Visual wire feeding welding detection and auxiliary wire feeding method
The relative relationship between the welding wire head from the laser light point is detected by a visual sensor and wire feeding compensation is performed, which solves the problem of inaccurate wire feeding in the welding process and improves the welding effect and product yield.
Patent Information
- Application Number
- CN202411734035.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-29
- Publication Date
- 2025-02-28
AI Technical Summary
In the welding process, due to the gap between the welding wire and the pipe and the twisting of the shape of the wire tube during wire feeding, the wire feeding distance is inaccurate, which can easily lead to the inability to be sent out or sent to the incorrect position, affecting the welding effect.
The visual wire feed welding detection and auxiliary wire feeding method are used to detect the relative relationship between the welding wire head from the laser light point through a visual sensor, and determine whether it is within the allowable error range. If it is inaccurate, wire feed compensation will be performed, and the wire head will be automatically adjusted to the accurate position.
Effectively detect whether the welding wire is sent to the correct position, and automatically assist in adjusting the welding wire head, which improves the effect of wire feed welding and product yield, avoids the problem of poor welding.
Smart Images
Figure CN119525632A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the field of welding equipment, and in particular to a method for visual wire feeding welding detection and auxiliary wire feeding. Background Art
[0002] In the welding process requirements of some workpieces, wire feeding is often required to meet the requirements of some products with wider welds. However, when feeding the wire, there is often a certain gap between the welding wire and the pipe, and the wire tube is a soft tube. As the posture of the laser welding head changes during processing, the shape of the wire tube will also be twisted and changed, resulting in the wire feeding distance not being as expected.
[0003] However, if the wire tube is designed to be thinner so that there is no gap at all between it and the welding wire, it is easy for the welding wire to be unable to be delivered or even blocked in the wire tube, making it impossible to accurately deliver the welding wire to the laser light output point, and failing to achieve the expected filler wire welding effect, resulting in poor welding effect on the workpiece, increased defective product rate, and increased production and processing costs. Summary of the invention
[0004] To solve the above problems, the present invention provides a method for visual wire feeding welding detection and assisted wire feeding, including a method for visually detecting whether the welding wire is delivered to the welding light position before welding light is emitted, and a method for automatically assisting in delivering the welding wire to the expected position when it is not in the expected position, thereby improving the wire feeding welding effect and product yield.
[0005] According to one aspect of the present invention, a method for visual wire feeding welding detection and auxiliary wire feeding is provided, which acts on a wire feeding welding device, wherein the wire feeding welding device comprises a multi-axis motion module connected to a control system, a laser welding head, a wire feeder and a visual sensor, wherein the laser welding head is mounted on the multi-axis motion module, the wire feeder feeds the welding wire, the welding wire head passes through the wire tube and is sent to the bottom of the laser welding head, wherein the visual sensor is mounted on the laser welding head and is coaxially mounted with the laser path, the visual sensor is used for collection and detection, and the accurate welding position is the laser light emitting point; it is characterized in that: it comprises the following steps
[0006] 1) Mark the laser light output point on the visual system;
[0007] 2) Use a visual sensor to obtain the relative position of the welding wire head from the laser light output point;
[0008] 3) The above relative relationship is transmitted back to the control system to determine whether it is within the allowable error range, wherein if the wire feeding is inaccurate, step 4) is executed, and if the wire feeding is accurate, jump to step 5);
[0009] 4) Enter wire feeding compensation and move the wire head to the correct position;
[0010] 5) Start wire feeding welding.
[0011] In some embodiments, in step 1), the motor used by the wire feeder is a servo motor, and the visual sensor is a visual camera. The benefit is that the motor used by the wire feeder includes but is not limited to a servo motor, and the visual sensor includes but is not limited to a visual camera, and the above-mentioned devices can be selected from suitable types as needed.
[0012] In some embodiments, the control system can handle visual recognition, machine control and wire feeding control simultaneously. It is beneficial to describe the specific functions of the control system.
[0013] In some embodiments, the control system can communicate with the vision recognition and / or wire feed control system. It is beneficial to describe another arrangement of the control system, which can also effectively control various processes.
