, the fixed end of the six-axis robotic arm is connected to the detection table, and the free end of the six-axis robotic arm clamps a detection camera; and also includes a control system, wherein the control system is used to control the rotation positioning shaft to drive the component to be detected to rotate, control the six-axis robotic arm to drive the detection camera to move around the rotation positioning shaft, control the detection camera to shoot the component to be detected, receive the digital image signal generated by the detection camera shooting and analyze it to obtain a detection result.

[0007] Furthermore, the positioning structure includes a vacuum adsorption hole arranged on the rotating positioning shaft, and the vacuum adsorption hole is connected to a vacuum extraction device.

[0008] Furthermore, the positioning structure includes a baffle, a support plate and an insert plate which are detachably arranged on the rotating positioning shaft, the baffle is used to block the side edge of the component to be detected in the horizontal direction, the support plate is used to block the lower edge of the component to be detected in the vertical direction, and the insert plate is used to be inserted into the corresponding slot on the component to be detected.

[0009] Furthermore, the detection platform is provided with a first vertical slide rail and a second vertical slide rail, the rotation positioning shaft is horizontally arranged between the first vertical slide rail and the second vertical slide rail, and both ends of the rotation positioning shaft are respectively slidably connected to the first vertical slide rail and the second vertical slide rail.

[0010] Furthermore, it also includes an alarm device electrically connected to the control system, and the alarm device is a speaker or a light group or an audible and visual alarm.

[0011] Furthermore, two six-axis robotic arms are provided, and the fixed ends of the two six-axis robotic arms are respectively close to the two ends of the rotation positioning axis.

[0012] Furthermore, it also includes a display screen electrically connected to the control system, and the display screen is used to display the image captured by the detection camera.

[0013] Furthermore, the control system includes a memory, and the memory is used to store historical file information generated by shooting with the detection camera.

[0014] In a second aspect, an embodiment of the present invention provides a method for adjusting the vision of a welding robot, using the device for adjusting the vision of a welding robot as described above, and comprising the following steps:

[0015] Position the component to be inspected on the rotary positioning shaft;

[0016] Outputting an opening instruction to the inspection camera through the control system, controlling the inspection camera to open and take pictures of the component to be inspected;

[0017] The control system outputs a lateral movement command to the six-axis robot arm, so that the six-axis robot arm drives the inspection camera to sweep across the entire range of the component to be inspected positioned on the rotating positioning axis;

[0018] Output a rotational motion instruction to the rotary positioning shaft through the control system, so that the rotary positioning shaft drives the rotary positioning shaft to rotate;

[0019] The control system receives the digital image signal generated by the detection camera after shooting, and the control system converts the received digital image signal into an image and displays it on a display screen;

[0020] Analyzing the digital image signal by a control system to determine whether there is a defective part in the weld on the component to be inspected;

[0021] If there is no defective part, the test is deemed qualified and displayed on the display screen;

[0022] If there is a defective part, the test is deemed unqualified and displayed on the display screen, and the alarm device is activated to start the alarm.

[0023] Furthermore, the process of analyzing the digital image signal by a control system to determine whether there is a defective part on the component to be inspected comprises the following steps:

[0024] Integrating all the digital image signals in the control system to construct an actual three-dimensional model of the component to be inspected;

[0025] Compare and analyze the actual 3D model of the component to be inspected with the standard 3D model in the database to identify the weld difference value points on the actual 3D model;

[0026] Separate the weld difference value point on the actual three-dimensional model from the actual three-dimensional model, and calculate the minimum enclosing rectangular area of ​​the weld difference value point;

[0027] If the minimum enclosing rectangular area of ​​the weld difference value point is less than the preset error threshold, it is determined that the weld difference value point does not belong to a bad part;

[0028] If the minimum enclosing rectangular area of ​​the weld difference value point is greater than or equal to the preset error threshold, the weld difference value point is judged to be a bad part.

