螺旋管埋弧焊焊缝自动跟踪系统的研究
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摘要
随着焊接自动化和智能化的不断发展,焊缝跟踪系统的应用显得越来越重要。在螺旋管生产过程中,焊接质量往往会受到生产加工误差,焊接过程的热变形以及人员操作不准确等各类因素的影响,为了保证在不利因素情况下,将焊缝误差控制在规定的范围之内焊缝自动跟踪成为当今国内外十分重视的课题。
本课题与辽阳大泽钢管有限公司螺旋管生产线相结合,以其实际生产环境为研究基础,研究与设计螺旋管焊缝自动跟踪系统。
本文设计的螺旋管焊缝自动跟踪系统原理为:通过CCD视觉传感器采集焊接区域前端焊缝图像,将图像传输于CG300图像采集卡上,在图像采集卡中进行数据形式转换,将转换后图像信息传输于在上位机中进行VB图像分析处理,得到焊缝的准确位置及焊缝特性等,再利用VB程序与PLC控制器间的自由口通讯方式将焊缝位置信息实时传输于PLC控制中,PLC控制系统控制两个直流电机带动焊炬运动,消除焊炬与焊缝的偏差,形成一个闭环的控制系统,以期达到埋弧焊焊缝跟踪的目的。
本文设计了以PLC为控制核心,以基于VB开发的图像处理为算法的自动跟踪系统。采用8mm软管式工业CCD,克服了普通CCD体积大的弱点,而且采用该CCD摄像头作为焊缝自动跟踪传感器,图像更清晰,易于安装。利用欧陆508直流调速器,实现了软件程序对十字导轨中横向电机与纵电机的转速调整功能,提高了螺旋管焊缝自动跟踪系统的整体性能。
为研究螺旋管埋弧焊焊缝自动跟踪系统图像处理的算法,采用VB编程调用Windows API函数,对实际焊接过程焊缝AVI录像进行回放与捕捉,形成了焊缝跟踪影像仿真程序,该程序削弱了实际生产环节对前期研究工作的限制,缩短了图像处理算法研究周期,对焊缝跟踪研究具有重要意义。本文的算法研究始终是结合现场实际情况开展的,得出的图像处理算法对该领域的研究具有重要的参考价值。
With the development of welding automation and intellectualization, the application of welding seam tracking system appears more and more important. During manufacturing the spiral tube, kinds of influence factor in the welding production, such as the tolerance and thermal distortion and inaccuracy chucking appliance, would affect the welding quality. Welding seam automatic tracking which controls the bias following the specification in adverse circumstances takes seriously topic in domestic and foreign now.
The topic incorporates with the spiral pipe production line of Liao Yang DaZe Company Ltd. We design the welding seam automatic tracking system on the base of the environment of actual production.
In this paper, the principle of the welding seam automatic tracking system is: Capturing the front seam of the weld area image by CCD, the image signals reach CG300 image acquisition broad. It converts the date form in the preconditioning; then we can make Visual Basic image analysis by PC which the image transfer to, we will find the exact position of the welded seam and the properties of seam. What is more, it transfers the live dates of seam position to the PLC by the communication way between Visual Basic and PLC. The PLC controlling system controls two stepper motors to band the blowtorch moving, and eliminates the deviation of the blowtorch and welding seam, making up a closed-loop control system wholly in order to achieve the goal about the submerged-arc welding seam tracking.
With the controlling core of PLC, we exploit automatic tracking system on the base of the algorithm that is a kind of VB development of image processing. Getting across great bulk of the normal CCD, we adopt 8mm flexible tube industrial CCD. We use CCD camera as the transducer of automatic tracking system, which can make the image more clear and easy to install. Using the Eurofins 508 DC governor, we design the routine which can adjust rotating speed of lateral electrical engineering and longitudinal electrical engineering in cross type guides, which improve the integrity of welding seam automatic tracking system.
As the research spiral pipe submerged arc welding seam tracking system image processing algorithm, using VB programming calls Windows API functions, it can playback and capture the AVI video which is the actual welding process. Finally it formed the seam tracking image simulation program. The programs weaken the limit to the work by the actual production links, shorten the time of the image processing algorithm study, and enhance the efficiency of development of seam tracking research, which is importantly significant. Combining with the practical situation, the algorithm in this paper carries on along the way. The algorithm we get has important reference value in this area.
