Automatic welding photoelectric contact type welding seam tracking detection system

Abstract

The invention discloses an automatic welding photoelectric contact type welding seam tracking detection system, which relates to the technical field of welding seam tracking monitoring and comprises a photoelectric sensor, an image acquisition unit, an image processing module, a control module, an execution module, a human-computer interaction interface module, an error feedback module and a wireless communication storage module, the photoelectric sensor adopts a photosensitive device 3Du silicon phototriode for receiving far infrared light as a sensing element and is used for measuring the contour, depth and position of a welding seam in real time, and welding seam information is obtained by emitting light beams and detecting reflected light. According to the method, uncertainty and nonlinearity of parameters in the complex welding process can be effectively dealt with through combination of fuzzy control and PID control, a flexible and powerful control strategy is provided for optimizing the welding parameters, the control module synthesizes an image processing result, the welding parameters are adjusted in real time through the PID and fuzzy control strategy, and the welding quality is improved. Therefore, the welding stability and quality are kept.

Description

Technical Field

[0001] The invention relates to the technical field of welding seam tracking and monitoring, in particular to an automatic welding photoelectric contact type weld seam tracking and detection system. Background Art

[0002] With the rapid development of high-tech science and technology, the scientific and technological revolution has brought about an industrial technological revolution, which has prompted the rapid development of industrial welding production technology. Modern welding technology is both efficient and energy-saving, environmentally friendly and intelligent. It has gradually replaced the backward traditional manual welding. In modern industrial welding production, most companies use manual and semi-automatic welding methods. The welding environment is harsh, and on-site workers are susceptible to high labor intensity, sub-health and other problems. At the same time, manual welding is more dependent on workers' experience, which can easily lead to weld formation failure and poor weld joint quality, causing some production losses to the company.

[0003] At present, traditional weld tracking detection is affected by the environment and it is difficult to accurately capture the details of the weld. Rust, welding slag and oil stains are prone to exist on the surface of the material, which may affect the accuracy of image processing and positioning algorithms. In addition, image processing cannot meet the requirements of high-speed welding in terms of real-time performance and has poor adaptability to different types of welds. Summary of the invention

[0004] The purpose of the present invention is to provide an automatic welding photoelectric contact weld tracking and detection system to solve the problems proposed in the above background technology that traditional weld tracking and detection is affected by the environment, it is difficult to accurately capture the details of the weld, rust, welding slag and oil stains are easily present on the surface of the material, which may affect the accuracy of image processing and positioning algorithms, and the image processing cannot meet the requirements of high-speed welding in terms of real-time performance and has poor adaptability to different types of welds.

[0005] To achieve the above-mentioned object, the present invention provides the following technical solutions: an automatic welding photoelectric contact weld seam tracking detection system, comprising a photoelectric sensor, an image acquisition unit, an image processing module, a control module, an execution module, a human-computer interaction interface module, an error feedback module and a wireless communication storage module; The photoelectric sensor uses a 3Du silicon phototransistor as a sensor element, which is a photosensitive device that receives far-infrared light, and is used to measure the profile, depth and position of the weld in real time, and obtain weld information by emitting a light beam and detecting reflected light; The image acquisition unit is used to capture images of the weld area during welding through a camera for subsequent image analysis; The image processing module is used to identify and analyze the weld image, extract weld features and perform position identification; The control module is used to control the working state of the welding equipment in real time according to the output result of the image processing module; The execution module is used to receive system control instructions and forward them to the execution mechanism, and perform dynamic adjustments according to the instructions of the control system; The human-machine interaction interface module is used to provide a display screen for monitoring and operation, and operators can view real-time data, parameter settings and status feedback; The error feedback module is used to monitor the deviation in the welding process in real time and provide timely feedback to the control system; The wireless communication storage module is used to provide a factory internal network connection, realize remote monitoring and maintenance of welding equipment, and establish a local database to store real-time data during the welding process.

[0006] Preferably, the photoelectric sensor arranges four 3Du tubes in a receiving tube holder according to the height y-axis and the horizontal x-axis, wherein two 3Du tubes on the x-axis provide horizontal signals and two 3Du tubes on the y-axis provide height signals.

[0007] Preferably, the image acquisition unit includes an industrial camera, a signal processing module and a data transmission module; The industrial camera is used to capture images or videos during the welding process; The signal processing module is used to convert the analog signal collected by the camera into a digital signal and transmit it to the computer or processing unit; The data transmission module is used to transmit the collected image data to the image processing unit or the control system.

