Pipeline all-position welding system and method based on visual perception

Abstract

The invention discloses a pipeline all-position welding system and method based on visual perception, the system comprises a pipeline, a moving device, a welding facility and a welding master control system, the moving device is arranged on the pipeline, and the moving device comprises a moving trolley and magnetic type universal wheels; the magnetic type universal wheels are arranged at the four corners of the lower portion of the movable trolley, a welding facility is arranged on the movable trolley and comprises a clamp, a welding gun, a gas cylinder and a welding power source, the clamp is fixedly arranged on the movable trolley, the welding gun is fixedly arranged on the clamp, the gas cylinder is connected with the welding gun through a hose, and the welding power source is connected with the gas cylinder. The welding power source is electrically connected with the welding gun. According to the pipeline all-position welding system and method based on visual perception, real-time welding, real-time analysis, real-time detection and timely repair are achieved, and the welding efficiency and quality are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of welding robots, and in particular to a pipeline all-position welding system and method based on visual perception. Background Art

[0002] Welding robots are industrial robots that perform welding (including cutting and spraying). According to the definition of the International Organization for Standardization that industrial robots belong to standard welding robots, industrial robots are multi-purpose, reprogrammable automatic control manipulators with three or more programmable axes used in the field of industrial automation. In order to adapt to different uses, the mechanical interface of the last axis of the robot is usually a connecting flange that can be connected to different tools or end effectors. The welding robot is an industrial robot with a welding tongs or welding (cutting) gun installed on the end axis flange, so that it can perform welding, cutting or thermal spraying.

[0003] When welding some small-diameter pipes, due to the large curvature and large variation in welding position, small-diameter pipes have a greater impact on automatic welding and are more prone to defects such as lack of fusion and porosity. The requirements for base welding are higher, and defects can only be discovered through testing after welding is completed, which seriously affects welding efficiency and quality. The defect location and type cannot be fed back in real time, and welding repair requires cleaning of the weld at the defective location, wasting welding materials and welding efficiency and increasing welding costs. In particular, the lack of fusion defect at the root requires cleaning of the weld of the entire wall thickness at the defective location. After cleaning, burrs and flash will still exist on the inner wall of the pipe, which is prone to secondary defects. Summary of the invention

[0004] The technical solution of the present invention aims at the technical problem that the existing technical solutions are too single, and provides a solution that is significantly different from the existing technologies. Specifically, the purpose of the present invention is to provide a pipeline all-position welding system and method based on visual perception, so as to solve the problem that small-diameter pipelines have a large curvature and a large variation in welding position, which has a greater impact on automatic welding and is more prone to defects such as lack of fusion and pores. The requirements for the base weld are higher, and defects can only be discovered through inspection after welding is completed, which seriously affects the welding efficiency and welding quality, and the defect location and type cannot be fed back in real time.

[0005] To achieve the above object, the present invention provides the following technical solution: a pipeline all-position welding system based on visual perception, the system comprising: A welding robot comprises a pipeline, a mobile device, welding facilities and a welding master control system, wherein the mobile device is arranged on the pipeline, the mobile device comprises a mobile trolley and magnetic universal wheels, the magnetic universal wheels are arranged at four corners below the mobile trolley, the mobile trolley is provided with welding facilities, the welding facilities comprise a clamp, a welding gun, a gas cylinder and a welding power source, the clamp is fixedly arranged on the mobile trolley, the welding gun is fixedly arranged on the clamp, the gas cylinder and the welding gun are connected by a hose, and the welding power source and the welding gun are arranged to be electrically connected.

[0006] Furthermore, the system also includes a weld scanning device, which is arranged on the mobile trolley, and the weld scanning device includes a first device bracket and a weld scanning probe, the weld scanning probe can be extended and retracted according to the weld height, and the weld scanning probe is used to collect the molten pool image during the welding process.

[0007] Furthermore, the system also includes a pre-weld scanning device, which is arranged on the mobile trolley. The pre-weld scanning device includes a second device bracket and a 360° rotating detection probe, and the 360° rotating detection probe is used to collect the groove surface image.

[0008] Furthermore, the gas cylinder is provided with a gas flow and composition detection device, and the gas flow and composition detection device is used to detect the composition and flow of the protective gas.

[0009] Furthermore, the system also includes a laser scanning detection device, which is arranged on the mobile vehicle. The laser scanning detection device includes a third bracket and a laser scanning probe, and the laser scanning probe is used to scan the weld model composed of the pipeline groove and the welding area.

