Online visual inspection system for weld pool

Abstract

The utility model relates to the technical field of on-line visual inspection, in particular to an on-line visual inspection system for a weld pool. And the high-speed CCD camera and the observation light generating unit are respectively used as mounting bases of the upper heavy frame and the lower heavy frame. The observation light generation unit comprises a first annular light source and a second annular light source. The first annular light source and the second annular light source are sequentially arranged from top to bottom. According to different types and forms of the pre-camera welding pool, the relative positions and heights of the first annular light source and the second annular light source can be adjusted. Therefore, on one hand, the first annular light source and the second annular light source are combined, cooperated and complemented with each other, more uniform illumination is provided for the high-speed CCD camera, and the high-speed CCD camera can capture images with better imaging quality; and on the other hand, the problem that the visual field is blocked can be effectively avoided, and the high-speed CCD camera can completely shoot the welding pool.

Description

Technical Field

[0001] The utility model relates to the technical field of on-line visual inspection, in particular to an on-line visual inspection system for a weld pool. Background Art

[0002] The on-line visual inspection system can provide real-time monitoring and precise control during the welding process, thereby improving the quality and efficiency of welding. In addition, the on-line visual inspection system can also be used to monitor the formation of welds. By taking real-time images of the welding pool, the shape, form and temperature field of the pool can be observed, which can be used as a basis for operators to adjust welding parameters and timely discover and handle potential problems.

[0003] The on-line visual inspection system mainly consists of a high-speed CCD camera and an annular light source. The annular light source is usually composed of multiple annular arrays of LED lights to facilitate high-definition photography by the high-speed CCD camera. In the prior art, the number of annular light sources is one, which is installed directly below the high-speed CCD camera, and the relative height position is not adjustable. However, the following problems have been found in practical applications: 1) The structure of the annular light source itself may block the field of view in some application scenarios, so that the high-speed CCD camera cannot completely obtain the image information of the object to be illuminated; 2) Although the annular light source can provide relatively uniform illumination, in some special cases, there may still be uneven distribution of light, resulting in problems such as brightness changes or light spots in the image, which will affect the imaging quality of the high-speed CCD camera; 3) Due to the limitation of the light incident angle, the high-speed CCD camera is very likely to have problems such as lack of imaging clarity or ghosting. Therefore, it is urgent for those skilled in the art to solve the above problems. Summary of the Utility Model

[0004] Therefore, in view of the above existing problems and defects, the development and design team of the present utility model collected relevant materials, evaluated and considered them from multiple aspects, and through continuous experiments and modifications by the development and design team members, finally led to the emergence of the on-line visual inspection system for the weld pool.

[0005] To solve the above technical problems, the utility model relates to an on-line visual inspection system for a weld pool, which includes an upper bearing frame, a lower bearing frame, a high-speed CCD camera, and an observation light generating unit. The high-speed CCD camera is used to collect welding pool images in real time, and it takes the upper bearing frame as the installation basis. The observation light generating unit is used to support the high-speed CCD camera. It is used to highlight the welding pool in a light diffuse reflection manner and takes the lower bearing frame as the installation basis. The observation light generating unit includes a first annular light source and a second annular light source. Along the up-down direction, the first annular light source and the second annular light source are arranged in sequence. The distance between the first annular light source and the high-speed CCD camera is d1, and the distance between the first annular light source and the second annular light source is d2. According to the type and shape of the pre-shot welding pool, the relative position and height position of the first annular light source and the second annular light source can be adjusted. At the same time, d1 and d2 will change.

[0006] As a further improvement of the technical solution disclosed by the utility model, the observation light generating unit further includes a first mounting seat and a second mounting seat. Among them, the first mounting seat serves as the connection transition between the lower bearing frame and the first annular light source, while the second mounting seat serves as the connection transition between the lower bearing frame and the second annular light source.

[0007] As a further improvement of the technical solution disclosed by the utility model, the first mounting seat includes a first vertical plate and a first horizontal plate. The first vertical plate is in contact with the front side wall of the lower bearing frame and is fixed together in a detachable manner. The first horizontal plate directly serves as the installation basis for the first annular light source and is fixed together with the first vertical plate in a corner joint manner. The second mounting seat includes a second vertical plate and a second horizontal plate. The second vertical plate is also in contact with the front side wall of the lower bearing frame. It is located directly below the first vertical plate and is fixed together in a detachable manner. The second horizontal plate directly serves as the installation basis for the second annular light source and is fixed together with the second vertical plate in a corner joint manner. First light-transmitting holes and second light-transmitting holes that are conducive to the high-speed CCD camera performing imaging operations are respectively provided on the first horizontal plate and the second horizontal plate.