[0008] Preferably, the image processing module includes image preprocessing, feature extraction, weld identification and positioning, and real-time data processing modules; The image preprocessing is used to remove noise in the image using a median filtering algorithm, improve image quality, and perform contrast enhancement processing on the image; The feature extraction is used to extract edge information of the weld using the Canny edge detection algorithm to identify the contour of the weld; The weld seam identification and positioning is used to separate the weld seam area from the background through image segmentation, and to analyze the extracted weld seam contour to determine the geometric features of the weld seam; The real-time data processing module is used for real-time feedback and data recording during the welding process.

[0009] Preferably, the control module includes a control algorithm, a data acquisition and analysis module and a communication interface; The control algorithm adopts a combination of PID control and fuzzy control, uses fuzzy logic to adjust PID parameters, and uses a proportional-integral-differential control algorithm to adjust welding parameters to achieve optimization of steady-state and dynamic performance; The data acquisition and analysis module collects real-time data of the welding process and trains and learns historical welding data through a convolutional neural network algorithm to optimize future welding parameters and process control; The communication interface is used to exchange data with the image processing module through a high-speed communication protocol to obtain real-time weld information, and to connect with a host computer or cloud system to achieve connection with a host monitoring system or production management system to support remote monitoring and management.

[0010] Preferably, the fusion control strategy of PID control and fuzzy control in the control algorithm includes implementation control and feedback control; The implementation control is used to apply the adjusted PID parameters to the control of the welding process and monitor the welding status in real time; The feedback control is used to continuously adjust the fuzzy control rules and PID parameters according to the feedback of the welding process during the control process to form a closed-loop control.

[0011] Preferably, the human-computer interaction interface module includes an interface display interaction module, a status indication alarm module, a data input and export module and a user management module; The interface display interaction module is used for multi-terminal device interface display and provides dynamic interaction between the user and the interface; The status indication alarm module is used to monitor the working status of the welding equipment in real time and the abnormal conditions during the welding process in real time, and to prompt the user to handle the situation through sound and light prompts or pop-up window alarms; The data input and export module is used to provide control data input and data export functions; The user management module supports multi-user login, setting different user permissions, and synchronously recording user operation history.

[0012] Preferably, the error feedback module includes an error detection module, a feedback processing module and a record analysis module; The error detection module performs judgment by setting thresholds of key parameters to detect potential errors; After detecting an error, the feedback processing module promptly notifies the operator through an audible and visual alarm and tracks the processing results; The record analysis module is used to automatically record the occurrence time, type, severity and related parameters of each error event.

[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. In the present invention, the combination of fuzzy control and PID control can effectively cope with the uncertainty and nonlinearity of parameters in complex welding processes, and provides a flexible and powerful control strategy for optimizing welding parameters. The control module integrates the results of image processing and uses PID and fuzzy control strategies to adjust welding parameters in real time to maintain welding stability and quality.

[0014] 2. In the present invention, the photoelectric sensor and the image acquisition unit work together to obtain the contour, depth and position of the weld in real time, and the captured image is preprocessed, feature extracted and weld identified to extract accurate weld data, improve the accuracy of subsequent feature extraction, and achieve precise control of welding.

[0015] 3. In the present invention, the instructions of the control module are efficiently converted into execution actions to ensure the accurate implementation of the welding process, which can quickly respond to the adjustment of the control system, improve the overall flexibility of the system, provide an intuitive interface, make it easy for operators to understand and operate efficiently, and timely feedback the status and abnormal information of the welding equipment to reduce operational risks. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The present invention is a system block diagram of an automatic welding photoelectric contact weld seam tracking and detection system.

