Welding detection method

Abstract

The invention discloses a welding detection method. The method comprises the following steps: acquiring an image of a welding area before welding to obtain a physical map, and then drawing a 2D image and a 3D image to obtain first image information; a welding visual inspection platform is used, the obtained first image information is used for analyzing and positioning the position of a welding seam and measuring the height difference between a flat plate and a nut, and automatic alarming is conducted when abnormal data are detected; after welding, a camera is used for collecting images of a welding area, a physical map is obtained, 2D and 3D images are drawn respectively, and second image information is obtained; a welding visual inspection platform is used, the obtained second image information is used for analyzing the position degree of the welding seam, detecting whether the pre-welding position and the welding seam position have deviation or not, whether the deviation range is exceeded or not, whether the appearance of the welding seam is good or not and whether common defects exist or not, second detection information is obtained and displayed on an industrial personal computer, and automatic alarming is conducted when abnormal data are detected; the problems of time and labor consumption and unstable precision in the existing detection technology are solved.

Description

Technical Field

[0001] The invention relates to the field of visual inspection, in particular to a welding inspection method. Background Art

[0002] Welding, also known as fusion, is a manufacturing process and technology that joins metals or other thermoplastic materials such as plastics by heating, high temperature or high pressure. There are many sources of energy for modern welding, including gas flame, arc, laser, electron beam, friction and ultrasound. In addition to being used in factories, welding can also be performed in a variety of environments, such as outdoors, underwater and in space.

[0003] In traditional welding work, the inspection process often relies on manual vision and mechanical tools, which leads to slow inspection speed and low efficiency, especially in large-scale production environments. The accuracy of manual inspection is limited by individual differences, such as vision, experience and fatigue. Due to the welding process, some welding parts may be located in difficult-to-observe positions, which may lead to inconsistency and errors in the inspection results. Summary of the invention

[0004] The purpose of the present invention is to provide a welding detection method to solve the problems of time-consuming, labor-intensive and unstable accuracy in existing detection technologies.

[0005] In order to solve the above technical problems, the present invention is achieved through the following technical solutions: The present invention is a welding detection method, comprising the following steps: S1. After the product to be welded arrives at the inspection position, the camera is triggered to take a photo, and an image of the welding area is collected before welding to obtain a physical image, and then 2D and 3D images are drawn to obtain first image information; S2. Use the welding visual inspection platform to analyze and locate the weld position and measure the height difference between the plate and the nut using the first image information obtained, and collect the production time, product number, production station, whether the inspection is qualified, monitoring item quality threshold, measured parameters, and inspection process and result information to make a table, obtain the first inspection information and display it on the industrial computer, and automatically alarm when abnormal data is detected; S3, after welding, using a camera to collect an image of the welding area, obtain a physical image, draw 2D and 3D images respectively, and obtain second image information; S4. Use the welding visual inspection platform to analyze the weld position using the acquired second image information, detect whether there is a deviation between the pre-welding position and the weld position, whether it exceeds the set deviation range, whether the weld appearance is good or whether there are common defects, collect production time, product number, production station, whether it is qualified, monitoring item quality threshold, measured parameters and inspection process result information, obtain the second inspection information, display it on the industrial computer, and automatically alarm when abnormal data is detected; S5. Record and store the first and second detection information in a local database, which can be viewed using Microsoft Excel / PDF after export.

[0006] Preferably: in step S1, the product to be welded is a nut plate.

[0007] Preferably: in the step S2, the welding visual inspection platform includes welding visual inspection software, a camera assembly, a visual light source and a computer.

[0008] Preferably: in steps S2 and S4, the detection accuracy is higher than 0.2 mm.

[0009] Preferably, in step S4, common defects include surface pores, weld penetration, undercut, collapse and weld nodules.