[0008] As a further improvement of the disclosed technical solution of the present utility model, the first mounting seat further includes a first bolt fastening assembly. The first bolt fastening assembly is used to connect the lower bearing frame and the first vertical plate, and it is composed of two columns of first bolts arranged linearly. The first vertical plate is provided with a plurality of first bolt mounting holes for the first bolts to freely pass through. Correspondingly, the lower bearing frame is provided with first long oblong holes adapted to the first bolts. The second mounting seat further includes a second bolt fastening assembly. The second bolt fastening assembly is used to connect the lower bearing frame and the second vertical plate, and it is composed of two columns of second bolts arranged linearly. The second vertical plate is provided with a plurality of second bolt mounting holes for the second bolts to freely pass through. Correspondingly, the lower bearing frame is provided with second long oblong holes adapted to the second bolts.

[0009] As a further improvement of the disclosed technical solution of the present utility model, the first mounting seat further includes a first reinforcing rib plate. The rear side wall and the bottom wall of the first reinforcing rib plate are respectively in abutment with and fixed to the front side wall of the lower bearing frame and the top wall of the first horizontal plate. The number is 1, and its neutral plane passes through the central axis of the first light transmission hole. The second mounting seat further includes a second reinforcing rib plate. The rear side wall and the bottom wall of the second reinforcing rib plate are respectively in abutment with and fixed to the front side wall of the lower bearing frame and the top wall of the second horizontal plate in a one-to-one correspondence. The number is 2, and they are arranged opposite to each other in the left-right direction.

[0010] As a further improvement of the disclosed technical solution of the present utility model, the observation light generating unit further includes an assembly reference block. The assembly reference block is in abutment with the left side wall of the lower bearing frame and is fixed integrally in a detachable manner. After installation, the assembly reference block extends a set distance d3 beyond the front side wall of the lower bearing frame. During the process of assembling the observation light generating unit, the first vertical plate and the second vertical plate are both in abutment with the assembly reference block. In this case, the first bolt mounting holes are aligned with the first long oblong holes, the second bolt mounting holes are aligned with the second long oblong holes, and the first annular light source is aligned with the second annular light source.

[0011] In practical applications, the on-line visual inspection system for weld pools disclosed by the present utility model can at least achieve the following beneficial technical effects:

[0012] 1) The combination of the first annular light source and the second annular light source cooperates and complements each other. In this way, not only can the weld pool be illuminated, but it is also beneficial for the high-speed CCD camera to capture images with better imaging quality;

[0013] 2) The relative height positions of the first annular light source and the second annular light source are both adjustable. In this way, on the one hand, the problem of blocking the field of view can be effectively avoided, which is beneficial for the high-speed CCD camera to completely capture the welding molten pool. On the other hand, both the light brightness and the incident angle can be adjusted, which is conducive to providing more uniform illumination for the high-speed CCD camera, and thus effectively avoiding problems such as brightness changes, light spots, and lack of imaging clarity in the image.

[0014] 3) Excellent lighting assistance can better distinguish the welding molten pool area from the base material area in the imaging of the high-speed CCD camera, which is beneficial for reducing the difficulty of subsequent image processing algorithms and laying a good foundation for improving the reliability and comprehensive performance of the weld pool online vision detection system. Brief Description of the Drawings

[0015] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0016] Figure 1 It is a three-dimensional schematic diagram of the weld pool online vision detection system in the present invention.

[0017] Figure 2 is Figure 1 the side view of

[0018] Figure 3 It is a three-dimensional schematic diagram of the upper support frame in the weld pool online vision detection system of the present invention.

[0019] Figure 4 It is a three-dimensional schematic diagram of the lower support frame in the weld pool online vision detection system of the present invention.

[0020] Figure 5 It is a three-dimensional schematic diagram of the observation light generating unit in the weld pool online vision detection system of the present invention.

[0021] Figure 6 is Figure 5 the side view of

[0022] Figure 7 It is a three-dimensional schematic diagram of the first mounting seat in the weld pool online vision detection system of the present invention.

[0023] Figure 8 It is a three-dimensional schematic diagram of the second mounting seat in the weld pool online vision detection system of the present invention.

[0024] Figure 9 This is a schematic diagram of the state after the observation light generating unit in the on-line visual inspection system for the weld pool of the present utility model is assembled relative to the lower bearing frame.