[0017] In the figure: 1. Photoelectric sensor; 2. Image acquisition unit; 3. Image processing module; 31. Image preprocessing; 32. Feature extraction; 33. Weld seam identification and positioning; 34. Real-time data processing module; 4. Control module; 41. Control algorithm; 42. Data acquisition and analysis module; 43. Communication interface; 5. Execution module; 6. Human-computer interaction interface module; 7. Error feedback module; 8. Wireless communication storage module. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the implementation regulations described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] Reference Figure 1 As shown: an automatic welding photoelectric contact weld seam tracking detection system, including a photoelectric sensor 1, an image acquisition unit 2, an image processing module 3, a control module 4, an execution module 5, a human-computer interaction interface module 6, an error feedback module 7 and a wireless communication storage module 8; The photoelectric sensor 1 uses a 3Du silicon phototransistor as a sensing element, which is a photosensitive device that receives far-infrared light. It is used to measure the profile, depth and position of the weld in real time, and obtains weld information by emitting a light beam and detecting reflected light. It can obtain specific information of the weld by emitting a light beam and detecting reflected light, and provide high-precision weld position data; Among them, the photoelectric sensor 1 arranges four 3Du tubes in the receiving tube holder according to the height y-axis and the horizontal x-axis, of which two on the x-axis provide horizontal signals and two on the y-axis provide height signals; The image acquisition unit 2 is used to capture the image of the weld area during the welding process through a camera for subsequent image analysis; specifically, it includes an industrial camera, a signal processing module and a data transmission module; Industrial cameras are used to capture images or videos of the welding process; The signal processing module is used to convert the analog signal collected by the camera into a digital signal and transmit it to the computer or processing unit to ensure fast and accurate data transmission; The data transmission module is used to transmit the collected image data to the image processing unit or the control system; The image processing module 3 is used to identify and analyze the weld image, extract weld features and perform position recognition; specifically, it includes image preprocessing 31, feature extraction 32, weld recognition and positioning 33 and real-time data processing module 34; The image preprocessing 31 is used to remove noise in the image using a median filtering algorithm to improve the image quality, and to perform contrast enhancement processing on the image to enhance the contrast of the image and improve the accuracy of subsequent processing; Feature extraction 32 is used to extract edge information of the weld using a Canny edge detection algorithm to identify the contour of the weld; Weld seam identification and positioning 33 is used to separate the weld seam area from the background through image segmentation, and analyze the extracted weld seam contour to determine the geometric features of the weld seam to ensure accurate identification of its position; The real-time data processing module 34 is used for real-time feedback and data recording during the welding process to ensure the timeliness of the data; The control module 4 is used to control the working state of the welding equipment in real time according to the output result of the image processing module; specifically, it includes a control algorithm 41, a data acquisition and analysis module 42 and a communication interface 43; Control algorithm 41 adopts a combination of PID control and fuzzy control, uses fuzzy logic to adjust PID parameters, and uses proportional-integral-differential control algorithm to adjust welding parameters to achieve steady-state and dynamic performance optimization. The combination of fuzzy control and PID control can effectively deal with the uncertainty and nonlinearity of parameters in complex welding processes, providing a flexible and powerful control strategy for optimizing welding parameters; Among them, the integrated control strategy of PID control and fuzzy control includes implementation control and feedback control; The implementation control is used to apply the adjusted PID parameters to the control of the welding process and monitor the welding status in real time; Feedback control is used to continuously adjust the fuzzy control rules and PID parameters according to the feedback of the welding process during the control process to form a closed-loop control; The data acquisition and analysis module 42 performs real-time data acquisition of the welding process and trains and learns historical welding data through a convolutional neural network algorithm to optimize future welding parameters and process control; The communication interface 43 is used to exchange data with the image processing module through a high-speed communication protocol to obtain real-time weld information, and to connect with a host computer or a cloud system to achieve connection with a host monitoring system or a production management system to support remote monitoring and management; The execution module 5 is used to receive system control instructions and forward them to the execution mechanism, and perform dynamic adjustments according to the instructions of the control system; The human-machine interaction interface module 6 is used to provide a display screen for monitoring and operation, so that the operator can view real-time data, parameter settings and status feedback, thereby improving the operator's convenience; specifically, it includes an interface display interaction module, a status indication alarm module, a data input and export module and a user management module; The interface display interaction module is used for multi-terminal device interface display and provides dynamic interaction between users and the interface; The status indication alarm module is used to monitor the working status of the welding equipment in real time and abnormal conditions during the welding process in real time. It also prompts the user to handle the problem through sound and light prompts or pop-up window alarms to ensure the safety of the equipment. The data input and export module is used to provide control data input and data export functions; The user management module supports multi-user login, setting different user permissions, and synchronously recording user operation history The error feedback module 7 is used to monitor the deviation in the welding process in real time and provide timely feedback to the control system; specifically, it includes an error detection module, a feedback processing module and a record analysis module; The error detection module sets thresholds for key parameters to detect potential errors. After the feedback processing module detects an error, it promptly notifies the operator through sound and light alarms and tracks the processing results; The record analysis module is used to automatically record the occurrence time, type, severity and related parameters of each error event; The wireless communication storage module 8 is used to provide a factory internal network connection, realize remote monitoring and maintenance of welding equipment, and establish a local database to store real-time data during the welding process.

[0020] The usage method and working principle of the present invention are as follows: the photoelectric sensor and the image acquisition unit work together to obtain the contour, depth and position of the weld in real time, and the captured image is subjected to preprocessing, feature extraction and weld identification processing to extract accurate weld data. The control module integrates the results of image processing and uses PID and fuzzy control strategies to adjust the welding parameters in real time to maintain the stability and quality of welding. Through the human-computer interaction interface, the operator can monitor the real-time status and parameter settings of the welding and respond in time. The error feedback module monitors the deviation in the welding process and notifies the operator in time to handle it. The wireless communication storage module supports remote monitoring and data storage of the system to ensure the safe transmission and storage of information. By integrating photoelectric measurement, image processing and intelligent control technology, efficient and intelligent weld tracking and detection can be achieved, and the level of automation and intelligence in the welding process can be improved.