[0010] Compared with the prior art, the present invention has the following beneficial effects: 1. In the present invention, the weld can be quickly scanned and analyzed by an automated visual inspection system, significantly improving the inspection speed and production efficiency; 2. In the present invention, the visual camera combined with advanced image processing software can provide high-precision detection results, reduce human errors, and ensure the consistency of detection results; 3. In the present invention, visual inspection can access weld locations that are difficult to observe, ensuring that all critical areas are properly inspected; 4. In the present invention, by using visual detection, the need for operators to directly contact dangerous environments can be reduced, thereby improving work safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 This is a schematic diagram of a single welding hole on the surface of a nut plate before welding in the present invention; Figure 2 It is a schematic diagram of the welding hole on the surface of the nut plate after welding in the present invention; Figure 3 This is a schematic diagram of 2D photography and detection of welding holes before welding by the visual camera in the present invention; Figure 4 This is a schematic diagram of 3D photography and detection of welding holes before welding by the visual camera in the present invention; Figure 5 This is a schematic diagram of 2D photography and detection of the weld position after welding of the welding hole by the visual camera in the present invention; Figure 6 2D, 3D and physical schematic diagrams of qualified products after welding in the present invention; Figure 7 2D, 3D and physical schematic diagrams of unqualified products after welding detected in the present invention; Figure 8 This is a schematic diagram of the main page of the welding visual inspection software in the present invention; Fig. 9 This is a schematic diagram of the program setting page of the welding visual inspection software in the present invention; Fig.10 This is a schematic diagram of the parameter setting page of the welding visual inspection software in the present invention; Fig.11 This is a schematic diagram of the switching product page of the welding visual inspection software in the present invention; Fig.12 It is a schematic diagram of the unqualified level recording page of the welding visual inspection software in the present invention. DETAILED DESCRIPTION

[0012] 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.

[0013] See also Figure 1-12 , the figure shows that the present invention is a welding detection method, comprising the following steps; S1. After the product to be welded arrives at the inspection position, the camera is triggered to take a photo, and an image of the welding area is collected before welding to obtain a physical image, and then 2D and 3D images are drawn to obtain first image information; S2. Use the welding visual inspection platform to analyze and locate the weld position and measure the height difference between the plate and the nut using the first image information obtained, and collect the production time, product number, production station, whether the inspection is qualified, monitoring item quality threshold, measured parameters, and inspection process and result information to make a table, obtain the first inspection information and display it on the industrial computer, and automatically alarm when abnormal data is detected; S3, after welding, using a camera to collect an image of the welding area, obtain a physical image, draw 2D and 3D images respectively, and obtain second image information; S4. Use the welding visual inspection platform to analyze the weld position using the acquired second image information, detect whether there is a deviation between the pre-welding position and the weld position, whether it exceeds the set deviation range, whether the weld appearance is good or whether there are common defects, collect production time, product number, production station, whether it is qualified, monitoring item quality threshold, measured parameters and inspection process result information, obtain the second inspection information, display it on the industrial computer, and automatically alarm when abnormal data is detected; S5. Record and store the first and second detection information in a local database, which can be viewed using Microsoft Excel / PDF after export.

[0014] Specifically, in step S1, the product to be welded is a nut plate, and the welding method is laser welding.

[0015] Among them, in step S2, the welding vision inspection platform includes welding vision inspection software, camera components, visual light sources, computers and corresponding auxiliary equipment, such as camera communications, power cords, industrial control cabinets and visual part mounting brackets.

[0016] Specifically, in steps S2 and S4, the detection accuracy is higher than 0.2 mm.

[0017] It can be understood that in step S4, common defects include surface pores, weld penetration, undercut, collapse and weld nodules.

[0018] In the specific application of this embodiment, pre-welding and post-welding inspections are installed on a three-axis machine tool, and the inspection system is modified to match the machine tool program. The inspection system traceability software can collect inspection process information and inspection result information in real time, and can query the photographic results of each part before and after welding, and prompt the qualified and unqualified positions. The records must include monitoring item quality thresholds and measured parameters to facilitate comparative analysis. The traceability file is saved in the local database and can be viewed using Microsoft Excel / PDF after export.

[0019] It should be added that, as shown in the attached drawings of the specification, Figure 3-Figure 7 The perspective camera capture and detection images shown, where color difference is set in the 3D image to clearly describe the detection content, and green marking lines are set in the 2D detection image to indicate the distance difference.