[0025] Figure 10 is Figure 9 a side view of

[0026] 1. Upper bearing frame; 2. Lower bearing frame; 21. First long oblong hole; 22. Second long oblong hole; 3. High-speed CCD camera; 4. Observation light generating unit; 41. First annular light source; 42. Second annular light source; 43. First mounting seat; 431. First vertical plate; 4311. First bolt mounting hole; 432. First horizontal plate; 4321. First light transmission hole; 433. First reinforcing rib plate; 44. Second mounting seat; 441. Second vertical plate; 4411. Second bolt mounting hole; 442. Second horizontal plate; 4421. Second light transmission hole; 443. Second reinforcing rib plate; 45. Assembly reference block. Detailed implementation manners

[0027] In the description of the present utility model, it should be understood that the orientation or positional relationship indicated by terms such as "left", "right", "upper", "lower", "front", "rear", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present utility model.

[0028] The following will further elaborate on the content disclosed in the present utility model in combination with specific embodiments. Figure 1 , Figure 2 jointly show a schematic structural diagram of the on-line visual inspection system for the weld pool in the present utility model. It can be seen that it mainly consists of an upper bearing frame 1 (as shown in Figure 3 ), a lower bearing frame 2 (as shown in Figure 4 ), a high-speed CCD camera 3, and an observation light generating unit 4, etc. Among them, the high-speed CCD camera 3 is used to collect welding pool images in real time, and it takes the upper bearing frame 1 as the installation basis. The observation light generating unit 4 is used to support the high-speed CCD camera 3. It is used to highlight the welding pool in a light diffuse reflection manner and takes the lower bearing frame 2 as the installation basis. The observation light generating unit 4 is used to provide light assistance for the imaging of the high-speed CCD camera, which is beneficial for the high-speed CCD camera to take high-definition photos.

[0029] As shown in Figure 5 , 6As shown, the observation light generating unit 4 is mainly composed of a first annular light source 41 and a second annular light source 42. Along the up-down direction, the first annular light source 41 and the second annular light source 42 are arranged in sequence. Assume the distance between the first annular light source 41 and the high-speed CCD camera 3 is d1, and the distance between the first annular light source 41 and the second annular light source 42 is d2 (as Figure 2 shown). According to the type and form of the pre-shot welding molten pool, the relative position and height position of the first annular light source 41 and the second annular light source 42 can be adjusted. At the same time, d1 and d2 will change. By adopting the above technical solution for setting, on the one hand, the first annular light source 41 and the second annular light source 42 are combined, cooperating and complementing each other. In this way, not only can the weld molten pool be illuminated, but it is also beneficial for the high-speed CCD camera 3 to capture images with better imaging quality; on the other hand, the problem of blocking the field of view is effectively avoided, which is beneficial for the high-speed CCD camera 3 to completely photograph the welding molten pool; both the light brightness and the incident angle can be adjusted, which is beneficial for providing more uniform illumination for the high-speed CCD camera 3, and thus effectively avoids problems such as brightness changes, light spots, and lack of imaging clarity in the image.

[0030] Here, it should also be noted that excellent lighting assistance can better distinguish the welding molten pool area from the base material area in the imaging of the high-speed CCD camera 3, which is beneficial for reducing the difficulty of subsequent image processing algorithms, greatly improving the image processing speed, and laying a good foundation for the improvement of the reliability and comprehensive performance of the weld molten pool on-line visual inspection system.

[0031] It is known that according to design common sense, various design structures can be adopted to realize the assembly of the first annular light source 41, the second annular light source 42 and the lower bearing frame 2. However, here a implementation scheme with a simple design structure, easy disassembly and assembly operations, and good installation stability is recommended. Specifically: Similarly as Figure 5 、 6 shown, the first annular light source 41 is assembled with the lower bearing frame 2 by means of a first mounting seat 43, and the second annular light source 42 is assembled with the lower bearing frame 2 by means of a second mounting seat 44. As Figure 7 shown, the first mounting seat 43 is mainly composed of a first vertical plate 431 and a first horizontal plate 432. The first vertical plate 431 is abutted against the front side wall of the lower bearing frame 2 and is fixed as a whole in a detachable manner. The first horizontal plate 432 directly serves as the installation base of the first annular light source 41, and it is fixed as a whole with the first vertical plate 431 in a corner joint manner. As Figure 8As shown in the figure, the second mounting base 44 is mainly composed of a second vertical plate 441 and a second horizontal plate 442. The second vertical plate 441 also abuts against the front side wall of the lower bearing frame 2. It is located directly below the first vertical plate 431 and is fixed integrally in a detachable manner. The second horizontal plate 442 directly serves as the mounting base for the second annular light source 42 and is fixed integrally with the second vertical plate 441 in a corner joint manner. First light-transmitting holes 4321 and second light-transmitting holes 4421 that facilitate the high-speed CCD camera 3 to perform imaging operations are respectively provided on the first horizontal plate 432 and the second horizontal plate 442.

