A through-flow wind wheel welding device based on a three-camera recognition system

Abstract

The application relates to a through-flow wind wheel welding device based on a three-camera recognition system, and belongs to the field of welding devices.The device comprises a machining mechanism and a PLC controller, the top of the machining mechanism is provided with a plurality of cameras, the bottom of the plurality of cameras is provided with positioning cores, the bottom of the positioning cores is provided with motors, the output shaft of the motor always drives the positioning core to rotate, the PLC controller comprises an origin identification module for identifying the origin of a workpiece and an angle adjustment module for rotating the positioning core, the origin identification module is electrically connected with the plurality of cameras, and the angle adjustment module is electrically connected with the motor.The application can shorten the time for angle correction and adjustment of each single wind blade, and improve the efficiency and quality of single wind blade splicing.

Description

Technical Field

[0001] This application relates to the field of welding equipment, and in particular to a cross-flow wind turbine welding device based on a three-camera recognition system. Background Technology

[0002] The cross-flow wind turbine body is a multi-bladed, long cylindrical shape with forward-facing multi-bladed blades. When the cross-flow wind turbine body rotates, the airflow enters the blade grid from the open part of the cross-flow wind turbine body, passes through the interior of the cross-flow wind turbine body, and is discharged into the volute from the other side of the blade grid, forming the working airflow.

[0003] In the existing production process of cross-flow wind turbines, the welding of individual blade sections is a crucial step. To ensure the quality and performance of the cross-flow wind turbine, individual blade sections are typically placed one by one into the welding equipment and then joined together manually. Specifically, operators manually place each blade section into its designated position, aligning it with the origin marked during injection molding, and then use welding equipment to fix them together. In addition, auxiliary tools are used to help calibrate the angle of the individual blade sections to ensure the accuracy of the final product.

[0004] While existing technologies can meet basic production needs to a certain extent, they also have significant shortcomings. The most significant problem is that, due to reliance on manual operation, the splicing angles of adjacent blade sections are prone to deviation. Furthermore, angular deviations generated during welding require substantial time for adjustment to reduce errors. This not only increases calibration time costs but also reduces overall production efficiency and quality. Therefore, effectively improving the accuracy and efficiency of blade splicing has become an urgent technical problem to be solved. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this application provides a cross-flow wind turbine welding device based on a three-camera recognition system, which can shorten the time for angle calibration and adjustment of each individual blade section, and improve the efficiency and quality of blade section splicing.

[0006] This application provides a cross-flow wind turbine welding equipment based on a three-camera recognition system, which adopts the following technical solution:

[0007] A cross-flow fan wheel welding device based on a three-camera recognition system includes a processing mechanism and a PLC controller. The processing mechanism is equipped with several cameras on its top and positioning cores at the bottom of the cameras. A motor is installed at the bottom of the positioning cores, and the output shaft of the motor always drives the positioning cores to rotate. The PLC controller includes an origin recognition module for recognizing the origin of the workpiece and an angle adjustment module for rotating the positioning cores. The origin recognition module is electrically connected to the several cameras, and the angle adjustment module is electrically connected to the motor.

[0008] By adopting the above technical solution, during the processing and welding of single-section wind turbine blades, several cameras capture images of the processing mechanism and identify the origin position of the single-section wind turbine blade. When the origin position deviates from the position set in the origin identification module, the angle adjustment module controls the motor to drive the positioning core, which is fitted with the single-section wind turbine blade to be welded, to rotate according to the angle of deviation. This adjusts the origin of the single-section wind turbine blade to match the origin of the wind turbine blade after welding in the welding device before insertion welding. This achieves automatic calibration and adjustment of the angle of the single-section wind turbine blade, shortens the origin calibration time of each single-section wind turbine blade, and thus improves the efficiency and quality of single-section wind turbine blade insertion.

[0009] This application further provides that: the processing mechanism includes a welding device, a boss is provided on one side of the top of the welding device, a clamping member is provided at the bottom of the bottom surface of the welding device for clamping several single-section fan blades to be welded and after welding, a positioning core is provided on one side of the clamping member, a first camera is provided on one side of the boss, and the shooting direction of the first camera is set at an angle of 30°-60° with the extension direction of the vertical central axis of the clamping member.