[0029] The beneficial effects of the present invention are:

[0030] The present invention discloses a device for adjusting the vision of a welding robot and an adjustment method thereof. By combining a six-axis mechanical arm and a detection camera with a control system, fully automatic detection of weld defects of products processed by the welding robot is realized, which not only reduces labor intensity, but also greatly improves detection efficiency and accuracy, and reduces missed detection and false detection. The six-axis mechanical arm can drive the detection camera to move in a full range around the rotating positioning shaft, and combined with the rotation of the rotating positioning shaft, all-round and multi-angle shooting of the components to be detected is realized, which effectively avoids detection blind spots and improves the comprehensiveness of detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0032] Figure 1 A schematic diagram of the three-dimensional structure of a device for adjusting the vision of a welding robot according to the present invention;

[0033] Figure 2 A front view of a device for adjusting the vision of a welding robot according to the present invention;

[0034] Figure 3 A schematic diagram of a flow chart of a method for adjusting the vision of a welding robot according to the present invention;

[0035] Figure 4 The present invention is a schematic diagram of a sub-process of a method for adjusting the vision of a welding robot.

[0036] Description of main symbols

[0037] In the figure: 1. Testing table; 2. Six-axis robotic arm; 3. Rotary positioning axis; 4. Control system; 5. First vertical slide rail; 6. Second vertical slide rail; 7. Alarm device; 8. Display screen. DETAILED DESCRIPTION

[0038] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation methods, structures, features and effects of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments.

[0039] See also Figure 1-Figure 2The present embodiment provides a device for adjusting the vision of a welding robot, including a detection platform 1 and a six-axis robot 2. A rotation positioning shaft 3 is rotatably provided on the detection platform 1, and a positioning structure for positioning the component to be detected is provided on the rotation positioning shaft 3. The fixed end of the six-axis robot 2 is connected to the detection platform 1, and the free end of the six-axis robot 2 clamps a detection camera; it also includes a control system 4, the control system 4 is used to control the rotation positioning shaft 3 to drive the component to be detected to rotate, control the six-axis robot 2 to drive the detection camera to move around the rotation positioning shaft 3, control the detection camera to shoot the component to be detected, receive the digital image signal generated by the detection camera shooting and analyze it to obtain the detection result.

[0040] It is understandable that, based on the problem that the traditional visual inspection system in the prior art is limited by a fixed viewing angle and is difficult to comprehensively and meticulously inspect welding parts with complex shapes or irregular surfaces, in order to improve the flexibility and accuracy of the welding robot in visual inspection, this embodiment introduces a rotatable rotating positioning shaft 3 and a high-degree-of-freedom six-axis manipulator 2 to achieve multi-angle and high-precision inspection of welding parts, thereby ensuring a reliable evaluation of welding quality. Specifically, this embodiment also includes a power source, which is controlled by a control system 4 and is used to provide power for electric drive components such as the six-axis manipulator 2, the rotating positioning shaft 3, and the detection camera. In a feasible detection process, the part to be detected is placed in the positioning structure on the rotating positioning shaft 3 to perform preliminary positioning of the part to be detected; then the control system 4 starts the rotating positioning shaft 3 to drive the part to be detected to rotate, and at the same time, the six-axis manipulator 2 moves around the rotating positioning shaft 3 according to a preset path or real-time instruction, adjusts the shooting position and angle of the detection camera, and the detection camera captures images of the part to be detected at multiple angles, and transmits these images to the control system 4 in the form of digital signals. The control system 4 analyzes and processes the received image signals, identifies weld defects, and outputs the analysis results in the form of text / numbers / letters or images for user reference. The entire detection process is automatically completed by the control system 4, reducing manual intervention and improving production efficiency and automation level.

[0041] Furthermore, the positioning structure includes a vacuum adsorption hole provided on the rotating positioning shaft 3, and the vacuum adsorption hole is connected to a vacuum pumping device. When the vacuum pumping device is started, the air in the vacuum adsorption hole will be extracted through the vacuum pipe to form a negative pressure environment. At this time, the component to be detected is placed on the rotating positioning shaft 3 and covers the vacuum adsorption hole. Due to the effect of negative pressure, the component to be detected will be firmly adsorbed on the rotating positioning shaft 3, thereby achieving positioning. After the detection is completed, the control system 4 turns off the vacuum pumping device, the negative pressure in the vacuum adsorption hole disappears, and the component to be detected can be removed from the rotating positioning shaft 3.

