Real-time remote welding operation image acquisition system

Abstract

The invention relates to the technical field of welding, in particular to a real-time remote welding operation image collection system which comprises an operation table, an image collection unit and an audio collector are arranged on the operation table, and the image collection unit is used for collecting operation images when a test piece is welded; the audio collector is used for collecting audio when the test piece is welded; the tracking adjusting mechanism is connected with the image acquisition unit and is used for adjusting the position of the image acquisition unit, so that the image acquisition unit can track and shoot along with the welding position of the test piece; the synchronous adjusting unit is connected with the image acquisition unit and the audio acquisition unit. The transmission adjusting mechanism is used for carrying out synchronous processing on images acquired by the image acquisition unit and audios acquired by the audio acquisition unit. The problems that in existing welding image collection, picture shooting of a welding pool is not clear and not accurate, delay exists when network live broadcast is conducted on welding images, sound and pictures are not synchronous, and real-time network live broadcast training cannot be conducted are solved.

Description

Technical Field

[0001] The present invention relates to the field of welding technology, and in particular to a real-time remote welding operation image acquisition system. Background Art

[0002] When conducting remote welding technology training or real-time observation of the welding process during welding production, it is necessary to collect and transmit the welding images in real time. Especially when observing the welding process of narrow gap deep welds, it is necessary to observe the shape and dynamics of the molten pool in real time to determine whether welding defects are formed. If defects are found, they need to be repaired immediately.

[0003] Currently, cameras are mostly used for capturing welding images. Due to the presence of strong visible light during the welding process and the continuous movement of the weld point position and welding equipment during the welding process, fixed-position cameras are unable to capture the welding molten pool and operation images clearly, timely and accurately. At the same time, due to the high transmission rate of welding image video and network delays, online live training cannot be achieved. Summary of the invention

[0004] The present invention proposes a real-time remote welding operation image acquisition system to solve the problems of unclear and inaccurate welding pool images in existing welding image acquisition, as well as the delay in live broadcasting of welding images on the Internet, which leads to asynchrony of audio and video and makes it impossible to conduct real-time live broadcast training on the Internet.

[0005] According to one aspect of the present invention, a real-time remote welding operation image acquisition system is provided, comprising: an operation console, an image acquisition unit, an audio collector, a tracking adjustment mechanism, and a synchronization adjustment unit; The image acquisition unit and the audio collector are arranged on the operating table, the image acquisition unit is used to acquire the operation image when welding the test piece, and the audio collector is used to acquire the audio when welding the test piece; The tracking adjustment mechanism is connected to the image acquisition unit, and the tracking adjustment mechanism is used to adjust the position of the image acquisition unit so that it can track and shoot along with the welding position of the test piece; The synchronization adjustment unit is connected to the image acquisition unit and the audio collector respectively, and the transmission adjustment mechanism is used to synchronously process the image acquired by the image acquisition unit and the audio acquired by the audio collector.

[0006] Preferably, the image acquisition unit comprises: a high-definition molten pool camera, a first camera, a second camera and a third camera; The high-definition molten pool camera is connected to the tracking adjustment mechanism, and the high-definition molten pool camera is used to capture a real-time microscopic image of the molten pool when the test piece is subjected to a welding operation, and the tracking adjustment mechanism is used to adjust the position of the high-definition molten pool camera so that it can follow the molten pool for mobile shooting; The first camera is used to capture the main-view image of the welding operation, the second camera is used to capture the top-view image of the welding operation, and the third camera is used to capture the left-view image of the welding operation.

[0007] Preferably, the tracking adjustment mechanism comprises: a telescopic bracket, a support, a guide rail, a stepping motor, a gear, a toothed plate and a control unit; The guide rail is fixed on the operating table, and the weld of the guide rail and the test piece are parallel to each other; The rack is located inside the guide rail, the support is located above the guide rail, and the bottom of the support is connected to the top of the rack near one end; The top of the support is connected to one end of the telescopic bracket, and the other end of the telescopic bracket is connected to the image acquisition unit; The output shaft of the stepper motor is connected to the gear, and the gear is meshed with the rack; The control unit is connected to the stepper motor and the telescopic bracket respectively, and is used to start adjusting the position of the image acquisition unit by controlling the stepper motor and / or the telescopic bracket to achieve tracking and shooting of the welding position of the test piece.