[0032] As Figures 5 - 8 shown in the figure, the lower bearing frame 2 and the first vertical plate 431 are connected and fixed by means of a first bolt fastening assembly (not shown in the figure). The first bolt fastening assembly is composed of two columns of first bolts arranged linearly. The first vertical plate 431 is provided with a plurality of first bolt mounting holes 4311 for the first bolts to freely pass through. Correspondingly, the lower bearing frame 2 is provided with first long slotted holes 21 adapted to the first bolts (as Figure 4 shown in the figure). The lower bearing frame 2 and the second vertical plate 441 are connected and fixed by means of a second bolt fastening assembly (not shown in the figure). The second bolt fastening assembly is composed of two columns of second bolts arranged linearly. The second vertical plate 441 is provided with a plurality of second bolt mounting holes 4411 for the second bolts to freely pass through. Correspondingly, the lower bearing frame 2 is provided with second long slotted holes 22 adapted to the second bolts (as Figure 4 shown in the figure). Thus, in specific applications, when it is necessary to adjust the relative position height of the first annular light source 41, the worker only needs to loosen (but not remove) the nuts matching the first bolts in sequence, and then drag the first mounting base 43 along the height direction. At the same time, each column of bolts performs a directional sliding movement along the corresponding first long slotted hole 21 until the first annular light source 41 occupies a reasonable relative position height. Subsequently, the worker tightens each first bolt again. When it is necessary to adjust the relative position height of the second annular light source 42, the implementation method is exactly the same and will not be elaborated here.

[0033] It is known that in some cases, in order to meet the photographing requirements of the high-speed CCD camera 3, the lower bearing frame 2 needs to quickly approach / leave the upper bearing frame 1. Thus, the first mounting base 43 and the second mounting base 44 will inevitably be subjected to long-term vibration due to inertial forces, which will affect the irradiation angles of the first annular light source 41 and the second annular light source 42, the brightness will change unpredictably, and it will also affect their cooperation. In view of this, as a further optimization of the above technical solution, as Figure 7As shown in the figure, a first reinforcing rib plate 433 is further added to the first mounting seat 43. The rear side wall and the bottom wall of the first reinforcing rib plate 433 are respectively abutted against and fixed to the front side wall of the lower bearing frame 2 and the top wall of the first horizontal plate 432. The number is 1, and its neutral plane passes through the central axis of the first light-transmitting hole 4321. As Figure 8 As shown in the figure, a second reinforcing rib plate 443 is further added to the second mounting seat 44. The rear side wall and the bottom wall of the second reinforcing rib plate 443 are respectively abutted against and fixed to the front side wall of the lower bearing frame 2 and the top wall of the second horizontal plate 442. The number is 2, and they are arranged opposite to each other along the left-right direction. In this way, the structural strength and structural stability of the first mounting seat 43 and the second mounting seat 44 are effectively improved, so that the duration of maintaining vibration excitation due to the action of inertial force can be effectively shortened, which is beneficial to the full play of the respective performances and combined performances of the first annular light source 41 and the second annular light source 42.

[0034] It should be noted that, as Figure 8 As shown in the figure, there is a large gap between the two second reinforcing rib plates 443. In this way, on the premise of ensuring that the first annular light source 41 does not touch the two second reinforcing rib plates 443, the second annular light source 42 has a larger adjustable distance range value relative to the first annular light source 41.

[0035] As Figure 5 、 6 As shown in the figure, an assembly reference block 45 is further added to the observation light generating unit 4. The assembly reference block 45 is abutted against the left side wall of the lower bearing frame 2 and is fixed integrally in a detachable manner. After installation, the assembly reference block 45 extends beyond the front side wall of the lower bearing frame 2 by a set distance d3 (as Figure 9 、 10 As shown in the figure). By adopting the above technical solutions, on the premise of ensuring that the first mounting seat 43 and the second mounting seat 44 occupy the correct assembly positions relative to the lower bearing frame 2, such a design can effectively reduce the installation difficulty of the first mounting seat 43 and the second mounting seat 44 and is beneficial to shortening the installation duration. During the process of assembling the observation light generating unit 4, the first vertical plate 431 and the second vertical plate 441 are both abutted against the assembly reference block 45. In this case, the first bolt mounting hole 4311 is aligned with the first long slotted hole 21, the second bolt mounting hole 4411 is aligned with the second long slotted hole 22, and the first annular light source 41 is aligned with the second annular light source 42.