[0010] By adopting the above technical solution, the vertical center axis of the welding device boss and the clamping part are not in the same vertical extension direction. Therefore, the first camera installed on the boss needs to be angled at 30°-60° to shoot the origin of the single-section fan blade at the bottom of the welding device held by the clamping part, so as to avoid the welding device blocking the shooting field of the first camera during welding. The origin correction module is used to identify the origin, and then the positioning core is rotated by the angle adjustment module to calibrate the position of the origin before plugging and welding.

[0011] This application further specifies that the PLC controller also includes an origin correction module for correcting the origin image captured by the first camera, and the origin correction module is electrically connected to the first camera.

[0012] By adopting the above technical solution, since the first camera is shooting at the origin of the single-section fan blade being welded on the clamping part at an angle, the shape of the circular origin will form a different shape than the origin image when the first camera is shooting at an angle. The origin correction module needs to correct the deformed origin to a circle to obtain a more accurate deviation angle of the origin, so as to improve the rotation accuracy of the positioning core by the angle adjustment module.

[0013] This application further provides that: the processing mechanism includes a feeding device, which is disposed on the top of the positioning core on one side of the clamping member, and a second camera is disposed on the top of the gripper of the feeding device, which is facing the bottom of the gripper to take pictures.

[0014] By adopting the above technical solution, the second camera can further confirm whether the angle of the single blade that is sleeved on the positioning core and has been corrected at the origin has been adjusted according to the correct angle fed back by the first camera, thereby improving the insertion accuracy of the single blade. The gripper of the feeding device then picks up the single blade of the positioning core and puts it into the welding device for welding.

[0015] This application further provides that: the processing mechanism also includes a capping device, a positioning core is disposed at the bottom of the capping device, and a third camera is disposed on the top of the positioning core of the capping device, the third camera being directed to the top of the positioning core to take pictures.

[0016] By adopting the above technical solution, the first camera confirms the origin position of the welded wind blade assembly. After the positioning core at the bottom of the sealing device rotates and adjusts the end cap of the single wind blade sleeved on it, the third camera further confirms whether the angle of the origin of the end cap has been adjusted according to the correct angle fed back by the first camera, thereby improving the insertion accuracy of the end cap. The sealing device then seals the end cap onto the top of the welded wind blade assembly.

[0017] This application further provides that: a conveyor belt is provided at the end of the feeding device away from the welding device.

[0018] By adopting the above technical solution, the grippers of the feeding device grab the single section of fan blade conveyed on the conveyor belt and place it on the positioning core for angle adjustment, thereby improving the automation level of the welding equipment.

[0019] This application further provides that: a movable slide rail is provided at one end of the conveyor belt near the feeding device, and the bottom of the feeding device is slidably connected to the top of the movable slide rail.

[0020] By adopting the above technical solutions, the flexibility and adaptability of the feeding device are improved, and the feeding position can be controlled more precisely, thereby further improving the efficiency and quality of single-section fan blade splicing.

[0021] This application further specifies that the second camera is a flying camera.

[0022] By adopting the above technical solution, the second camera on the top of the feeding device is a high-speed continuous shooting camera, which can quickly and accurately capture the initial origin position information of a single blade during the feeding process, thereby further improving the working efficiency and accuracy of the welding equipment.

[0023] In summary, this application includes the following beneficial technical effects:

[0024] Through the collaborative work of the three-camera recognition system and PLC controller, the position and angle of a single fan blade can be automatically and accurately identified and corrected in a short time, significantly reducing the time cost of manual intervention and greatly improving production efficiency and quality. By using a motor to drive the positioning core to rotate, combined with the angle adjustment module, the insertion angle of the single fan blade is precisely controlled, improving the accuracy and consistency of the single fan blade insertion, thereby improving product quality. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of this application.

[0026] Figure 2 This is a schematic diagram of the overall structure of this application from another angle.

[0027] Figure 3 yes Figure 1 A magnified view of part A in the diagram.