[0042] Further, the positioning structure includes a baffle, a support plate and an insert plate which are detachably arranged on the rotating positioning shaft 3, the baffle is used to block the side edge of the component to be detected in the horizontal direction, the support plate is used to block the lower edge of the component to be detected in the vertical direction, and the insert plate is used to be inserted into the corresponding slot on the component to be detected. It can be understood that the baffle is arranged on the rotating positioning shaft 3 to limit the side edge of the component to be detected in the horizontal direction to prevent it from moving left and right; the support plate is arranged on the rotating positioning shaft 3, located below the baffle, and is used to support the lower edge of the component to be detected in the vertical direction to ensure its stability in the vertical direction; the insert plate can be inserted into the corresponding slot on the component to be detected to further fix the component to be detected and increase the accuracy and firmness of positioning; at the same time, the detachable baffle, support plate and insert plate in this embodiment can be easily installed and removed from the rotating positioning shaft 3 to adapt to components to be detected of different shapes and sizes. Optionally, the baffle, support plate and insert plate in this embodiment can be detachably connected to the rotating positioning shaft 3 through a snap structure or bolts.

[0043] Furthermore, a first vertical slide rail 5 and a second vertical slide rail 6 are provided on the detection table 1, and the rotation positioning shaft 3 is horizontally arranged between the first vertical slide rail 5 and the second vertical slide rail 6, and the two ends of the rotation positioning shaft 3 are respectively slidably connected to the first vertical slide rail 5 and the second vertical slide rail 6. The rotation positioning shaft 3 cooperates with the first vertical slide rail 5 and the second vertical slide rail 6 through the sliding connection devices (such as sliders, balls, etc.) at its two ends to achieve smooth sliding in the vertical direction. Through the design of the first vertical slide rail 5 and the second vertical slide rail 6, the rotation positioning shaft 3 can slide freely in the vertical direction, thereby realizing rapid adjustment of the position and improving the flexibility of detection.

[0044] Furthermore, it also includes an alarm device 7 electrically connected to the control system 4, and the alarm device 7 is a speaker or a light group or an audible and visual alarm. It is understandable that the control system 4 will continuously monitor whether there are weld defects on the parts to be inspected during the inspection process. When an abnormal situation is found, the control system 4 will immediately trigger the working mechanism of the alarm device 7. The alarm device 7 sends an alarm signal, such as a sound, light signal or an audible and visual signal, according to the instruction of the control system 4 to remind the operator to pay attention. The operator checks and handles the abnormal situation in time according to the prompt of the alarm signal to ensure the smooth progress of the inspection process.

[0045] Furthermore, two six-axis robotic arms 2 are provided, and the fixed ends of the two six-axis robotic arms 2 are respectively close to the two ends of the rotation positioning shaft 3. It can be understood that the six-axis robotic arm 2 drives each joint to rotate through its own transmission mechanism to achieve accurate positioning and movement of the detection camera installed at its end in three-dimensional space. In this technical solution, the fixed ends of the two six-axis robotic arms 2 are respectively close to the two ends of the rotation positioning shaft 3, so that they can detect the components to be detected from different angles, thereby achieving multi-angle and all-round coverage.

[0046] Furthermore, the present solution further includes a display screen 8 electrically connected to the control system 4, and the display screen 8 is used to display the image captured by the detection camera. In this embodiment, after capturing the image of the component to be detected, the detection camera transmits the image data to the control system 4 via a data line or wirelessly, and the control system 4 performs processing such as decoding and scaling on the received image data, and sends the processed image data to the display screen 8 for display, and the display screen 8 draws a corresponding image on the screen according to the received image data for viewing by the operator.