[0008] Preferably, the control unit comprises: a controller; The controller is used to control the stepping motor and / or the telescopic bracket to start and drive the image acquisition unit to move along the guide rail at a predetermined speed during welding; The predetermined speed is the moving speed of the equipment during welding.

[0009] Preferably, the control unit comprises: a light sensor and a controller; The light sensor is installed on one end of the telescopic bracket close to the image acquisition unit, the light sensor is connected to the controller, and the light sensor is used to collect the real-time light intensity signal of the test piece during welding and transmit it to the controller; The controller is used to determine that when the real-time light intensity signal is less than a predetermined light intensity signal, control the stepper motor and / or the telescopic bracket to start driving the image acquisition unit to move in a predetermined direction until the real-time light intensity signal is greater than or equal to the predetermined light intensity signal.

[0010] Preferably, the synchronization adjustment unit includes: a video collector and a director station; The video collector is connected to the image acquisition unit, and the director station is connected to the video collector and the audio collector respectively; The video collector is used to convert, decode and store the welding operation images collected by the image collection unit, and transmit them to the director's station. The director's station is used to synchronously process the received welding operation images and audio and then transmit them to several terminal devices in real time through the network.

[0011] Preferably, it also includes: a smoke exhaust fan; The smoke exhaust fan is arranged on the operating table and is located at one end of the test piece close to the welding end point. The blowing direction of the smoke exhaust fan is opposite to the welding direction.

[0012] Preferably, it also includes: a UV filter; The lens of the high-definition molten pool camera is provided with the UV filter for filtering visible stray light.

[0013] Preferably, it also includes: a fill light; The fill light comprises a magnetic base, and the magnetic base is connected to the lamp holder through a bendable metal tube; The magnetic base is fixed on the operating table by magnetic adsorption, and the lamp head is located above the test piece.

[0014] The present invention has at least the following beneficial effects: The present invention proposes a real-time remote welding operation image acquisition system. By setting a tracking adjustment mechanism, the image acquisition unit can track and shoot the welding position, thereby realizing real-time acquisition of the molten pool micro-welding image; by setting a synchronization adjustment unit, the collected image and audio are synchronously transmitted, thereby realizing real-time network broadcast of remote welding operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The accompanying drawings herein are incorporated into and constitute a part of the specification. These drawings illustrate embodiments consistent with the present invention and, together with the specification, are used to explain the technical solutions of the present invention.

[0016] Figure 1 A schematic structural diagram of a real-time remote welding operation image acquisition system according to an embodiment of the present invention is shown.

[0017] In the figure, 1-operating table, 2-high-definition molten pool camera, 3-first camera, 4-second camera, 5-third camera, 6-support, 7-guide rail, 8-horizontal telescopic bracket, 9-vertical telescopic bracket, 10-fan, 11-test piece, 12-weld. Implementation

[0018] Various exemplary embodiments, features and aspects of the present invention will be described in detail below with reference to the accompanying drawings. The same reference numerals in the accompanying drawings represent elements with the same or similar functions. Although various aspects of the embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless otherwise specified.

[0019] The word “exemplary” is used exclusively herein to mean “serving as an example, example, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0020] The term "and / or" herein is only a description of the association relationship of the associated objects, indicating that there may be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the term "at least one" herein represents any combination of at least two of any one or more of a plurality of. For example, including at least one of A, B, and C can represent including any one or more elements selected from the set consisting of A, B, and C.

[0021] In addition, in order to better illustrate the present invention, numerous specific details are provided in the following specific embodiments. It should be understood by those skilled in the art that the present invention can be implemented without certain specific details. In some examples, methods, means, components and circuits well known to those skilled in the art are not described in detail in order to highlight the subject matter of the present invention.

