埋弧焊焊缝跟踪系统的设计与试验
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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。焊接生产中工件的加工误差,焊接过程中的热变形、装卡具的不精确以及焊工疲劳等各种因素影响的存在,使焊缝的实时自动跟踪成为当今国内外十分重视的课题。本文采用CCD摄像头作为焊缝跟踪传感器,设计了以研华PCI-1711L板卡为控制核心的跟踪系统,对现有执行机构进行了重新设计,改善焊接小车的响应速度,文中还对埋弧焊图像处理算法进行了深入的探讨。
本文采用的焊缝跟踪系统的原理是:通过CCD采集埋弧焊焊剂覆盖区的前端焊缝及指针图像,把图像信号通过同轴电缆传到图像采集卡上,在图像采集卡中进行必要的处理(如量化);然后通过工控机中VB编制的系统软件进一步分析图像、提取焊缝的位置,最后把焊缝位置信息实时传给研华PCI-1711L板卡,板卡控制两个步进电机带动焊枪运动,消除焊枪与焊缝的偏差,形成一个闭环的控制系统,达到埋弧焊焊缝跟踪的目的。
在图像处理技术上,本文采用滤波程序来减少环境因素对程序的影响,效果颇佳,分别对在自然光、光源在上方、光源在一侧处理图像方法进行试验发现:自然光和光源在上方处理图像的方法已经失去了焊缝的信息,但光源在一侧的处理图像能准确的反应出焊缝的信息,所以光源在一侧的,阈值为90的图像跟踪的方法是最优的。
With the development of welding automation and intellectualization, the application of welding seam tracking system appears more and more important. Because in the welding production there are kinds of influence factor, for example the mismachining tolerance and thermal distortion and inaccuracy chucking appliance, welding seam real-time automatic tracking takes seriously topic in domestic and foreign now. In this paper, there is CCD camera as a seam tracking sensors, designed to Yan Hua PCI-1711L as the core of the tracking system, I will redesign the existing implementing agencies to improve the response speed of welding carriage and the article also discussed SAW image processing algorithms in-depth.
In this paper, the principle of the seam tracking system is: capturing Submerged Arc Flux collection in the area of coverage and the front seam indicator image by CCD, the image signals through coaxial cable reach image acquisition broad. Image acquisition board for some hardware in the preconditioning (such as quantification); Then we will use the VB system software in PC for further analysis of the image to find the welding seam and PC send the welding seam information into Yan Hua PCI-1711L in finally. PC further analyzes the images and extracts the position of the welding seam, and then gives the real-time welding information to Yan Hua PCI-1711L. Yan Hua PCI-1711L controlling system controlls two stepper motors to band the blowtorch moving, eliminates the deviation of the blowtorch and welding seam, makes up a closed-loop control system wholly in order to achive the goal about the submerged-arc welding seam tracking.
In this paper, we use filtering procedures to reduce the impact of environmental factors on the process in the image processing technology and results quite well; Respectively, I ma dealing with images in natural light, the light source at the top and the light source at one side:the image of natural light and lighting at the top has been lost weld information, however, the light in one side of the image can be accurately reflect the seam of information, So the tracking method of slight source on one side and the threshold value of 90 image is optimal.
本文采用的焊缝跟踪系统的原理是:通过CCD采集埋弧焊焊剂覆盖区的前端焊缝及指针图像,把图像信号通过同轴电缆传到图像采集卡上,在图像采集卡中进行必要的处理(如量化);然后通过工控机中VB编制的系统软件进一步分析图像、提取焊缝的位置,最后把焊缝位置信息实时传给研华PCI-1711L板卡,板卡控制两个步进电机带动焊枪运动,消除焊枪与焊缝的偏差,形成一个闭环的控制系统,达到埋弧焊焊缝跟踪的目的。
在图像处理技术上,本文采用滤波程序来减少环境因素对程序的影响,效果颇佳,分别对在自然光、光源在上方、光源在一侧处理图像方法进行试验发现:自然光和光源在上方处理图像的方法已经失去了焊缝的信息,但光源在一侧的处理图像能准确的反应出焊缝的信息,所以光源在一侧的,阈值为90的图像跟踪的方法是最优的。
With the development of welding automation and intellectualization, the application of welding seam tracking system appears more and more important. Because in the welding production there are kinds of influence factor, for example the mismachining tolerance and thermal distortion and inaccuracy chucking appliance, welding seam real-time automatic tracking takes seriously topic in domestic and foreign now. In this paper, there is CCD camera as a seam tracking sensors, designed to Yan Hua PCI-1711L as the core of the tracking system, I will redesign the existing implementing agencies to improve the response speed of welding carriage and the article also discussed SAW image processing algorithms in-depth.