[0020] In addition, as shown in the accompanying drawings Figure 8 As shown, the current interface is the main interface, which displays the camera picture. The left side is the 2D camera window interface, and the right side is the 3D camera window interface. The current interface will display the current photo results, photo data, current product number, location number, function number, etc.

[0021] Instruction Manual Fig. 9 In the figure, the A area is the visual program selection. The A box contains four detection programs of the camera, 1 is the height detection program, 2 is the positioning guidance program, 4 is the 3D post-weld detection program, and 3 is the reserved 2D post-weld detection program. The area selected in Zone B is the communication point, and the B box is for displaying and modifying the communication point, including the product number, function number, and location number; The area selected in the C box is the main visual program. By selecting different detection programs in the A box, the corresponding visual program will appear in the C window; The area selected in zone D is 1 simulation picture path, the simulation detection path of the picture; The selected area in zone E is for light source settings, manual light switch, and manual adjustment of light source brightness.

[0022] Instruction Manual Fig.10 In the middle, it is the parameter setting interface: the parameter setting is divided into four groups of parameters, the first group is the height detection step difference parameters, the second group is the upper and lower limit parameters of the guided detection displacement, the third group is the reserved program 2D ​​post-weld detection distance parameters, and the fourth group is the upper and lower limit parameters of the weld area after 3D welding.

[0023] Instruction Manual Fig.11 In the middle, it is for product selection and switching. On the left, you can select the product you want to switch or delete. Currently, product selection and type switching can only be done manually. On the right, you can add products.

[0024] Instruction Manual Fig.12 In the middle, it is the NG record interface, which records all NG situations: any subsequent problems can be traced back.

[0025] After inspection, the test results show that the position of the weld before welding can be detected, the height difference between the plate and the nut before welding can be detected, and the weld position after welding can be detected. It should be added that since the camera detection range is only ±5mm (standard working distance 100mm), the height deviation of the product incoming material cannot exceed ±2mm, otherwise the weld may not be imaged because it exceeds the detection range.

[0026] For visual inspection, specifically, the camera is installed vertically, with the distance from the bottom of the camera to the inspection surface being 100 mm, the light source is installed on the bottom of the camera, and the upper end of the light source is 5 mm from the bottom of the camera. The camera configuration parameters are shown in the following table: The above content is a further detailed description of the present invention in combination with specific implementation methods. It cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as belonging to the scope of protection determined by the claims submitted for the present invention.

Claims

1. A welding detection method, characterized in that: The method comprises the following steps: S1. After the product to be welded arrives at the inspection position, the camera is triggered to take a photo, and an image of the welding area is collected before welding to obtain a physical image, and then 2D and 3D images are drawn to obtain first image information; S2. Use the welding visual inspection platform to analyze and locate the weld position and measure the height difference between the plate and the nut using the first image information obtained, and collect the production time, product number, production station, whether the inspection is qualified, monitoring item quality threshold, measured parameters, and inspection process and result information to make a table, obtain the first inspection information and display it on the industrial computer, and automatically alarm when abnormal data is detected; S3, after welding, using a camera to collect an image of the welding area, obtaining a physical image, drawing 2D and 3D images respectively, and obtaining second image information; S4. Use the welding visual inspection platform to analyze the weld position using the acquired second image information, detect whether there is a deviation between the pre-welding position and the weld position, whether it exceeds the set deviation range, whether the weld appearance is good or whether there are common defects, collect production time, product number, production station, whether it is qualified, monitoring item quality threshold, measured parameters and inspection process result information, obtain the second inspection information, display it on the industrial computer, and automatically alarm when abnormal data is detected; S5. Record and store the first and second detection information in a local database, which can be viewed using Microsoft Excel / PDF after export.

2. The welding detection method according to claim 1, characterized in that: In the step S1, the product to be welded is a nut plate.

3. The welding detection method according to claim 1, characterized in that: In step S2, the welding vision inspection platform includes welding vision inspection software, a camera component, a visual light source and a computer.

4. The welding detection method according to claim 1, characterized in that: In the steps S2 and S4, the detection accuracy is higher than 0.2 mm.

5. The welding detection method according to claim 1, characterized in that: In step S4, common defects include surface pores, weld penetration, undercut, collapse and weld nodules.

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