Mobile welding robot based on binocular vision rapid teaching and operation method
By using a six-axis welding robot and a binocular vision rapid teaching system, the problems of insufficient flexibility and intelligence of existing welding robots have been solved, enabling efficient welding and easy operation in narrow spaces.
Patent Information
- Application Number
- CN202511176094.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-21
- Publication Date
- 2025-11-07
AI Technical Summary
Existing industrial welding robots lack flexibility and intelligence, making them difficult to apply in large-scale, long-distance, or outdoor scenarios. Furthermore, existing teaching and programming methods are time-consuming and complex.
Employing a six-axis welding robot and a binocular vision rapid teaching system, equipped with a long-necked 22.5° welding torch, combined with an idler wheel remote-controlled vehicle and a binocular measuring instrument, the robot can move flexibly and weld efficiently in narrow spaces, and is rapidly taught through a binocular measuring instrument and a target.
It enables robots to move flexibly and weld efficiently in confined spaces, improving welding efficiency and quality while reducing operational difficulty and personnel skill requirements.
Smart Images
Figure CN120901588A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application relates to a mobile welding robot based on binocular vision rapid teaching and an operation method, and belongs to the technical field of automatic welding. BACKGROUND
[0002] Current industrial welding robot technology mainly faces two challenges: first, most robots are limited to fixed workspaces and lack flexibility; second, most robots rely on teaching programming and lack intelligence. Traditional welding robots are often limited to limited areas within a factory building and are limited by track length and heavy load handling capacity, and are not suitable for large-scale, long-distance or outdoor welding tasks. In addition, existing teaching programming methods, such as teach pendant teaching and virtual reality teaching, although improve work efficiency, still require operators to invest a lot of time and effort, and have limitations for programming complex trajectories, and the prior art lacks a welding robot that can be quickly taught without range restrictions. SUMMARY
[0003] The application provides a mobile welding robot based on binocular vision rapid teaching, which adopts a six-axis welding robot, can stably and efficiently weld for a long time, and improves welding efficiency and welding quality; and is equipped with a long-neck 22.5-degree welding gun, which can improve the welding accessibility.
[0004] Technical scheme: To solve the above technical problems, the mobile welding robot based on binocular vision rapid teaching comprises a carrier, wherein the carrier is provided with a welding robot, a binocular measurement system and an industrial computer, the top of the carrier is provided with the welding robot and the industrial computer, and the welding robot is provided with the binocular measurement system; The carrier comprises a vehicle body, a pair of driving rudders and a pair of universal wheels are arranged at opposite corners of the bottom surface of the vehicle body, a power system compartment is formed in the side surface of the vehicle body, the power system compartment is internally provided with a power system, a warning light is arranged on the front surface of the vehicle body, an ultrasonic distance measuring sensor is arranged below the warning light on the surface of the vehicle body, a collision prevention shield is arranged on one side of the top of the vehicle body, a robot control cabinet and an industrial computer are arranged in the collision prevention shield, a double-layer support is connected to the tail surface of the vehicle body, a welding power supply is arranged on the top of the double-layer support, a gun cleaning and wire cutting station is arranged on the side surface of the welding power supply, and a cooling water tank is arranged in the double-layer support. The welding robot is a six-axis robot, a wire feeder is arranged on the third axis of the welding robot, a welding wire reel is arranged on the first axis of the welding robot, a binocular measuring instrument is arranged on the connecting flange of the sixth axis of the welding robot, and a welding gun is arranged on the sixth axis of the welding robot. The binocular measurement system comprises a binocular measuring instrument and a target, the binocular measuring instrument comprises two infrared cameras, a micro industrial computer and a Bluetooth receiver, and the target comprises a target body, a target ball, an infrared light emitting module, a power module, a trigger switch and a Bluetooth transmitter, the infrared light emitting module is arranged on the two ends and the middle of the target body through screws, the infrared light emitting module is provided with light emitting points on the surface, the target body is provided with two power modules on the back, the target body is connected with a connecting rod through an adapter flange at one end, the connecting rod is connected with the target ball at one end, and the trigger switch is arranged on the side of the target body.
[0005] As preferred, the welding gun is a long neck 22.5° standard welding gun. As preferred, the target body is a square tube made of carbon fiber material, the target ball is a hard alloy ball, the connecting rod and the adapter flange are of an integral structure, and the adapter flange is fixedly connected with the target body through screws.
[0006] As preferred, three light emitting points are arranged on each infrared light emitting module, and the three light emitting points are in a triangular distribution.
[0007] As preferred, the two power modules are connected in parallel.