In this paper, the principle of the seam tracking system is: capturing Submerged Arc Flux collection in the area of coverage and the front seam indicator image by CCD, the image signals through coaxial cable reach image acquisition broad. Image acquisition board for some hardware in the preconditioning (such as quantification); Then we will use the VB system software in PC for further analysis of the image to find the welding seam and PC send the welding seam information into Yan Hua PCI-1711L in finally. PC further analyzes the images and extracts the position of the welding seam, and then gives the real-time welding information to Yan Hua PCI-1711L. Yan Hua PCI-1711L controlling system controlls two stepper motors to band the blowtorch moving, eliminates the deviation of the blowtorch and welding seam, makes up a closed-loop control system wholly in order to achive the goal about the submerged-arc welding seam tracking.
In this paper, we use filtering procedures to reduce the impact of environmental factors on the process in the image processing technology and results quite well; Respectively, I ma dealing with images in natural light, the light source at the top and the light source at one side:the image of natural light and lighting at the top has been lost weld information, however, the light in one side of the image can be accurately reflect the seam of information, So the tracking method of slight source on one side and the threshold value of 90 image is optimal.
引文
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[37]周燕.数控机床滚珠丝杠副的选择与计算[J].机床与液压, 2005,(01).
[38]吴宗泽.机械设计实用手册[M].北京:化学工业出版社, 2005.
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[44]高向东,赵传敏,丁度坤.图像处理技术在焊缝跟踪中的应用研究[M].焊接技术,2006,35 (2):3-6.
[45]岳宏.基于结构光的机器人焊接实时图像处理方法的研究[J].机器人, 1999, 21(3): 144-147.
[46]张燏,吴志斌,陈淑珍等.一种新的自适应二值化方法[J].计算机工程, 2002, 28(5): 184-185.
[47]刘娜,张义顺,邵成吉等.基于VB的CCD焊缝自动跟踪程控系统研究[J].航天制造技术, 2003(2): 30-32.
[48]容观奥.计算机图象处理[M].北京:清华大学出版社, 2000.
[49] Ballard D H, Brown C M. Computer Vision[M]. New Jersey: Prentice-Hall, 1982.
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[62] Bill Lucas. Keeping an Electronic Eye on Automated Arc Welding [J]. Welding & Metal Fabrica_ tion, 2000(4): 6-14.
[63]朱若磊.基于焊缝中心的焊缝信息的直接提取[J].机床与液压, 2006(4): 22-23.
[2]林尚扬.焊接过程低成本自动化的选择与思考[J].机电产品开发与创新, 1999(6):8-12.
[3]宋天虎.我国焊接生产技术现状及其今后的发展(上)[J].焊接学会三十周年文集,焊接, 1992(11):6-10.
[4]程开富. CCD图像传感器的市场与发展[J].国外电子元器件, 2000(7): 2-7.
[5]崔元彪,阎志峰,刘立君等.焊缝跟踪图像处理系统的研究[J].哈尔滨理工大学学报, 2006,11(4): 85-88.
[6]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.
[7]张运川.球形储罐自动化焊接技术的进展[J].压力容器, 1997, 14(4): 49-56.
[8] Nomura H.et al. Automatic real-time bead height control with arc sensor in TIG welding[J], IIW Doc XII-844-85.
[9] Murakarni S. Weld-line Tracking Control of Arc Welding Robot Using Fuzzy Logic Controller [J]. Fuzzy Sets and Systems, 1989, 32(2): 221-237.
[10] 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 [J]. Welding Journal, 1993, 72(20): 60-66.
[11]刘嵩,高波,周大威等.焊缝自动跟踪系统的发展综述[J].黑龙江自动化技术与应用, 1995,14(4): 1-4.
[12] Hong Yue, Lixin Sun, Kai Li. Recognition and Tracking of Large Seam Based on Robotic Vision [J]. Dynamic system and control division, 2000, Vo1.1: 189-194.
[13] Nomura H. Automatic control of arc welding by arc sensor system[J]. NKK Technical Report, Overseas, 1986, 47-48.
[14]李云峰,张志金,宫文彪等.埋弧焊焊缝视频摄像传感器自动跟踪系统[J].焊管, 2006(1): 32-34.