[0021] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An automatic welding photoelectric contact weld seam tracking detection system, characterized in that: It comprises a photoelectric sensor (1), an image acquisition unit (2), an image processing module (3), a control module (4), an execution module (5), a human-computer interaction interface module (6), an error feedback module (7) and a wireless communication storage module (8); The photoelectric sensor (1) uses a 3Du silicon phototransistor as a sensing element, which is a photosensitive device for receiving far-infrared light, and is used to measure the profile, depth and position of the weld in real time, and obtains weld information by emitting a light beam and detecting reflected light; The image acquisition unit (2) is used to capture images of the weld area during the welding process through a camera for subsequent image analysis; The image processing module (3) is used to identify and analyze the weld image, extract weld features and perform position identification; The control module (4) is used to control the working state of the welding equipment in real time according to the output result of the image processing module; The execution module (5) is used to receive system control instructions and forward them to the execution mechanism, and perform dynamic adjustments according to the instructions of the control system; The human-machine interaction interface module (6) is used to provide a display screen for monitoring and operation, so that operators can view real-time data, parameter settings and status feedback; The error feedback module (7) is used to monitor the deviation in the welding process in real time and provide timely feedback to the control system; The wireless communication storage module (8) is used to provide a factory internal network connection, realize remote monitoring and maintenance of welding equipment, and establish a local database to store real-time data during the welding process.

2. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The photoelectric sensor (1) arranges four 3D tubes in a receiving tube holder according to the height y-axis and the horizontal x-axis, wherein two 3D tubes on the x-axis provide horizontal signals and two on the y-axis provide height signals.

3. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The image acquisition unit (2) comprises an industrial camera, a signal processing module and a data transmission module; The industrial camera is used to capture images or videos during the welding process; The signal processing module is used to convert the analog signal collected by the camera into a digital signal and transmit it to the computer or processing unit; The data transmission module is used to transmit the collected image data to the image processing unit or the control system.

4. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The image processing module (3) comprises image preprocessing (31), feature extraction (32), weld seam identification and positioning (33) and a real-time data processing module (34); The image preprocessing (31) is used to remove noise in the image using a median filtering algorithm, improve image quality, and perform contrast enhancement processing on the image; The feature extraction (32) is used to extract edge information of the weld using a Canny edge detection algorithm to identify the contour of the weld; The weld seam identification and positioning (33) is used to separate the weld seam area from the background by image segmentation, and to analyze the extracted weld seam contour to determine the geometric features of the weld seam; The real-time data processing module (34) is used for real-time feedback and data recording during the welding process.

5. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The control module (4) comprises a control algorithm (41), a data acquisition and analysis module (42) and a communication interface (43); The control algorithm (41) combines PID control with fuzzy control, uses fuzzy logic to adjust PID parameters, and uses a proportional-integral-differential control algorithm to adjust welding parameters to achieve optimization of steady-state and dynamic performance; The data acquisition and analysis module (42) performs real-time data acquisition on the welding process, and trains and learns historical welding data through a convolutional neural network algorithm to optimize future welding parameters and process control; The communication interface (43) is used to exchange data with the image processing module through a high-speed communication protocol to obtain real-time weld information, and to connect with a host computer or a cloud system to achieve connection with a host monitoring system or a production management system, supporting remote monitoring and management.

6. The automatic welding photoelectric contact weld seam tracking detection system according to claim 5, characterized in that: The fusion control strategy of PID control and fuzzy control in the control algorithm (41) includes implementation control and feedback control; The implementation control is used to apply the adjusted PID parameters to the control of the welding process and monitor the welding status in real time; The feedback control is used to continuously adjust the fuzzy control rules and PID parameters according to the feedback of the welding process during the control process to form a closed-loop control.

7. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The human-computer interaction interface module (6) comprises an interface display interaction module, a status indication alarm module, a data input and export module and a user management module; The interface display interaction module is used for multi-terminal device interface display and provides dynamic interaction between the user and the interface; The status indication alarm module is used to monitor the working status of the welding equipment in real time and abnormal conditions during the welding process in real time, and prompt the user to handle the situation through sound and light prompts or pop-up window alarms; The data input and export module is used to provide control data input and data export functions; The user management module supports multi-user login, setting different user permissions, and synchronously recording user operation history.

8. The automatic welding photoelectric contact weld seam tracking detection system according to claim 1, characterized in that: The error feedback module (7) comprises an error detection module, a feedback processing module and a record analysis module; The error detection module performs judgment by setting thresholds of key parameters to detect potential errors; After detecting an error, the feedback processing module promptly notifies the operator through an audible and visual alarm and tracks the processing results; The record analysis module is used to automatically record the occurrence time, type, severity and related parameters of each error event.

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