[0022] Figure 1 FIG. 2 is a schematic diagram showing the structure of a real-time remote welding operation image acquisition system according to an embodiment of the present invention. Figure 1 As shown, a real-time remote welding operation image acquisition system includes: an operating table, an image acquisition unit, an audio collector, a tracking adjustment mechanism and a synchronization adjustment unit; the image acquisition unit and the audio collector are arranged on the operating table, the image acquisition unit is used to collect the operation image when the test piece is welded, and the audio collector is used to collect the audio when the test piece is welded; the tracking adjustment mechanism is connected to the image acquisition unit, and the tracking adjustment mechanism is used to adjust the position of the image acquisition unit so that it can track and shoot along with the welding position of the test piece; the synchronization adjustment unit is respectively connected to the image acquisition unit and the audio collector, and the transmission adjustment mechanism is used to synchronously process the image collected by the image acquisition unit and the audio collected by the audio collector.

[0023] In the embodiment of the present invention, before performing the welding operation, it is first necessary to find a convenient welding position on the operating table, and perform spot welding reinforcement on the test piece to be welded, wherein the plate test piece is spot welded at both ends, and the spot welding welding material is selected to be consistent with the formal weld welding material. The plate test piece needs to be deformed 3°, and the pipe test piece needs to be spot welded at 3 locations.

[0024] When welding, start the image acquisition unit and the audio collector. After the image acquisition unit is started, it will collect the molten pool image during welding, the main view, top view, and left view images of the welding operation, and transmit them to the synchronous adjustment unit in real time; start the tracking adjustment mechanism, and the tracking adjustment mechanism drives the image acquisition unit to track and shoot as the welding point moves. After the audio collector is started, it will collect the sound during welding and the real-time voice of the on-site operator and transmit them to the synchronous adjustment unit.

[0025] After receiving the image collected by the image acquisition unit and the audio collected by the audio collector, the synchronization adjustment unit synchronizes the image and the audio and transmits them to each terminal through the network for live broadcast.

[0026] In the present invention, the image acquisition unit includes: a high-definition molten pool camera, a first camera, a second camera and a third camera; the high-definition molten pool camera is connected to the tracking and adjustment mechanism, the high-definition molten pool camera is used to capture a real-time microscopic image of the molten pool when the specimen is subjected to a welding operation, and the tracking and adjustment mechanism is used to adjust the position of the high-definition molten pool camera so that it can move and shoot following the molten pool; the first camera is used to capture the main perspective image of the welding operation, the second camera is used to capture the top-down perspective image of the welding operation, and the third camera is used to capture the left perspective image of the welding operation.

[0027] In an embodiment of the present invention, the initial position of the high-definition molten pool camera is directly above the welding starting point of the specimen and corresponds to the weld position. The high-definition molten pool camera is started. During welding, the operator holds the welding equipment and moves from the welding starting point of the specimen along the weld toward the end point. The high-definition molten pool camera takes a bird's-eye view of the molten pool during welding below. While the welding equipment is moving, the tracking and adjustment mechanism starts to drive the high-definition molten pool camera to move with the welding equipment, so that the microscopic image of the molten pool at the welding point can be tracked and photographed in real time. Among them, the pixel resolution of the high-definition molten pool camera is 1920x1080, and the resolution reaches 60 frames per second under full-screen natural light, and can reach 120 frames per second under an external fill light of 10W, supporting black and white line arrays.

[0028] The first camera, the second camera and the third camera are mainly used to collect the operator's operating posture, welding rod angle and swing amplitude. The camera can be selected from Huawei 360 cameras. Among them, the three cameras need to be able to clearly capture the angle between the welding rod and the parallel surface of the test piece (90°), the angle between the welding rod and the weld (30°~80°), and the welding operator's hands movements. The three cameras are fixed by corresponding three-axis adjustable straight arms, so that their position angles can be adjusted. Among them, the first camera is located opposite the operator, and the lens is facing the front of the operator, so that the operator's hand movements and welding images when operating from the front can be captured from the main perspective; the second camera is located above the operator, with the lens facing down, and the welding image is captured from a bird's-eye view, which can present the angle image between the welding rod and the weld; the third camera is located on the left side of the operator, with the lens facing the operator and the side of the test piece, so that the welding image can be captured from the left perspective, which can present the angle image between the welding rod and the parallel surface of the test piece.

[0029] The first camera, the second camera and the third camera are respectively fixed by corresponding clamping arms. The clamping arms are made of aluminum alloy and have a 3-axis adjustable function. The angle is 360 degrees and the adjustment range is a spherical diameter of 1.2-1.5 meters. It can be perpendicular to any plane.