本课题与辽阳大泽钢管有限公司螺旋管生产线相结合,以其实际生产环境为研究基础,研究与设计螺旋管焊缝自动跟踪系统。
本文设计的螺旋管焊缝自动跟踪系统原理为:通过CCD视觉传感器采集焊接区域前端焊缝图像,将图像传输于CG300图像采集卡上,在图像采集卡中进行数据形式转换,将转换后图像信息传输于在上位机中进行VB图像分析处理,得到焊缝的准确位置及焊缝特性等,再利用VB程序与PLC控制器间的自由口通讯方式将焊缝位置信息实时传输于PLC控制中,PLC控制系统控制两个直流电机带动焊炬运动,消除焊炬与焊缝的偏差,形成一个闭环的控制系统,以期达到埋弧焊焊缝跟踪的目的。
本文设计了以PLC为控制核心,以基于VB开发的图像处理为算法的自动跟踪系统。采用8mm软管式工业CCD,克服了普通CCD体积大的弱点,而且采用该CCD摄像头作为焊缝自动跟踪传感器,图像更清晰,易于安装。利用欧陆508直流调速器,实现了软件程序对十字导轨中横向电机与纵电机的转速调整功能,提高了螺旋管焊缝自动跟踪系统的整体性能。
为研究螺旋管埋弧焊焊缝自动跟踪系统图像处理的算法,采用VB编程调用Windows API函数,对实际焊接过程焊缝AVI录像进行回放与捕捉,形成了焊缝跟踪影像仿真程序,该程序削弱了实际生产环节对前期研究工作的限制,缩短了图像处理算法研究周期,对焊缝跟踪研究具有重要意义。本文的算法研究始终是结合现场实际情况开展的,得出的图像处理算法对该领域的研究具有重要的参考价值。
With the development of welding automation and intellectualization, the application of welding seam tracking system appears more and more important. During manufacturing the spiral tube, kinds of influence factor in the welding production, such as the tolerance and thermal distortion and inaccuracy chucking appliance, would affect the welding quality. Welding seam automatic tracking which controls the bias following the specification in adverse circumstances takes seriously topic in domestic and foreign now.
The topic incorporates with the spiral pipe production line of Liao Yang DaZe Company Ltd. We design the welding seam automatic tracking system on the base of the environment of actual production.
In this paper, the principle of the welding seam automatic tracking system is: Capturing the front seam of the weld area image by CCD, the image signals reach CG300 image acquisition broad. It converts the date form in the preconditioning; then we can make Visual Basic image analysis by PC which the image transfer to, we will find the exact position of the welded seam and the properties of seam. What is more, it transfers the live dates of seam position to the PLC by the communication way between Visual Basic and PLC. The PLC controlling system controls two stepper motors to band the blowtorch moving, and eliminates the deviation of the blowtorch and welding seam, making up a closed-loop control system wholly in order to achieve the goal about the submerged-arc welding seam tracking.
With the controlling core of PLC, we exploit automatic tracking system on the base of the algorithm that is a kind of VB development of image processing. Getting across great bulk of the normal CCD, we adopt 8mm flexible tube industrial CCD. We use CCD camera as the transducer of automatic tracking system, which can make the image more clear and easy to install. Using the Eurofins 508 DC governor, we design the routine which can adjust rotating speed of lateral electrical engineering and longitudinal electrical engineering in cross type guides, which improve the integrity of welding seam automatic tracking system.
As the research spiral pipe submerged arc welding seam tracking system image processing algorithm, using VB programming calls Windows API functions, it can playback and capture the AVI video which is the actual welding process. Finally it formed the seam tracking image simulation program. The programs weaken the limit to the work by the actual production links, shorten the time of the image processing algorithm study, and enhance the efficiency of development of seam tracking research, which is importantly significant. Combining with the practical situation, the algorithm in this paper carries on along the way. The algorithm we get has important reference value in this area.
引文
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[2]庞红印.我国油气管道焊接技术发展综述.现代焊接,2009(2):27~32.