[0047] Furthermore, the control system 4 includes a memory, which is used to store historical file information generated by the detection camera. Optionally, the memory can store one month of detection pictures, which can be traced back to the specific production time and operator, which is convenient for breakpoint management. In this embodiment, in order to improve the data management capability of the detection system and ensure the traceability of the detection process and the availability of historical data, by equipping the control system 4 with a memory, it is possible to conveniently store historical file information generated by the detection camera, including key data such as detection pictures, timestamps, and operator identification, which not only helps to achieve breakpoint management, that is, when a problem occurs, it can quickly locate the specific production time and operator, but also facilitates subsequent quality analysis, problem troubleshooting, and process improvement.

[0048] See also Figure 3-Figure 4 The present invention provides a method for adjusting the vision of a welding robot, using the device for adjusting the vision of a welding robot as described above, and comprising the following steps:

[0049] S1. Position the component to be tested on the rotating positioning axis 3;

[0050] S2. Output an opening command to the detection camera through the control system 4, control the detection camera to open and photograph the components to be detected;

[0051] S3 outputs a lateral movement command to the six-axis robot 2 through the control system 4, so that the six-axis robot 2 drives the inspection camera to sweep across the entire range of the component to be inspected positioned on the rotating positioning axis 3;

[0052] S4 outputs a rotational motion instruction to the rotational positioning shaft 3 through the control system 4, so that the rotational positioning shaft 3 drives the rotational positioning shaft 3 to rotate;

[0053] S5. The control system 4 receives the digital image signal generated by the detection camera after shooting, and the control system 4 converts the received digital image signal into an image and displays it on the display screen 8;

[0054] S6. Analyze the digital image signal by the control system 4 to determine whether there are defective parts in the weld on the part to be inspected;

[0055] S7. If there is no defective part, the test is deemed qualified and displayed on the display screen 8;

[0056] S8. If there is a defective part, the test is deemed unqualified and displayed on the display screen 8, and the alarm device 7 is activated to start the alarm.

[0057] Further, the step S6 includes the following steps S61-S65:

[0058] S61. Integrate all the digital image signals in the control system 4 to construct an actual three-dimensional model of the component to be detected;

[0059] S62. Compare and analyze the actual three-dimensional model of the component to be inspected with the standard three-dimensional model in the database to identify the weld difference value points on the actual three-dimensional model;

[0060] S63. Separating the weld difference value point on the actual three-dimensional model from the actual three-dimensional model, and calculating the minimum enclosing rectangular area of ​​the weld difference value point;

[0061] S64. If the minimum enclosing rectangular area of ​​the weld difference value point is less than the preset error threshold, it is determined that the weld difference value point does not belong to a bad part;

[0062] S65. If the minimum enclosing rectangular area of ​​the weld difference value point is greater than or equal to the preset error threshold, it is determined that the weld difference value point is a defective part.

[0063] This embodiment can more accurately identify the difference value points in the weld by constructing an actual three-dimensional model of the component to be detected and comparing it with the standard three-dimensional model. At the same time, by calculating the minimum enclosing rectangular area of ​​the weld difference value point and comparing it with the preset error threshold, it can be scientifically determined whether the weld difference value point belongs to a bad part, thereby avoiding misjudgment or missed judgment. It should be explained that the actual three-dimensional model refers to a three-dimensional model of the component to be detected constructed by three-dimensional reconstruction technology based on the digital image signal captured by the detection camera; the standard three-dimensional model refers to a three-dimensional model stored in the database that represents an ideal or qualified weld state, which is used for comparison and analysis with the actual three-dimensional model; the weld difference value point refers to the point where the difference is identified after the actual three-dimensional model is compared with the standard three-dimensional model, which is usually located in the weld area; the minimum enclosing rectangular area refers to an indicator used to quantify the size of the weld difference value point, which is obtained by calculating the minimum rectangular area containing the point; the preset error threshold is an area threshold set according to actual needs to determine whether the weld difference value point belongs to a bad part.