[0030] In the present invention, the tracking and adjustment mechanism includes: a telescopic bracket, a support, a guide rail, a stepping motor, a gear, a rack bar and a control unit; the guide rail is fixed on the table top of the operating table, and the guide rail and the weld of the specimen are parallel to each other; the rack is inside the guide rail, and the support is above the guide rail, and the bottom of the support is connected to the top of the rack near one end; the top of the support is connected to one end of the telescopic bracket, and the other end of the telescopic bracket is connected to the image acquisition unit; the output shaft of the stepping motor is connected to the gear, and the gear is meshed with the rack; the control unit is respectively connected to the stepping motor and the telescopic bracket, and the control unit is used to start adjusting the position of the image acquisition unit by controlling the stepping motor and / or the telescopic bracket to achieve tracking and shooting of the welding position of the specimen.

[0031] In an embodiment of the present invention, the telescopic bracket includes a vertical telescopic bracket and a horizontal telescopic bracket, the bottom end of the vertical telescopic bracket is connected to the top of the support, the top end of the vertical telescopic bracket is connected to one end of the horizontal telescopic bracket, the other end of the horizontal telescopic bracket is connected to a high-definition molten pool camera, the vertical telescopic bracket is perpendicular to the top surface of the support, and the horizontal telescopic bracket is above the specimen and perpendicular to the weld of the specimen in the horizontal direction. The vertical telescopic bracket and the horizontal telescopic bracket are respectively connected to a control unit. The vertical telescopic bracket can adjust the height of the high-definition molten pool camera by telescoping, and the horizontal telescopic bracket can drive the high-definition molten pool camera to move back and forth in the horizontal direction, that is, on both sides of the weld of the specimen by telescoping.

[0032] In the initial state, the support is located at one end of the guide rail close to the initial point of the specimen welding. Before shooting, the control unit adjusts the high-definition molten pool camera to a predetermined shooting height through the vertical telescopic bracket, and adjusts the lens of the high-definition molten pool camera to move to just above the weld of the specimen through the horizontal telescopic bracket, and corresponds to the starting point of the weld.

[0033] During tracking shooting, the control unit controls the stepper motor to start and drive the gear to rotate. Since the toothed plate is meshed with the gear, when the gear rotates, it will drive the toothed plate to move along the guide rail, thereby driving the support, telescopic bracket and high-definition molten pool camera to move. The control unit adjusts the movement speed of the high-definition molten pool camera by adjusting the rotation speed of the gear, so that its movement speed is the same as the movement speed of the molten pool during welding; since the guide rail and the weld are parallel to each other, the lens of the high-definition molten pool camera is always above the weld when it moves along the guide rail, and tracks and shoots as the molten pool moves during welding.

[0034] Under the condition of ensuring the clarity of the molten pool image in the shooting picture, the height of the high-definition molten pool camera from the molten pool cannot be too large. When shooting the molten pool image at a close distance, the weld length that can be recorded by the high-definition molten pool camera at a fixed angle can only reach 6-8 cm. For welds longer than 8 cm, the weld position or camera position needs to be adjusted in time, which affects the collection of real-time images of the welding process. The continuity of image recording and transmission during the welding process is achieved by setting a tracking adjustment mechanism.

[0035] In the present invention, the control unit includes: a controller; the controller is used to control the stepper motor and / or the telescopic bracket to start driving the image acquisition unit to move along the guide rail at a predetermined speed during welding; wherein the predetermined speed is the moving speed of the equipment during welding.

[0036] In the embodiment of the present invention, when welding starts, the controller controls the motor to start, drives the gear to rotate at a predetermined speed, the gear drives the rack to move along the guide rail toward the gear, and the rack drives the support seat and the telescopic bracket to move, thereby driving the high-definition molten pool camera to track the movement of the molten pool above the molten pool and shoot. The predetermined speed can be set according to the speed during welding. The speed generally does not change significantly during welding. Even if the speed becomes faster or slower at a certain point, it will not exceed the shooting range of the high-definition molten pool camera, and can meet the needs of automatic tracking shooting.