[0028] Figure 4 yes Figure 2 A magnified view of part B in the diagram.

[0029] Reference numerals: 1. Processing mechanism; 10. Welding device; 11. Feeding device; 12. Sealing device; 2. Positioning core; 3. Clamping component; 4. First camera; 5. Second camera; 6. Third camera; 7. Conveyor belt. Detailed Implementation

[0030] The following is in conjunction with the appendix Figures 1 to 4 This application will be described in further detail.

[0031] refer to Figure 1 and Figure 2 In this embodiment, a cross-flow fan wheel welding device based on a three-camera recognition system includes a processing mechanism 1 and a PLC controller. Several cameras are fixedly connected to the top of the processing mechanism 1, and a positioning core 2 is rotatably connected to the bottom of the cameras. A motor is installed at the bottom of the positioning core 2, and the output shaft of the motor always drives the positioning core 2 to rotate in order to adjust the position of the single-section fan blade sleeved on the top of the positioning core 2. The PLC controller includes an origin recognition module for recognizing the origin of the workpiece, and an angle adjustment module for rotating the positioning core 2. The origin recognition module is electrically connected to the several cameras, and the angle adjustment module is electrically connected to the motor.

[0032] In this embodiment, the origin point of a single-section wind turbine blade is marked on the top of the blade. The image recognition algorithm of the origin point recognition module can identify the shape of the single-section wind turbine blade and its origin point, and mark and record the position of the origin point on the top of the blade. It then confirms whether the origin point of the next single-section wind turbine blade entering the camera's field of view is consistent with the recorded position. The angle adjustment module drives the positioning core 2, which is fitted with the blade to be welded, to rotate according to the position deviation of the origin point. The rotation is adjusted until the origin point of the single-section wind turbine blade matches the origin point of the blade after welding in the welding device 10 before insertion welding. This achieves automatic calibration and adjustment of the angle of the single-section wind turbine blade and shortens the time for origin point calibration of each blade, thereby improving the efficiency and quality of blade insertion.

[0033] refer to Figures 2 to 4 In this embodiment, the processing mechanism 1 includes a welding device 10. A boss is fixedly connected to one side of the top of the welding device 10. A clamping member 3 is provided at the bottom of the bottom surface of the welding device 10. The clamping member 3 is used to clamp several single-section fan blades that need to be welded and those that have been welded. A positioning core 2 is rotatably connected to one side of the clamping member 3. Only when the single-section fan blade on the positioning core 2 is rotated to the correct origin point of the top of the single-section fan blade in the welding of the clamping member 3 by the drive motor controlled by the angle adjustment module can it enter the welding device 10 for welding. A first camera 4 is fixedly connected to one side of the boss. The shooting direction of the first camera 4 is set at an angle of 30°-60° with the extension direction of the vertical central axis of the clamping member 3. The function of the first camera 4 is to take pictures of the position of the clamping member 3 located on the welding fan blade of the welding equipment. The oblique shooting method can avoid the step of moving the camera to the top of the fan blade of the clamping member 3 for picture recognition and then moving the camera out of the welding station before welding can be carried out, thereby shortening the overall welding time and improving the efficiency of identifying the origin position of the fan blade. In this embodiment, the shooting direction of the first camera 4 is set at an angle of 45° to the extension direction of the vertical central axis of the clamping member 3.

[0034] Furthermore, the PLC controller also includes an origin correction module, which is used to correct the origin image captured by the first camera 4. The origin correction module is electrically connected to the first camera 4.

[0035] In this embodiment, the origin at the top of the single-section blade is circular. When photographed at an angle, the origin becomes elliptical. Since the origin of the single-section blade on the positioning core 2 is also circular, errors occur when the origin identification module analyzes the angular deviation of the origin. The origin correction module preprocesses the image of the origin captured by the origin identification module from the first camera 4 at an angle, including grayscale conversion, noise reduction, and edge detection, to extract a clear elliptical outline. Then, it uses ellipse fitting algorithms such as least squares to extract the geometric parameters of the ellipse from the edge information, including the center point, major axis, minor axis, and rotation angle. Next, it performs rotation correction on the image based on the ellipse's rotation angle, aligning its principal axis with the horizontal or vertical direction. Finally, it performs non-uniform scaling on the image based on the ratio of the major and minor axes, adjusting the ellipse to a circle. The excess portion is then cropped, and the corrected circular image, representing the correct shape of the origin, is output. This allows for a more accurate determination of the origin's deviation angle, improving the rotation accuracy of the positioning core 2 by the angle adjustment module.