[0010] A pipeline all-position welding method based on visual perception comprises the following steps: S1. Accumulate the process database of robot welding of pipes of corresponding sizes in the welding master control system; S2. Control the pre-weld scanning device to move to the vicinity of the pipe groove through the welding master control system, collect the groove surface image by using the 360° rotating detection probe, and then collect the image of the inner wall of the pipe end by bending the end of the 360° rotating detection probe; S3. The pre-welding scanning device transmits the collected images to the welding master control system, and the quality of the groove surface and the inner wall of the pipe end is judged by manual work. If there are defects such as burrs, gaps and flash, they are manually cleaned. If not, proceed to the next step; S4. Then the mobile trolley is controlled by the welding master control system to move on the pipeline, and the images of the groove and inner wall of the pipeline at each position are collected by the pre-welding scanning device until the defects such as burrs, notches and flashes at each position are cleaned up; S5. First, manually spot weld the pipe ports and grind the spot weld positions to make them smooth. At the same time, scan the entire weld bead using a laser scanning detection device. S6. Use the welding master control system to control the gas cylinder to test the gas, and use the gas flow and composition detection device to detect whether the gas in the gas cylinder meets the welding requirements. If not, replace it; S7. After the preparation work is completed, the welding master control system controls the welding power supply, the mobile trolley, the gas cylinder, the pre-welding scanning device and the weld scanning device to start. The welding master control system calls the accumulated pipeline robot welding process and adjusts the welding power supply to output the corresponding welding current and voltage. The welding master control system then controls the moving speed of the mobile trolley; S8. The pre-welding scanning device collects the molten pool image during the welding process and transmits it to the welding master control system. The weld scanning device collects the weld image after welding and transmits it to the welding master control system. The welding master control system extracts the image data and combines manual analysis to analyze and find out the defects of the weld and realize positioning; S9. The mobile trolley moves along the pipeline for one circle and returns to the starting point along the original route. During the process of the mobile trolley returning to the starting point, the weld scanning device scans the weld again and confirms the defects. After the weld defects are found, the welding master control system controls all systems to stop working and wait for manual repair. After the repair is completed, the welding master control system controls all equipment to continue welding according to the welding process again until all welding is completed.

[0011] Compared with the prior art, the present invention has the following beneficial effects: The present invention is provided with a mobile trolley and a magnetic universal wheel at the bottom, which can adjust the curvature of the mobile trolley according to the curvature of the pipeline, ensuring that the mobile trolley is approximately parallel to the pipeline, which is convenient for welding with a welding gun and data collection by a scanning device; The present invention is provided with a pre-welding scanning device, and uses a 360° rotating detection probe to collect the image of the groove surface, and then collects the image of the inner wall of the pipe end by bending the end of the 360° rotating detection probe, so as to judge the quality of the groove surface and the inner wall of the pipe end. If there are defects such as burrs, notches and flashes, manual cleaning is performed, and if not, the next step is performed, thereby eliminating the minor defects caused by processing and grinding at the pipe groove and the inner wall of the pipe end, and reducing the probability of generating unfused defects; The present invention is provided with a gas flow and composition detection device, and uses the welding master control system to control the gas cylinder to test the gas, thereby strengthening the detection of the gas output from the gas cylinder and reducing the probability of generating pore defects; The present invention is provided with a laser scanning detection device, which scans the entire weld bead, and establishes a weld bead model consisting of a pipeline groove and a welding area in a welding master control system. After each layer is welded, the laser scanning detection device scans and detects the entire weld bead again. According to the scanning detection data, a weld bead is filled in the weld bead model, and the welding master control system performs real-time weld bead arrangement adjustment and welding process adjustment according to the remaining welding area, thereby reducing defects such as lack of fusion and lack of penetration, and improving welding quality. In summary, the present invention realizes real-time welding, real-time analysis, real-time detection, and timely repair, thereby improving welding efficiency and quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic structural diagram of the welding robot of the present invention.

[0013] In the figure: 1. Pipeline; 2. Mobile trolley; 3. Magnetic universal wheel; 4. Weld scanning device; 5. Clamp; 6. Welding gun; 7. Pre-weld scanning device; 8. 360° rotating detection probe; 9. Weld scanning probe; 10. Gas cylinder; 11. Gas flow and composition detection device; 12. Welding power supply; 13. Welding master control system; 14. Laser scanning detection device 14; 15. Laser scanning detection probe. DETAILED DESCRIPTION

[0014] 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 described embodiments 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.