[0037] In the present invention, the control unit includes: a light sensor and a controller; the light sensor is installed on one end of the telescopic bracket close to the image acquisition unit, the light sensor is connected to the controller, and the light sensor is used to collect the real-time light intensity signal of the test piece during welding and transmit it to the controller; the controller is used to determine when the real-time light intensity signal is less than the predetermined light intensity signal, control the stepper motor and / or the telescopic bracket to start and drive the image acquisition unit to move in a predetermined direction until the real-time light intensity signal is greater than or equal to the predetermined light intensity signal and stops.

[0038] In an embodiment of the present invention, the optical sensor is fixed on a horizontal telescopic bracket and is located close to the high-definition molten pool camera.

[0039] In the initial state, the light sensor is above the welding starting point. When welding starts, the strong light generated at the molten pool is collected by the light sensor above and converted into an electrical signal and transmitted to the controller in real time. The controller determines whether the collected real-time light intensity signal is less than the predetermined light intensity signal. If not, it means that the molten pool at the welding point is within the detection range of the light sensor. If the detection range of the light sensor is less than the shooting range of the high-definition molten pool camera, it means that the molten pool is also within the shooting range of the high-definition molten pool camera. As the welding equipment moves, the position of the molten pool changes and gradually moves out of the detection range of the light sensor. When the controller determines that the real-time light intensity signal detected by the light sensor is less than the predetermined light intensity signal, it means that the molten pool is about to move out of the shooting range of the high-definition molten pool camera. Then the controller controls the stepper motor to start, driving the high-definition molten pool camera and the light sensor to move along the weld toward the molten pool. When the light sensor gradually moves to the top of the molten pool, the controller determines that the real-time light intensity signal will be greater than or equal to the predetermined light intensity signal, and the controller controls the stepper motor to turn off.

[0040] Through the controller and light sensor, the high-definition molten pool camera can be controlled to automatically track the molten pool in real time during the welding process. Even if there is a speed change or pause during the welding process, the real-time molten pool image can be captured continuously and accurately.

[0041] In the present invention, the synchronization adjustment unit includes: a video collector and a director's station; the video collector is connected to the image acquisition unit, and the director's station is respectively connected to the video collector and the audio collector; the video collector is used to convert, decode and store the welding operation image acquired by the image acquisition unit, and transmit it to the director's station, and the director's station is used to synchronize the received welding operation image with the audio and transmit it to a number of terminal devices in real time through the network.

[0042] In an embodiment of the present invention, the synchronization processing is: if the terminal device is a domestic network connection terminal device, the audio is transmitted with a delay of 1-1.5s; if the terminal device is a foreign network connection terminal device, the audio is transmitted with a delay of 2-3.25s.

[0043] The video collector is connected to the high-definition molten pool camera, the first camera, the second camera, the third camera and the audio collector respectively. The HDMI video collector performs secondary conversion on the videos collected by each camera and decodes them through the network monitoring hard disk recording box. After decoding, the video and the audio collected by the audio collector are transmitted to each terminal device through the director's station and the network live broadcast software. Through the terminal device, you can watch the molten pool picture, multi-angle shooting pictures during welding, and listen to the explanation voice of the on-site operator in real time, thereby realizing the training of welding practice during remote online viewing or online teaching.

[0044] The present invention further comprises: a smoke exhaust fan; the smoke exhaust fan is arranged on the operating table and is located at one end of the test piece close to the welding end point, and the blowing direction of the smoke exhaust fan is opposite to the welding direction.

[0045] In the embodiment of the present invention, in order to overcome the influence of metal splash and smoke on the image during welding and improve the quality of the image, a fan is added in the welding area to change the direction of the welding smoke. The fan is set near the welding terminal of the test piece. When welding, the fan is started and the wind blows from the end point of the weld to the initial point, so as to ensure that the picture taken by the camera will not be blurred by the welding smoke and prevent the operator from inhaling the smoke. The air volume of the fan cloth should not be too large to prevent the formation of welding pores and ensure that the welding smoke can be blown away.

[0046] The present invention also includes: a fill light; the fill light includes a magnetic base, and the magnetic base is connected to a lamp holder through a bendable metal tube; the magnetic base is fixed to the operating table through magnetic adsorption, and the lamp holder is located above the test piece.