[0036] Furthermore, the processing mechanism 1 includes a feeding device 11, which is disposed on the top of the positioning core 2 on one side of the clamping member 3. A second camera 5 is fixedly connected to the top of the gripper of the feeding device 11. The second camera 5 faces the bottom of the gripper to take pictures. In this embodiment, the second camera 5 faces the bottom of the vertical central axis of the gripper to take pictures, which can improve the accuracy of the second camera 5 in identifying single-section blades. After the first camera 4 identifies the origin of the single-section blade on the clamping table through the origin recognition module, and then the origin correction module corrects the deformed origin, the angle adjustment module controls the origin of the single-section blade on the positioning core 2 at the bottom of the feeding device 11 to rotate to a position consistent with the origin of the blade on the clamping table. Then, the second camera 5 further checks whether the angle of the single blade to be welded has been adjusted. When the second camera 5 detects that the angle of the origin of the single-section blade on the positioning core 2 does not match the angle of the origin of the single blade at the clamping member 3 after the angle adjustment, the rotation angle of the positioning core 2 is adjusted by the angle adjustment module, thereby improving the insertion accuracy of the single blade. Finally, the grippers of the feeding device 11 pick up the single blade of the positioning core 2 and place it into the welding device 10 for welding.

[0037] Furthermore, the processing mechanism 1 also includes a sealing device 12. A positioning core 2 is rotatably connected to the bottom of the sealing device 12, and an end cap is fitted onto the top of the positioning core 2. A third camera 6 is fixedly connected to the top of the sealing device 12 at the top of the positioning core 2. The third camera 6 is facing the top of the positioning core 2 to take pictures. The first camera 4 confirms the origin position of the welded wind blade assembly through the origin recognition module and the origin correction module. Then, the angle of the positioning core 2 at the bottom of the sealing device 12 is adjusted by the angle adjustment module so that the origin position of the end cap of the single wind blade at the top matches the origin position of the welded wind blade assembly. The third camera 6 further confirms whether the angle of the origin of the end cap has been adjusted according to the correct angle feedback from the first camera 4, further improving the insertion accuracy of the end cap. The sealing device 12 then seals the end cap onto the top of the welded wind blade assembly.

[0038] Furthermore, a conveyor belt 7 is provided at the end of the feeding device 11 away from the welding device 10. The single fan blade is transmitted to the end of the feeding device 11 that is close to the welding device 10 via the conveyor belt 7. The single fan blade transmitted on the conveyor belt 7 is picked up by the gripper of the feeding device 11 and placed on the positioning core 2 for angle adjustment, thereby improving the automation level of the welding equipment.

[0039] Furthermore, a movable slide rail is provided at one end of the conveyor belt 7 near the feeding device 11. The bottom of the feeding device 11 is slidably connected to the top of the movable slide rail, thereby realizing the movement of the gripper, improving the flexibility and adaptability of the feeding device 11, and also enabling more precise control of the feeding position of the single-section fan blade, thereby improving the efficiency and quality of the single-section fan blade insertion.

[0040] Furthermore, the second camera 5 is a flying camera. When the feeding device 11 moves along the sliding rail, the second camera 5, which is located on top of the feeding device 11, can achieve high-speed continuous shooting. During the feeding process, it can start to capture the initial origin position information of a single blade, shortening the recognition time of the second camera 5, thereby improving the working efficiency and accuracy of the welding equipment.