[0008] As preferred, the trigger switch is provided with three, one trigger switch is arranged at the end of the target body, one trigger switch is arranged on the side of the target body, and one trigger switch is arranged on the front of the target body, and the three trigger switches are connected in parallel.
[0009] Compared with the prior art, the present application has the following advantages: 1. The mobile welding robot based on binocular vision rapid teaching of the present application is provided with an idler remote control vehicle, and is self-provided with a power system, can freely move, and the rudder wheel can be turned by 90°, so that the remote control vehicle can move straight and horizontally, and can be flexibly used in narrow space.
[0010] 2. The mobile welding robot based on binocular vision rapid teaching of the present application adopts a six-axis welding robot, can long-term stably and efficiently weld, improves welding efficiency and welding quality, and is provided with a long neck 22.5° welding gun, so that the welding reachability can be improved.
[0011] 3. The mobile welding robot based on binocular vision rapid teaching of the present application uses the binocular measuring instrument and the target to teach the welding path of the robot, is simple to operate, fast in teaching speed, and simple in operation, reduces the skill level requirement of the welding robot to the operator, and is simple to train, easy to use, and reduces the requirement for personnel stability. BRIEF DESCRIPTION OF DRAWINGS
[0012] Figure 1 It is a whole structure schematic view of the mobile welding robot based on binocular vision rapid teaching of the present application. Figure 2 A rudder remote control car structure schematic diagram of a mobile welding robot based on binocular vision fast teaching according to the present application; Figure 3 A binocular measurement system schematic diagram of a mobile welding robot based on binocular vision fast teaching according to the present application; Figure 4 A use schematic diagram of a mobile welding robot based on binocular vision fast teaching according to the present application.
[0013] In the figure: 1, rudder remote control car; 2, welding robot; 3, binocular measuring instrument; 4, industrial computer; 11, car body; 121, drive rudder; 122, universal wheel; 13, power system bin; 14, power system; 15, ultrasonic ranging sensor; 16, warning light; 17, anti-collision shield; 18, double-layer support; 20, connecting flange; 21, robot control cabinet; 22, wire feeder; 23, welding gun; 24, cooling water tank; 25, welding wire reel; 26, gun cleaning and wire cutting station; 27, welding power supply; 31, target; 311, target body; 312, target ball; 313, connecting rod; 314, adapter flange; 315, screw; 316, infrared light-emitting module; 317, light-emitting point; 318, trigger switch; 319, Bluetooth transmitter; 320, power module; 321, infrared camera; 322, micro industrial computer; 323, Bluetooth receiver; 324, carbon fiber shell; 325, dust cover. DETAILED DESCRIPTION
[0014] The present application will be further described below in conjunction with the accompanying drawings.
[0015] Please refer to Figures 1-3 The present application provides a technical solution: a mobile welding robot based on binocular vision fast teaching, comprising a rudder remote control car 1, a welding robot 2, a binocular measuring instrument 3 and an industrial computer 4, the welding robot 2 is installed on one side of the top of the rudder remote control car 1, the binocular measuring instrument 3 is installed on one end of the welding robot 2, and the industrial computer 4 is installed on the other side of the top of the rudder remote control car 1. The binocular measuring instrument 3 is connected with the industrial computer 4 through a network cable, the industrial computer 4 is connected with the robot control cabinet 21 through a network cable, and the binocular measuring instrument 3 and the welding robot 2 are calibrated by hand and eye. The principle is that the binocular measuring instrument 3 obtains pixel coordinates, and the welding robot 2 uses a spatial coordinate system. One of the core purposes of hand-eye calibration is to obtain the coordinate conversion relationship between the pixel coordinate system and the spatial robot coordinate system. Through the calibrated coordinate conversion matrix, the pixel position of the target detected by the binocular measuring instrument 3 in the image can be transformed into the spatial coordinate system of the welding robot 2. After completing the coordinate conversion, the welding robot 2 can calculate the movement mode of each motor according to the converted coordinates to control the welding robot to reach the specified position.
[0016] The binocular measurement system aims to calculate the disparity information of each pixel in the image from the images obtained by the left and right infrared cameras, and then obtain the three-dimensional information of the object in the actual space. According to the principle that the human eyes have parallax when looking at an object, in computer vision, two images are obtained at different positions of the same baseline to estimate the shape, distance and proximity of the object, that is, the position difference of the target object in the two images is used to calculate the disparity map of the image, and then the three-dimensional information of the target can be obtained through the principle of similar triangles.