[0014] In some embodiments, in step 3), when it is determined that the distance from the welding wire head to the laser light-emitting point is not greater than the allowable error range, the wire feeding is accurate. The benefit thereof is that a method for determining accurate wire feeding is described.
[0015] In some embodiments, in step 3), when it is determined that the distance from the welding wire head to the laser light-emitting point is greater than the allowable error range, the wire feeding is inaccurate. The benefit of this is that a method for determining inaccurate wire feeding is described.
[0016] In some embodiments, in step 3), a flag indicating that the welding wire head has not reached or exceeded the laser light-emitting point is also transmitted back to the control system. The benefit of this is that the specific content that needs to be transmitted back is further described.
[0017] In some embodiments, in step 4), when entering wire feeding compensation, it is determined whether the visually recognized distance exceeds the field of view of the camera. If it is determined to be no, wire feeding compensation continues. If it is determined to be yes, it ends directly. The benefit is that it describes the pre-steps for entering wire feeding compensation. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 A flow chart of a method for visual wire feeding welding detection and auxiliary wire feeding implemented in the present invention;
[0019] Figure 2 for Figure 1 The flowchart for judging the wire feeding situation is shown;
[0020] Figure 3 for Figure 1 The schematic diagram shows the situation when the distance from the welding wire head to the laser light-emitting point is not greater than the allowable error range;
[0021] Figure 4 for Figure 1 The schematic diagram shows the situation when the distance from the welding wire head to the laser light-emitting point is greater than the allowable error range;
[0022] Figure 5 for Figure 1 Flow chart of wire feed compensation is shown. DETAILED DESCRIPTION
[0023] The present invention will be further described in detail below in conjunction with the accompanying drawings.
[0024] The method includes a wire feeding welding device, which includes a multi-axis motion module, a laser welding head, a wire feeder and a visual sensor. The laser welding head is installed on the multi-axis motion module, and the welding wire sent out from the wire feeder passes through the wire tube and is sent to the bottom of the laser welding head for welding.
[0025] In addition, the visual sensor is installed on the laser welding head, and the visual sensor needs to be installed coaxially with the laser path of the laser welding head, so as to collect and detect the surroundings of the laser welding head. The accurate welding position is assumed to be the laser light-emitting point.
[0026] Among them, all the above structures are connected to the control system, and the control system can simultaneously handle visual recognition, machine control and wire feeding control.
[0027] Preferably, other processing systems may be configured to process visual identification and / or wire feeding control, and the control system can communicate with these processing systems using appropriate industrial communication methods, and thus can also effectively control each process.
[0028] Preferably, the motor used by the wire feeder includes but is not limited to a servo motor, etc., and the visual sensor includes but is not limited to a visual camera, etc., and the above-mentioned devices can be selected into appropriate types according to needs.
[0029] like Figure 1 As shown, the method includes several main steps, which are described as follows.
[0030] First, start the processing, mark the laser light output point on the visual system, and capture and identify the visual image information containing the welding wire in the camera image.
[0031] Then, visual recognition detection is performed through a visual sensor, and the relative relationship between the welding wire head and the laser light output point is obtained using the visual sensor, and the wire feeding situation is judged in combination with a pre-set allowable error range.
[0032] like Figure 2As shown, when judging the wire feeding situation, the welding wire is first identified to determine whether the welding wire is identified. If it is, the next step is executed. If it is not, the process ends directly, and then a visual inspection is performed to determine the situation of the welding wire head to determine whether the welding wire head "does not reach" or "exceeds" the laser light-emitting point.
[0033] Then, the relative relationship between the welding wire head and the laser light-emitting point is transmitted back to the control system to determine whether it is within the allowable error range. If it is judged to be no, the wire feeding is inaccurate, and if it is judged to be yes, the wire feeding is accurate.
[0034] In addition, the flags of "not reached" or "exceeded" are also sent back to the control system;
[0035] like Figure 3-4 As shown, the wire L in the figure is the welding wire, the arrow direction is the wire feeding direction, the center point O in the figure is the laser light output point, and the dotted circle is the allowable error range.