[0041] The implementation principle of this embodiment is as follows: The gripper of the feeding device 11 moves along the sliding rail to grab the single-section fan blade on the conveyor belt 7, and then moves along the sliding rail to the positioning core 2 on one side of the clamping member 3, placing the single-section fan blade on top of the positioning core 2. While the feeding device 11 is working, the second camera 5 uses a high-speed shooting method to quickly capture images of the bottom of the gripper and the grabbed single-section fan blade, providing the origin position of the single-section fan blade to the origin recognition module, and providing the initial position for subsequent angle adjustment.

[0042] Meanwhile, the first camera 4, mounted on the boss on one side of the welding device 10, captures an image of the welded fan blade of the clamping part 3 by means of oblique shooting. This image is provided to the origin recognition module to identify the origin position of the fan blade. After the origin correction module corrects the deformed origin to the correct shape, the angle adjustment module obtains the angle deviation between the origin position of the welded fan blade and the positioning core 2 on one side of the clamping part 3. Based on the angle deviation, the drive motor controls the positioning core 2 to rotate, correcting the origin position of the single section fan blade at the top of the positioning core 2 so that it matches the origin position of the welded fan blade, and then the middle section is welded.

[0043] After the middle section of the fan blade is welded, the end cap of the sealing device 12 needs to be welded to the top of the fan blade. The third camera 6 captures an image of the end cap of the positioning core 2 at the bottom of the sealing device 12 and provides it to the origin recognition module to identify the origin position of the end cap. The first camera 4 captures an image of the top fan blade located on the clamping part 3 and provides it to the origin recognition module and the origin correction module to obtain the origin position of the welded top fan blade. Then, the angle adjustment module obtains the angle deviation between the origin position of the welded fan blade and the positioning core 2 at the bottom of the sealing device 12. Based on the angle deviation, the drive motor controls the positioning core 2 to rotate and correct the origin position of the single section fan blade at the top of the positioning core 2 at the bottom of the sealing device 12 so that it matches the origin position of the welded top fan blade before the end cap is welded.

[0044] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A cross-flow wind wheel welding device based on a three-camera recognition system, characterized in that, The device includes a processing mechanism (1) and a PLC controller. The processing mechanism (1) is equipped with several cameras on its top and positioning cores (2) at the bottom of the cameras. A motor is installed at the bottom of the positioning cores (2). The output shaft of the motor always drives the positioning cores (2) to rotate. The PLC controller includes an origin identification module for identifying the origin of the workpiece and an angle adjustment module for rotating the positioning cores (2). The origin identification module is electrically connected to the several cameras, and the angle adjustment module is electrically connected to the motor.

2. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 1, characterized in that, The processing mechanism (1) includes a welding device (10). A boss is provided on one side of the top of the welding device (10). A clamping member (3) for clamping several single-section wind blades that need to be welded and have been welded is provided at the bottom of the bottom surface of the welding device (10). A positioning core (2) is provided on one side of the clamping member (3). A first camera (4) is provided on one side of the boss. The shooting direction of the first camera (4) is at an angle of 30°-60° to the extension direction of the vertical central axis of the clamping member (3).

3. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 2, characterized in that, The PLC controller also includes an origin correction module for correcting the origin image captured by the first camera (4), and the origin correction module is electrically connected to the first camera (4).

4. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 2, characterized in that, The processing mechanism (1) includes a feeding device (11), which is located on the top of the positioning core (2) on one side of the clamping member (3). A second camera (5) is provided on the top of the gripper of the feeding device (11), and the second camera (5) is facing the bottom of the gripper to take pictures.

5. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 2, characterized in that, The processing mechanism (1) also includes a sealing device (12), and a positioning core (2) is disposed at the bottom of the sealing device (12). The sealing device (12) is provided with a third camera (6) at the top of the positioning core (2), and the third camera (6) shoots towards the top of the positioning core (2).

6. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 4, characterized in that, The feeding device (11) has a conveyor belt (7) at the end away from the welding device (10).

7. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 6, characterized in that, The conveyor belt (7) is provided with a movable slide rail at one end near the feeding device (11), and the bottom of the feeding device (11) is slidably connected to the top of the movable slide rail.

8. The through-flow wind wheel welding device based on a three-camera recognition system according to claim 7, characterized in that, The second camera (5) is a flying camera.

Images