[15]王秀涣.图形处理法在焊缝识别中的应用[J].电焊机, 2002(10): 32-35.
[16]余震,曾晓雁. CCD传感器在工业测控中的应用现状及展望[J].计量与测试技术. 2002(3): 30-32.
[17]范剑英,于小洋.三位视觉传感技术进展[J].兵工自动化,2000(2):25-33.
[18] Ferrier I. Zero-Gap Seam Tracking With Laster Vision Can [J] Welding Fabricator, 1989(1): 9-12.
[19] Faugeras O D. Maybank S. Motion from Point Matches: Multiplicity of Solutions[J]. Computer vision, 1990(4): 225-246.
[20]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[J].焊接,2000(1): 8-11.
[21]章毓晋.图像处理与计算机视觉[M].北京:清华大学出版社,2000.
[22]朱六妹,宋国军,王伟等.基于CCD图像处理的CO2焊自动跟踪系统设计[J].光电子技术,2002,9(22):160-163.
[23] Pratt W K. Digital Image Processing[M]. New York: John Wiley and Sons Inc, 1998.
[24] Frei W, Chen C C. Fast boundary detection: a generalization and a new algorithm[J]. IEEE, 1997, C-26: 988-998.
[25]张敏.二值图像中一种改进的细化算法[J].现代电子技术, 2005(19): 96-98.
[26] Pratt W K. Digital Image Processing[M]. N.Y: John Wiley and Sons Inc, 1998.
[27] Min Young Kim, Kuk Won Ko, Hyung Suck Cho, et al. Visual sensing and recognition of welding environment for intelligent shipyard welding robot. Intelligent Robots and Systems[J], 2000 IEEE/RSJ International Conference on Volume, 2000, 2159-2165.
[28] Bill Lucas. Keeping an Electronic Eye on Automated Arc Welding[J]. Welding & Metal Fabrication, 2000(4): 6-13.
[29]李素芝著.时域离散信号处理[M].长沙:国防科技大学出版社, 1994.
[30]殷洪义.可编程控制器选择设计与维护[J].机械工业出版社, 2003(1):118-162.
[31]陈强,孙振国.计算机视觉传感技术在焊接中的应用[J].焊接学报, 2001, 22(1):83-90.
[32]孙立新,戴士杰.基于线结构光多道焊跟踪系统图像处理[J].焊接学报, 2002, 29(3): 45-49.
[33]胡铁军,王克争,陈新征等.半导体激光器在CCD焊缝跟踪系统中的应用[J].电焊机, 2002, 32(3): 25-27.
[34]何斌,马天予,王运坚等. Visual C++数字图像处理[M].北京:人民邮电出版社, 2001.
[35]高晋占.微弱信号检测[M].北京:清华大学出版社, 2004.
[36] Berdyaev A.M.etal. Special features of Melting the Electrode Metal when welding in an external Magnetic Field [J]. Welding Production, 2003, (5): 28-30.
[37]周燕.数控机床滚珠丝杠副的选择与计算[J].机床与液压, 2005,(01).
[38]吴宗泽.机械设计实用手册[M].北京:化学工业出版社, 2005.
[39]王之枥,王大康.机械设计综合课程设计[M].北京:机械工业出版社, 2003.
[40]姚明武,邹红雨.步进电机工作原理的探讨[M].贵州:中国振华(集团)科技公司建新分司, 2007.
[41]梁明,王国荣,石永华等.焊缝自动跟踪系统中的智能控制[J].电焊机,2000,30(8):17-20.
[42]陈裕川.钢制压力容器焊接工艺[M].北京:机械工业出版社,2007.
[43]董大勤,袁凤隐.压力容器设计手册.北京:化学工业出版社,2005.
[44]高向东,赵传敏,丁度坤.图像处理技术在焊缝跟踪中的应用研究[M].焊接技术,2006,35 (2):3-6.
[45]岳宏.基于结构光的机器人焊接实时图像处理方法的研究[J].机器人, 1999, 21(3): 144-147.
[46]张燏,吴志斌,陈淑珍等.一种新的自适应二值化方法[J].计算机工程, 2002, 28(5): 184-185.
[47]刘娜,张义顺,邵成吉等.基于VB的CCD焊缝自动跟踪程控系统研究[J].航天制造技术, 2003(2): 30-32.
[48]容观奥.计算机图象处理[M].北京:清华大学出版社, 2000.
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