[0036] When it is determined that the distance from the welding wire head to the laser light-emitting point is not greater than the allowable error range, the wire feeding is accurate; when it is determined that the distance from the welding wire head to the laser light-emitting point is greater than the allowable error range, the wire feeding is inaccurate. Then, according to the distance value detected by vision, it is determined again whether the current wire feeding does not reach the laser light-emitting point or exceeds the laser light-emitting point. Figure 4 (a) is the situation when the current wire feeding does not reach the laser light-emitting point. Figure 4 (b) is the situation where the current wire feeding exceeds the laser light-emitting point.
[0037] Finally, based on the judgment result, a wire feeding instruction is issued to the wire feeder. When the judgment result is that the wire feeding is accurate, the laser welding head is moved to the welding starting point and wire feeding welding is started. When the judgment result is that the wire feeding is inaccurate, the wire feeding compensation process is entered.
[0038] like Figure 5 As shown, when entering the wire feeding compensation process, first determine whether the visually recognized distance exceeds the camera's field of view. If it is judged to be no, execute the next step, and if it is judged to be yes, end directly; then, according to the set wire feeding speed, visually recognized distance value, direction and other related parameters, issue a servo incremental wire feeding movement instruction, and the wire head can be moved according to the instruction.
[0039] After the wire feeding compensation process, the wire head can be moved to the exact position, and then the laser welding head can be moved to the welding starting point to start wire feeding welding.
[0040] The method of visual wire feeding welding detection and auxiliary wire feeding in the present invention mainly has the following beneficial effects:
[0041] 1. It can effectively detect whether the welding wire has been delivered to the welding light position before welding light;
[0042] 2. When it is detected that the welding wire has not been delivered to the expected welding light position, it can automatically assist in delivering the welding wire to the position;
[0043] 3. Avoid the problem of poor welding of products caused by welding when the welding wire is not delivered to the expected position;
[0044] 4. Improved the wire feeding welding effect and product yield.
[0045] The above are only some embodiments of the present invention. For those skilled in the art, several modifications and improvements can be made without departing from the creative concept of the present invention, which all belong to the protection scope of the present invention.
Claims
1. A method for visual wire feeding welding detection and auxiliary wire feeding, which acts on a wire feeding welding device, wherein the wire feeding welding device includes a multi-axis motion module, a laser welding head, a wire feeder and a visual sensor, all of which are connected to a control system. The laser welding head is mounted on the multi-axis motion module, the wire feeder feeds the welding wire, and the welding wire head passes through a wire tube and is sent to the bottom of the laser welding head, wherein: The visual sensor is installed on the laser welding head and coaxially with the laser path. The visual sensor is used for collection and detection. The accurate welding position is the laser light point; it is characterized by: comprising the following steps 1) Mark the laser light output point on the visual system; 2) Use a visual sensor to obtain the relative position of the welding wire head from the laser light output point; 3) The above relative relationship is transmitted back to the control system to determine whether it is within the allowable error range, wherein if the wire feeding is inaccurate, step 4) is executed, and if the wire feeding is accurate, jump to step 5); 4) Enter wire feeding compensation and move the wire head to the correct position; 5) Start wire feeding welding.
2. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 1, characterized in that: The motor used by the wire feeder is a servo motor, and the visual sensor is a visual camera.
3. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 1, characterized in that: The control system can handle vision recognition, machine control and wire feeding control simultaneously.
4. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 1, characterized in that: The control system can communicate with the vision recognition and / or wire feed control systems.
5. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 1, characterized in that: In step 3), when it is determined that the distance from the welding wire head to the laser light-emitting point is not greater than the allowable error range, the wire feeding is accurate.
6. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 5, characterized in that: In step 3), when it is determined that the distance from the welding wire head to the laser light-emitting point is greater than the allowable error range, the wire feeding is inaccurate.
7. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 5, characterized in that: In step 3), a flag indicating that the welding wire head has not reached or has exceeded the laser light-emitting point is also transmitted back to the control system.
8. A method for visual wire feeding welding detection and auxiliary wire feeding according to claim 1, characterized in that: In step 4), when entering wire feeding compensation, determine whether the visual recognition distance exceeds the field of view of the camera. If it is judged to be no, continue with wire feeding compensation. If it is judged to be yes, end directly.