[0047] In the embodiment of the present invention, the fill light is a 12V / 50W LED light source with a base having a magnetic suction function and a tightening function, and a metal hose connected to the light source can be rotated at any angle, and has the characteristics of no flash and no glare, thereby achieving the purpose of fill light. When fill light is not performed, the live broadcast screen is black due to insufficient brightness, and the molten pool and the parent material can only be seen after the arc is struck. By setting the fill light, the image of the electrode contacting the arc can be presented in real time in the image before welding.

[0048] The present invention also includes: a UV filter; the lens of the high-definition molten pool camera is provided with the UV filter for filtering visible stray light.

[0049] In the embodiment of the present invention, adding a UV filter can obtain sufficiently clear dynamic welding pool images, avoid the influence of harmful factors on image acquisition during welding, and obtain video data that meets the requirements.

[0050] In the embodiment of the present invention, in order to realize the integration of the skill operation platform and the image acquisition unit, the operating table needs to have a welding station with a specification of 4M*2M, which can accommodate 2-3 people. The welding station must have a smoke exhaust and dust removal device, comply with safety and environmental protection regulations, and the lighting must reach 85-90lx. The welding operation platform and the station frame must meet the function of full-position welding of pipes and plates. When welding, turn on the fill light and adjust the position of the molten pool camera through the telescopic bracket to correspond to the starting end of the weld. The high-definition molten pool camera needs to be aligned with the center line of the weld.

[0051] The present invention can meet the welding needs of plate specimens and all-position welding of pipe specimens with a diameter of Ø530mm or more. Originally, the welding of pipes with a diameter of Ø530mm or more was limited by the length of the guide rail, and the camera position needed to be adjusted for every 200-250mm weld. The welding of pipes with a diameter of less than Ø114mm also required manual cooperation. The present invention uses a molten pool camera for the first time to realize molten pool tracking and shooting, which has a huge impact on the fields of engineering construction and remote training.

[0052] It can be understood that the above-mentioned various method embodiments mentioned in the present invention can be combined with each other to form a combined embodiment without violating the principle logic. Due to space limitations, the present invention will not go into details.

[0053] The present invention uses a high-definition molten pool camera to shoot the microscopic state of the welding molten pool, continuously shoots the welding process through a tracking and adjusting mechanism, combines multiple cameras to present macro technical parameters such as welding posture, welding action, and welding rod angle from multiple angles, and combines a director station, a video collector, and a live broadcast software to remotely guide students to perform welding skills operations in real time, thereby realizing online teaching of welding skills operation courses. Welding training includes macro training and micro training. Macro training includes training visible to the naked eye such as equipment operation, welding rod angle, welding posture, grinding method, pairing method, and surface treatment. The most important thing is the perception and feedback processing of the microscopic molten pool state. By mastering the molten pool state, the operating method is changed in time to control the molten pool temperature and the shape of the rod to control the quality of the weld. The present invention uses a high-definition molten pool camera, an ordinary camera, a tracking and adjusting mechanism, a director station, and a network software to form a remote training technology for welders that combines appearance guidance with microscopic molten pool guidance.

[0054] During the trial phase, the present invention conducted joint training cooperation with the Uzbekistan Welding Technical School, and conducted remote welding operation teaching for 400 hours for 14 Uzbek welders. The 14 welders obtained international welder qualifications through third-party assessment. This cooperation was highly praised by the Ministry of Labor of Uzbekistan and reported by mainstream media. Through remote training and technical guidance, welders can master basic welding operation skills, be familiar with operating techniques, understand the essentials and defects of basic test piece groups, improve the overall welding technology level, and solve the problem of low qualification rate during construction. At the same time, the present invention also provides molten pool monitoring for welding rods, arc welding, and surfacing in multiple welding construction unit equipment factories, and the first-time welding qualification rate reaches more than 98%, solving the technical problem of low qualification rate of root welds.

[0055] This invention is used for the first time in China and the industry, laying a foundation and expanding direction for training, construction and teaching. In particular, it can be promoted to various institutions and vocational schools, realizing remote guidance and solutions to welding problems.