[0064] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A device for adjusting the vision of a welding robot, characterized in that: It includes a detection platform and a six-axis robot arm, wherein a rotating positioning shaft is rotatably provided on the detection platform, a positioning structure for positioning the component to be detected is provided on the rotating positioning shaft, the fixed end of the six-axis robot arm is connected to the detection platform, and the free end of the six-axis robot arm clamps a detection camera; it also includes a control system, wherein the control system is used to control the rotating positioning shaft to drive the component to be detected to rotate, control the six-axis robot arm to drive the detection camera to move around the rotating positioning shaft, control the detection camera to shoot the component to be detected, receive the digital image signal generated by the detection camera shooting and analyze it to obtain the detection result.

2. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: The positioning structure comprises a vacuum adsorption hole arranged on the rotating positioning shaft, and the vacuum adsorption hole is connected to a vacuum pumping device.

3. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: The positioning structure includes a baffle, a support plate and an insert plate which are detachably arranged on the rotating positioning shaft. The baffle is used to block the side edge of the component to be detected in the horizontal direction, the support plate is used to block the lower edge of the component to be detected in the vertical direction, and the insert plate is used to be inserted into the corresponding slot on the component to be detected.

4. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: The detection table is provided with a first vertical slide rail and a second vertical slide rail, the rotation positioning shaft is horizontally arranged between the first vertical slide rail and the second vertical slide rail, and two ends of the rotation positioning shaft are respectively slidably connected to the first vertical slide rail and the second vertical slide rail.

5. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: It also includes an alarm device electrically connected to the control system, and the alarm device is a speaker, a light group, or an audible and visual alarm.

6. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: The six-axis robotic arms are provided with two, and the fixed ends of the two six-axis robotic arms are respectively close to the two ends of the rotation positioning shaft.

7. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: It also includes a display screen electrically connected to the control system, and the display screen is used to display the image captured by the detection camera.

8. The device for adjusting the vision of a welding robot according to claim 1, characterized in that: The control system includes a memory, and the memory is used to store historical file information generated by shooting with the detection camera.

9. A method for adjusting the vision of a welding robot, characterized in that: The device for adjusting the vision of a welding robot as claimed in any one of claims 1 to 8 comprises the following steps: Position the component to be inspected on the rotary positioning shaft; Outputting an opening instruction to the inspection camera through the control system, controlling the inspection camera to open and take pictures of the component to be inspected; The control system outputs a lateral movement command to the six-axis robot arm, so that the six-axis robot arm drives the inspection camera to sweep across the entire range of the component to be inspected positioned on the rotating positioning axis; Output a rotational motion instruction to the rotary positioning shaft through the control system, so that the rotary positioning shaft drives the rotary positioning shaft to rotate; The control system receives the digital image signal generated by the detection camera after shooting, and the control system converts the received digital image signal into an image and displays it on a display screen; Analyzing the digital image signal by a control system to determine whether there is a defective part in the weld on the component to be inspected; If there is no defective part, the test is deemed qualified and displayed on the display screen; If there is a defective part, the test is deemed unqualified and displayed on the display screen, and the alarm device is activated to start the alarm.

10. A method for adjusting the vision of a welding robot according to claim 9, characterized in that: The process of analyzing the digital image signal by a control system to determine whether there is a defective part on the component to be inspected comprises the following steps: Integrating all the digital image signals in the control system to construct an actual three-dimensional model of the component to be inspected; Compare and analyze the actual 3D model of the component to be inspected with the standard 3D model in the database to identify the weld difference value points on the actual 3D model; Separate the weld difference value point on the actual three-dimensional model from the actual three-dimensional model, and calculate the minimum enclosing rectangular area of ​​the weld difference value point; If the minimum enclosing rectangular area of ​​the weld difference value point is less than the preset error threshold, it is determined that the weld difference value point does not belong to a bad part; If the minimum enclosing rectangular area of ​​the weld difference value point is greater than or equal to the preset error threshold, the weld difference value point is judged to be a bad part.

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