[0015] See also Figure 1 The present invention provides a technical solution: a pipeline all-position welding system based on visual perception, the system comprising: A welding robot comprises a pipeline 1, a mobile device, welding facilities and a welding master control system 13. The mobile device is arranged on the pipeline 1. The mobile device comprises a mobile trolley 2 and magnetic universal wheels 3. The magnetic universal wheels 3 are arranged at four corners below the mobile trolley 2. The mobile trolley 2 is provided with welding facilities. The welding facilities comprise a clamp 5, a welding gun 6, a gas cylinder 10 and a welding power source 12. The clamp 5 is fixedly arranged on the mobile trolley 2. The welding gun 6 is fixedly arranged on the clamp 5. The gas cylinder 10 and the welding gun 6 are connected by a hose. The welding power source 12 and the welding gun 6 are arranged to be electrically connected.

[0016] The system also includes a weld scanning device 4, which is arranged on the mobile trolley 2, and the weld scanning device 4 includes a first device bracket and a weld scanning probe 9. The weld scanning probe 9 can be extended and retracted according to the weld height, and the weld scanning probe 9 is used to collect the molten pool image during the welding process.

[0017] The system also includes a pre-welding scanning device 7, which is arranged on the mobile vehicle 2. The pre-welding scanning device 7 includes a second device bracket and a 360° rotating detection probe 8, and the 360° rotating detection probe 8 is used to collect the groove surface image.

[0018] The gas cylinder 10 is provided with a gas flow and composition detection device 11, which is used to detect the composition and flow of the protective gas.

[0019] The system also includes a laser scanning detection device 14, which is arranged on the mobile vehicle 2. The laser scanning detection device 14 includes a third bracket and a laser scanning probe 15. The laser scanning probe 15 is used to scan the weld model composed of the pipeline groove and the welding area.

[0020] A pipeline all-position welding method based on visual perception comprises the following steps: S1. Accumulate the corresponding size pipeline robot welding process database 1 in the welding master control system 13; S2. The pre-welding scanning device 7 is moved to the vicinity of the groove of the pipe 1 by the welding master control system 13, and the groove surface image is collected by the 360° rotating detection probe 8, and then the image of the inner wall of the end of the pipe 1 is collected by bending the end of the 360° rotating detection probe 8; S3. The pre-welding scanning device 7 transmits the collected image to the welding master control system 13, and combines manual work to determine the quality of the groove surface and the inner wall of the end of the pipe 1. If there are defects such as burrs, notches and flash, manual cleaning is performed. If not, the next step is performed; S4. Then the mobile trolley 2 is controlled by the welding master control system 13 to move on the pipeline 1, and the pre-welding scanning device 7 is used to collect the groove of the pipeline 1 and the inner wall image of the pipeline 1 at each position until the burrs, notches and flash defects at each position are cleaned up; S5. First, the ports of the pipeline 1 are manually spot welded and fixed, and the spot welding positions are polished to make a smooth transition. At the same time, the entire weld is scanned by the laser scanning detection device 14, and a weld model consisting of the groove of the pipeline 1 and the welding area is established in the welding master control system 13. After each layer of welding, the laser scanning detection device 14 scans and detects the entire weld again. According to the scanning detection data, a weld is filled in the weld model. The welding master control system 13 adjusts the weld arrangement and welding process in real time according to the remaining welding area, thereby reducing defects such as lack of fusion and lack of penetration, and improving welding quality; S6. The welding master control system 13 is used to control the gas cylinder 10 for gas testing, and the gas flow and composition detection device 11 detects whether the gas in the gas cylinder 10 can meet the welding requirements, and if not, replace it; S7. After the preparation work is completed, the welding master control system 13 controls the welding power supply 12, the mobile trolley 2, the gas cylinder 10, the pre-welding scanning device 7 and the weld scanning device 4 to start, the welding master control system 13 calls the accumulated pipeline 1 robot welding process, and adjusts the welding power supply 12 to output the corresponding welding current and voltage, and the welding master control system 13 controls the travel speed of the mobile trolley 2, thereby controlling the welding speed; S8. The pre-welding scanning device 7 collects the molten pool image during the welding process and transmits it to the welding master control system 13. The weld scanning device 4 collects the image of the weld after welding and transmits it to the welding master control system 13. The welding master control system 13 extracts the image data and combines it with manual analysis to analyze and find out the defects of the weld and realize positioning; S9. The mobile carriage 2 moves along the pipeline 1 for one circle and returns to the starting point along the original route. During the process of the mobile carriage 2 returning to the starting point, the weld scanning device 4 scans the weld again and confirms the defects. After the weld defects are found, the welding master control system 13 controls all systems to stop working and wait for manual repair. After the repair is completed, the welding master control system 13 controls all equipment to continue welding according to the welding process again until all welding is completed.