[0056] The embodiments of the present invention have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The selection of terms used herein is intended to best explain the principles of the embodiments, practical applications, or technical improvements in the market, or to enable other persons of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

1. A real-time remote welding operation image acquisition system, characterized in that: include: An operating console, an image acquisition unit, an audio collector, a tracking adjustment mechanism, and a synchronization adjustment unit; The image acquisition unit and the audio collector are arranged on the operating table, the image acquisition unit is used to acquire the operation image when welding the test piece, and the audio collector is used to acquire the audio when welding the test piece; The tracking adjustment mechanism is connected to the image acquisition unit, and the tracking adjustment mechanism is used to adjust the position of the image acquisition unit so that it can track and shoot along with the welding position of the test piece; The synchronization adjustment unit is connected to the image acquisition unit and the audio collector respectively, and the transmission adjustment mechanism is used to synchronously process the image acquired by the image acquisition unit and the audio acquired by the audio collector.

2. The real-time remote welding operation image acquisition system according to claim 1 is characterized in that: The image acquisition unit includes: a high-definition molten pool camera, a first camera, a second camera and a third camera; The high-definition molten pool camera is connected to the tracking adjustment mechanism, and the high-definition molten pool camera is used to capture a real-time microscopic image of the molten pool when the test piece is subjected to a welding operation, and the tracking adjustment mechanism is used to adjust the position of the high-definition molten pool camera so that it can follow the molten pool for mobile shooting; The first camera is used to capture the main-view image of the welding operation, the second camera is used to capture the top-view image of the welding operation, and the third camera is used to capture the left-view image of the welding operation.

3. The real-time remote welding operation image acquisition system according to claim 1, characterized in that: The tracking adjustment mechanism includes: a telescopic bracket, a support, a guide rail, a stepping motor, a gear, a toothed plate and a control unit; The guide rail is fixed on the operating table, and the weld of the guide rail and the test piece are parallel to each other; The rack is located inside the guide rail, the support is located above the guide rail, and the bottom of the support is connected to the top of the rack near one end; The top of the support is connected to one end of the telescopic bracket, and the other end of the telescopic bracket is connected to the image acquisition unit; The output shaft of the stepper motor is connected to the gear, and the gear is meshed with the rack; The control unit is connected to the stepper motor and the telescopic bracket respectively, and is used to start adjusting the position of the image acquisition unit by controlling the stepper motor and / or the telescopic bracket to achieve tracking and shooting of the welding position of the test piece.

4. The real-time remote welding operation image acquisition system according to claim 3 is characterized in that: The control unit comprises: a controller; The controller is used to control the stepping motor and / or the telescopic bracket to start and drive the image acquisition unit to move along the guide rail at a predetermined speed during welding; The predetermined speed is the moving speed of the equipment during welding.

5. The real-time remote welding operation image acquisition system according to claim 3 is characterized in that: The control unit includes: a light sensor and a controller; The light sensor is installed on one end of the telescopic bracket close to the image acquisition unit, the light sensor is connected to the controller, and the light sensor is used to collect the real-time light intensity signal of the test piece during welding and transmit it to the controller; The controller is used to determine that when the real-time light intensity signal is less than a predetermined light intensity signal, control the stepper motor and / or the telescopic bracket to start driving the image acquisition unit to move in a predetermined direction until the real-time light intensity signal is greater than or equal to the predetermined light intensity signal.

6. The real-time remote welding operation image acquisition system according to claim 1, characterized in that: The synchronization adjustment unit includes: a video collector and a director station; The video collector is connected to the image acquisition unit, and the director station is connected to the video collector and the audio collector respectively; The video collector is used to convert, decode and store the welding operation images collected by the image collection unit, and transmit them to the director's station. The director's station is used to synchronously process the received welding operation images and audio and then transmit them to several terminal devices in real time through the network.

7. The real-time remote welding operation image acquisition system according to claim 1, characterized in that: Also includes: Smoke exhaust fans; The smoke exhaust fan is arranged on the operating table and is located at one end of the test piece close to the welding end point. The blowing direction of the smoke exhaust fan is opposite to the welding direction.

8. The real-time remote welding operation image acquisition system according to claim 2, characterized in that: Also includes: UV filter; The lens of the high-definition molten pool camera is provided with the UV filter for filtering visible stray light.

9. The real-time remote welding operation image acquisition system according to any one of claims 1 to 8, characterized in that: Also includes: Fill light; The fill light comprises a magnetic base, and the magnetic base is connected to the lamp holder through a bendable metal tube; The magnetic base is fixed on the operating table by magnetic adsorption, and the lamp head is located above the test piece.

Images