[0017] As shown in Figure 3 The binocular measuring instrument 3 includes an infrared camera 321 and a micro industrial computer 322. The micro industrial computer 322 is installed with special calculation software for calculating measurement data. The target 31 includes a target body 311, an infrared light emitting module 316, and a target ball 312. The infrared light emitting module 316 has three or four circular light emitting points 317. The position relationship of all light emitting points relative to the target ball 312 is known and clear. During the measurement process, the infrared camera 321 of the binocular measuring instrument 3 can accurately capture the image of the light emitting point 317. By identifying these light emitting points, the corresponding positions of the same light emitting point 317 in the left and right images are found out by using a matching algorithm, and the disparity of these feature points is calculated. According to the known camera parameters (such as focal length, baseline length, etc.) and the calculated disparity, the three-dimensional coordinates of the target light emitting points in the world coordinate system are calculated by using the principle of similar triangles. Through the three-dimensional coordinates of the target light emitting points, the detailed spatial position of the target ball 312 can be further calculated, including the turning angle, deflection angle and other information of the object.
[0018] The industrial computer 4 is installed with special control software, which has five functions. First, it communicates with the binocular measuring instrument 3 to obtain the measurement results of the binocular measuring system, that is, the coordinates of the target ball 312. Second, it converts the obtained coordinates of the target ball 312 into the target coordinates of the welding robot welding gun 23 through the above coordinate conversion matrix. Third, it automatically generates the motion trajectory of the welding gun 23. Fourth, it transmits the motion trajectory to the welding robot 2 to perform welding operation. Fifth, it automatically matches the welding process based on the built-in expert database according to the type and posture of the weld.
[0019] The steering wheel remote control vehicle 1 comprises a vehicle body 11, a pair of steering wheels 121 and a pair of universal wheels 22 arranged at four corners of the bottom surface of the vehicle body 11, wherein the steering wheels 121 can be turned by 90° and -90°, and the universal wheels 22 can realize the straight and horizontal movement of the steering wheel remote control vehicle 1, a power system compartment 13 is formed in the side surface of the vehicle body 1, a power system 14 is installed in the power system compartment 13, the power system 14 is modularly designed, can be installed and removed from the side opening of the power system compartment 13, and is convenient for replacement and maintenance, a warning light 15 is installed on the front surface of the vehicle body 11, an ultrasonic ranging sensor 15 is installed below the warning light 15 on the surface of the vehicle body 11, the distance between the vehicle body and the front object is automatically judged by the ultrasonic ranging sensor 15, so that the steering wheel remote control vehicle 1 will not collide with the object, a collision protection cover 17 is arranged on one side of the top of the vehicle body 11, a robot control cabinet 21 and an industrial computer 4 are installed in the collision protection cover 17, a double-layer support 18 is connected to the tail surface of the vehicle body 11, a welding power supply 27 is installed on the top of the double-layer support 18, a gun cleaning and wire cutting station 26 is installed on the side surface of the welding power supply 27 on the tail surface of the vehicle body 11, and a cooling water tank 24 is installed in the double-layer support 18; The welding robot 2 is a six-axis robot, a wire feeder 22 is installed on the third axis of the welding robot 2, a welding wire reel 25 is installed on the first axis of the welding robot 2, a binocular measuring instrument 3 is installed on the connecting flange of the sixth axis of the welding robot 2, and a welding gun 23 is installed on the sixth axis of the welding robot 2; The six-axis robot is a mature technology, and thus will not be described in detail here; The binocular measuring system comprises the binocular measuring instrument 3 and a target 31, the binocular measuring instrument 3 comprises two infrared cameras 321, a micro industrial computer 322, a Bluetooth receiver 323, a carbon fiber shell 324 and a dust cover 325, the two infrared cameras 321 are installed on the two sides of the carbon fiber shell 324, the micro industrial computer 322 is installed in the middle of the carbon fiber shell 324, the dust cover 325 is installed outside the micro industrial computer 322, and the Bluetooth receiver 323 is installed on the dust cover 325. The infrared cameras 321 are responsible for taking pictures of the target 31, the micro industrial computer is responsible for processing the photographed information, communicating with the target 31 to obtain the pose information of the target 31, converting the coordinate information of the center of the target ball 312, and communicating with the industrial computer 4; the target 31 comprises a target body 311, a target ball 312, an infrared light emitting module 316, a power module 320, a trigger switch 318 and a Bluetooth transmitter 319, the infrared light emitting module 316 is installed at both ends and in the middle of the target body 311 through screws 315, the infrared light emitting module 316 is provided with light emitting points 317 on the surface, two power modules 320 are installed on the back of the target body 311, a connecting rod 313 is connected to one end of the target body 311 through an adapter flange 314, the target ball 312 is connected to one end of the connecting rod 313, and the trigger switch 318 is installed on the side surface of the target body 311.
[0020] Further, the welding gun 23 adopts a long neck 22.5° specification.