[3]张建.西气东输管道工程中管道焊接的质量控制.现代焊接,2003(5):47~51.
[4]朱旭,罗天宝,白光明.浅谈螺旋缝埋弧焊管焊缝夹杂产生原因及解决措施.现代焊接, 2006(9):42~45.
[5]王力,王胜华.机器人焊接轨迹自动跟踪视觉技术研究.电焊机,2009,39(4):37~39.
[6]孔德杰.基于CCD图像处理的焊缝跟踪控制系统的研究.山东大学,2005.
[7]林尚扬.我国焊接生产现状与焊接技术的发展.船舶工程,2005(S1):12~15.
[8]谭一炯,周方明,王江超,黄志杰.焊接机器人技术现状与发展趋势.电焊机,2006,36(3):55~57.
[9] Chu W-H,Tung P-C (2005) Development of an automatic arc welding system using a sliding mode control. Int J Mach Tool Manual 45:933~936.
[10] Nomura H.et al. Automatic real-time bead height control with arc sensor in TIG welding, IIW Doc XII-844~845.
[11] Murakarni S. Weld-line Tracking Control of Arc Welding Robot Using Fuzzy Logic Controller. Fuzzy Sets and Systems, 2001,32(2):221~237.
[12] JWKIM,S J NA. A Self-Organizing Fuzzy Control Approach to Arc Sensor for Welding Joint Tracking in Gas Metal Arc Welding of Butt Joint. Welding Journal,1993,72(20):60~66.
[13]陈裕川.我国自动化焊接装备的当代发展水平.现代焊接,2010(1):47~48.
[14]黄石生,王秀媛,高向东.埋弧焊焊缝跟踪控制系统及发展状况.焊接.2000(1):16~18.
[15]陈善本.焊接过程现代控制技术.哈尔滨:哈尔滨工业大学出版社,2001.
[16]李为卫,左晨.石油天然气管道焊接材料发展现状及建议.现代焊接.2007(11):52~56.
[17]张建.西气东输管道工程中管道焊接的质量控制.现代焊接,2003(5):15~18.
[18]雷毅,袁晓波,孙晓娜.面向压力容器焊接自动化技术的应用现状与展望.压力容器,2004(10):19~21.
[19]朱旭,罗天宝,白光明.浅谈螺旋缝埋弧焊管焊缝夹杂产生原因及解决措施.现代焊接, 2006(9):37~39.
[20]陈邦固,金立鸿,王秀文.新世纪我国焊接产业的发展与展望.焊接技术,2002,33(5):7~9.
[21]刘嵩,高波,周大威等.焊缝自动跟踪系统的发展综述.黑龙江自动化技术与应用,1995,14(4):31~32.
[22]崔元彪,阎志峰,刘立君等.焊缝跟踪图像处理系统的研究.哈尔滨理工大学学报,2006,11(4):85~88.
[23]李树槐,李桂中.焊接质量自动控制.长春:吉林工业大学焊接专业教材,2003.
[24]李慨.基于视觉传感管道焊接机器人跟踪系统研究.哈尔滨工业大学,2007.
[25]程开富.CCD图像传感器的市场与发展.国外电子元器件,2000(7):1~4.
[26]张昊,程永进,景锐平.线阵CCD图象采集系统.电子技术,2009(5):21~24.
[27]陈彦宾,李俐群,陈凤东,陈杰.图像处理在自动焊接中的应用和展望.材料科学与工艺,2003(1):39~41.
[28]王秀涣.图形处理法在焊缝识别中的应用.电焊机,2002,30(10):23~24.
[29]吕学勤,杨洁,杨旭红.图像处理在焊缝熔池控制中的应用.上海电力学院学报,2009,25(1):28~30.
[30]王明常,邢立新,杨毅恒,吕凤军,刘志会.基于方向加权二维多级中值滤波的遥感图像处理方法.测绘技术装备,2005(1):43~44.
[31]杨平先,孙兴波.一种改进多尺度形态边缘检测算法.光电工程,2005(11):18~19.
[32]程世东,汤楠,高炜欣,穆向阳.埋弧焊焊缝跟踪系统数字图像处理方法研究.焊管,2008,32(2):23~25.
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