[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. A pipeline all-position welding system based on visual perception, characterized in that: The system comprises: A welding robot comprises a pipeline (1), a mobile device, a welding facility and a welding master control system (13), wherein the mobile device is arranged on the pipeline (1), the mobile device comprises a mobile trolley (2) and magnetic universal wheels (3), the magnetic universal wheels (3) are arranged at four corners below the mobile trolley (2), the mobile trolley (2) is provided with a welding facility, the welding facility comprises a clamp (5), a welding gun (6), a gas cylinder (10) and a welding power source (12), the clamp (5) is fixedly arranged on the mobile trolley (2), the welding gun (6) is fixedly arranged on the clamp (5), the gas cylinder (10) and the welding gun (6) are connected via a hose, and the welding power source (12) and the welding gun (6) are arranged to be electrically connected.

2. The visual perception-based pipeline all-position welding system according to claim 1 is characterized in that: The system further comprises a weld scanning device (4), the weld scanning device (4) being arranged on the mobile trolley (2), and the weld scanning device (4) comprising a first device bracket and a weld scanning probe (9), the weld scanning probe (9) being extendable and retractable according to the weld height, and the weld scanning probe (9) being used to collect a molten pool image during the welding process.

3. The visual perception-based pipeline all-position welding system according to claim 1, characterized in that: The system further comprises a pre-welding scanning device (7), wherein the pre-welding scanning device (7) is arranged on the mobile trolley (2), and the pre-welding scanning device (7) comprises a second device bracket and a 360° rotating detection probe (8), wherein the 360° rotating detection probe (8) is used to collect an image of the groove surface.

4. The visual perception-based pipeline all-position welding system according to claim 1, characterized in that: The gas cylinder (10) is provided with a gas flow and composition detection device (11), and the gas flow and composition detection device (11) is used to detect the composition and flow of the protective gas.

5. The visual perception-based pipeline all-position welding system according to claim 1 is characterized in that: The system further comprises a laser scanning detection device (14), wherein the laser scanning detection device (14) is arranged on the mobile vehicle (2), and the laser scanning detection device (14) comprises a third bracket and a laser scanning probe (15), wherein the laser scanning probe (15) is used to scan a weld bead model composed of a pipeline groove and a welding area.

6. A pipeline all-position welding method based on visual perception, used in a pipeline all-position welding system based on visual perception as claimed in any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Accumulating a process database of robot welding of corresponding size pipes (1) in the welding master control system (13); S2. Control the pre-welding scanning device (7) to move to the vicinity of the groove of the pipeline (1) through the welding master control system (13), collect the surface image of the groove by using the 360° rotating detection probe (8), and then collect the image of the inner wall of the end of the pipeline (1) by bending the end of the 360° rotating detection probe (8); S3. The pre-welding scanning device (7) transmits the collected image to the welding master control system (13), and manually determines the quality of the groove surface and the inner wall of the end of the pipe (1). If there are defects, they are manually cleaned. If not, proceed to the next step; S4. Then, the mobile trolley (2) is controlled by the welding master control system (13) to move on the pipeline (1), and the pre-welding scanning device (7) is used to collect images of the groove of each position of the pipeline (1) and the inner wall of the pipeline (1) until the defects at each position are cleaned; S5. First, the pipe (1) port is manually fixed by spot welding, and the spot welding position is polished to a smooth transition, and the entire weld is scanned by a laser scanning detection device (14); S6. Using the welding master control system (13) to control the gas cylinder (10) to test the gas, and using the gas flow and composition detection device (11) to detect whether the gas in the gas cylinder (10) can meet the welding requirements, and if not, replace it; S7. After the preparation work is completed, the welding master control system (13) controls the welding power supply (12), the mobile trolley (2), the gas cylinder (10), the pre-welding scanning device (7) and the weld scanning device (4) to start, the welding master control system (13) calls the accumulated pipeline (1) robot welding process, and adjusts the welding power supply (12) to output the corresponding welding current and voltage, and the welding master control system (13) then controls the travel speed of the mobile trolley (2); S8. The pre-welding scanning device (7) collects the molten pool image during the welding process and transmits it to the welding master control system (13). The weld scanning device (4) collects the weld image after welding and transmits it to the welding master control system (13). The welding master control system (13) finds and locates the defects of the weld by image extraction and analysis. S9. The mobile carriage (2) moves along the pipeline (1) for one circle and returns to the starting point along the original route. During the process of the mobile carriage (2) returning to the starting point, the weld scanning device (4) scans the weld again and confirms the defects. After the weld defects are found, the welding master control system (13) controls all systems to stop working and wait for manual repair. After the repair is completed, the welding master control system (13) controls all equipment to continue welding according to the welding process again until all welding is completed.

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