[0021] Further, the target body 311 is a carbon fiber square tube, the target ball 312 is a hard alloy ball, the connecting rod 313 and the adapter flange 314 are an integral structure, and the adapter flange 314 is stably connected with the target body 311 through the screw 315.
[0022] Further, three light emitting points 317 are arranged for each infrared light emitting module 316, and the three light emitting points 317 are in a triangular distribution.
[0023] Further, the two power modules 320 are connected in parallel.
[0024] Further, the trigger switch 318 is provided with three, one of which is located at the end of the target body 311, one of which is located at the side of the target body 311, and one of which is located at the front of the target body 311. The three trigger switches 318 are connected in parallel, which functions to trigger the infrared light emitting module 316 to emit light, and simultaneously communicates with the binocular measuring instrument 3 through the Bluetooth module 319 and triggers the binocular measuring instrument 3 to take a photo of the target 31.
[0025] Working principle: (1) The target 31 is used to sequentially calibrate the camera and the hand-eye of the binocular measuring instrument 3 and the welding robot 2; (2) The target 31 is used to extract a plurality of point positions between the starting position and the ending position of the weld; (3) The system automatically converts the point position coordinate information into a coordinate transformation to generate the running track of the welding gun 23; (4) The system automatically matches the welding process according to the weld position and the weld type; (5) The system starts to weld from the starting position until the ending position; (6) The robot returns to the initial position.
[0026] The above only describes the preferred embodiments of the present application, and it should be noted that for ordinary skilled in the art, without departing from the principles of the present application, a number of improvements and refinements can be made, and these improvements and refinements should be considered as the protection scope of the present application.
Claims
1. A mobile welding robot based on binocular vision rapid teaching, characterized in that: The carrier is provided with a welding robot, a binocular measurement system and an industrial computer, the welding robot and the industrial computer are installed on the top of the carrier, and the binocular measurement system is installed on the welding robot. The carrier comprises a vehicle body, a pair of driving rudders and a pair of universal wheels are arranged at opposite corners of the bottom surface of the vehicle body, a power system compartment is formed in the side surface of the vehicle body, the power system compartment is internally provided with a power system, a warning light is installed on the front surface of the vehicle body, an ultrasonic ranging sensor is installed below the warning light on the surface of the vehicle body, a collision-proof shield is arranged on one side of the top of the vehicle body, a robot control cabinet and an industrial computer are installed in the collision-proof shield, a double-layer support is connected to the tail surface of the vehicle body, a welding power supply is installed on the top of the double-layer support, a gun cleaning and wire cutting station is installed on the side of the welding power supply, and a cooling water tank is installed in the double-layer support. The welding robot is a six-axis robot, a wire feeder is installed on the third axis of the welding robot, a welding wire reel is installed on the first axis of the welding robot, a binocular measurement instrument is installed on the connecting flange of the sixth axis of the welding robot, and a welding torch is installed on the sixth axis of the welding robot. The binocular measurement system comprises a binocular measurement instrument and a target, the binocular measurement instrument comprises two infrared cameras, a micro industrial computer and a Bluetooth receiver, and the target comprises a target body, a target ball, infrared light emitting modules, power modules, a trigger switch and a Bluetooth transmitter.
2. The mobile welding robot based on binocular vision quick teaching according to claim 1, characterized in that: The target body is a square tube made of carbon fiber material, the target ball is a hard alloy ball, the connecting rod and the adapter flange are of an integral structure, and the adapter flange is fixedly connected to the target body by screws.
3. The mobile welding robot based on binocular vision rapid teaching according to claim 1, characterized in that: Each infrared light emitting module is provided with three light emitting points, and the three light emitting points are in a triangular distribution.
4. The mobile welding robot based on binocular vision quick teaching according to claim 1, characterized in that: The two power modules are connected in parallel.
5. The mobile welding robot based on binocular vision quick teaching according to claim 1, characterized in that: The trigger switch is provided with three trigger switches, one of which is located at the end of the target body, one of which is located on the side of the target body, and one of which is located on the front of the target body, and the three trigger switches are connected in parallel.
6. A method of operating a mobile welding robot based on binocular vision rapid teaching according to any one of claims 1 to 5, characterized in that, The method comprises the following steps: (1) calibrating the camera and the hand-eye of the binocular measurement instrument and the welding robot in sequence through the target; (2) extracting a plurality of points between the start point and the end point of the weld through the target in sequence; (3) the system automatically converts the point coordinate information into a coordinate transformation to generate the running track of the welding torch; (4) the system automatically matches the welding process according to the weld position and the weld type; (5) the system starts to weld from the start point until the end point; (6) the robot returns to the initial position.