[0036] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present utility model. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present utility model. Therefore, the present utility model will not be limited to the embodiments shown herein, but rather to the broadest scope consistent with the principles and novel features disclosed herein.

Claims

1. An online visual inspection system for a weld pool, comprising an upper bearing frame, a lower bearing frame, a high-speed CCD camera and an observation light generating unit; the high-speed CCD camera is used to collect images of the weld pool in real time, and the upper bearing frame is used as an installation base; the observation light generating unit is used to match the high-speed CCD camera, and is used to highlight the weld pool in a light diffuse reflection manner, and the lower bearing frame is used as an installation base, characterized in that: The observation light generating unit includes a first ring-shaped light source and a second ring-shaped light source; the first ring-shaped light source and the second ring-shaped light source are arranged in sequence from top to bottom; the distance between the first ring-shaped light source and the high-speed CCD camera is d1, and the distance between the first ring-shaped light source and the second ring-shaped light source is d2; according to the type and shape of the pre-imaged welding molten pool, the relative position and height position of the first ring-shaped light source and the second ring-shaped light source can be adjusted, and at the same time, d1 and d2 can be changed.

2. The weld pool online visual inspection system according to claim 1, characterized in that: The observation light generating unit also includes a first mounting seat and a second mounting seat; wherein the first mounting seat serves as a connection transition between the lower bearing frame and the first annular light source, and the second mounting seat serves as a connection transition between the lower bearing frame and the second annular light source.

3. The weld pool online visual inspection system according to claim 2, characterized in that: The first mounting seat includes a first vertical plate and a first horizontal plate; the first vertical plate is abutted against the front side wall of the lower bearing frame and is fixed as a whole in a detachable manner; the first horizontal plate directly serves as the mounting base of the first annular light source, and is fixed as a whole with the first vertical plate in an angle-jointed manner; the second mounting seat includes a second vertical plate and a second horizontal plate; the second vertical plate is also abutted against the front side wall of the lower bearing frame, and is located directly below the first vertical plate, and is fixed as a whole in a detachable manner; the second horizontal plate directly serves as the mounting base of the second annular light source, and is fixed as a whole with the second vertical plate in an angle-jointed manner; a first light-transmitting hole and a second light-transmitting hole are respectively provided on the first horizontal plate and the second horizontal plate, which are convenient for the high-speed CCD camera to perform the camera operation.

4. The weld pool online visual inspection system according to claim 3 is characterized in that: The first mounting seat also includes a first bolt fastening assembly; the first bolt fastening assembly is used to connect the lower bearing frame and the first vertical plate, and is composed of two rows of first bolts arranged linearly; the first vertical plate is provided with a plurality of first bolt mounting holes for the first bolts to pass freely through, and correspondingly, the lower bearing frame is provided with a first long waist-shaped hole adapted to the first bolt; the second mounting seat also includes a second bolt fastening assembly; the second bolt fastening assembly is used to connect the lower bearing frame and the second vertical plate, and is composed of two rows of second bolts arranged linearly; the second vertical plate is provided with a plurality of second bolt mounting holes for the second bolts to pass freely through, and correspondingly, the lower bearing frame is provided with a second long waist-shaped hole adapted to the second bolt.

5. The weld pool online visual inspection system according to claim 4, characterized in that: The first mounting seat also includes a first reinforcing rib plate; the rear side wall and the bottom wall of the first reinforcing rib plate are respectively abutted against and fixed to the front side wall of the lower load-bearing frame and the top wall of the first flat plate, the number is 1, and the neutral plane thereof passes through the central axis of the first light-transmitting hole; the second mounting seat also includes a second reinforcing rib plate; the rear side wall and the bottom wall of the second reinforcing rib plate are respectively abutted against and fixed to the front side wall of the lower load-bearing frame and the top wall of the second flat plate, the number is 2, and they are arranged opposite to each other along the left and right directions.

6. The weld pool online visual inspection system according to any one of claims 4-5, characterized in that: The observation light generating unit also includes an assembly reference block; the assembly reference block is abutted against the left side wall of the lower bearing frame and is fixed as a whole in a detachable manner; after installation, the assembly reference block passes over the front side wall of the lower bearing frame by a set distance d3; in the process of assembling the observation light generating unit, the first vertical plate and the second vertical plate are both abutted against the assembly reference block, in this case, the first bolt mounting hole is aligned with the first long waist-shaped hole, the second bolt mounting hole is aligned with the second long waist-shaped hole, and the first ring-shaped light source is aligned with the second ring-shaped light source.

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