CN118180560B - A grid ball weld seam tracking system device and automatic adjustment method - Google Patents
A grid ball weld seam tracking system device and automatic adjustment method Download PDFInfo
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract
本发明涉及网架球焊缝跟踪系统装置技术领域，线激光器对大型球和小型球的球面激光成像长度控制并不相同，易对后续图像处理引入干扰；本发明提供一种网架球焊缝跟踪系统装置及自动调节方法，腔体式结构内部设有用于拍摄焊缝图像的相机组件和用于调节激光器的激光组件，采用PWM信号控制推杆电机改变线激光器的角度，既能够稳定控制激光的光路，也便于调整激光器与相机的合焦点，对不同距离的网架球焊缝进行清晰且准确的自动识别与追踪，三角定位法进行网架球距离计算，全自动完成变焦合焦与夹角调整工作，快速高效的针对不同距离的工况进行调节，极大的减少了工人的使用难度和生产成本。
The invention relates to the technical field of mesh ball weld tracking system devices. Line lasers control spherical laser imaging lengths of large balls and small balls differently, which can easily introduce interference to subsequent image processing. The invention provides a mesh ball weld tracking system device and an automatic adjustment method. A camera component for photographing weld images and a laser component for adjusting the laser are arranged inside a cavity structure. A push rod motor is controlled by a PWM signal to change the angle of the line laser, which can stably control the optical path of the laser and facilitate adjustment of the focal point of the laser and the camera. Clear and accurate automatic identification and tracking of mesh ball welds at different distances are performed. The mesh ball distance is calculated by a triangulation positioning method. Zoom focusing and angle adjustment are completed automatically. Adjustment is performed quickly and efficiently for working conditions at different distances, which greatly reduces the difficulty of use for workers and production costs.
Description
技术领域Technical Field
本发明涉及网架球焊缝跟踪系统装置技术领域，具体的说，涉及一种焊缝跟踪系统装置及自动调节方法。The invention relates to the technical field of grid ball weld tracking system devices, and in particular to a weld tracking system device and an automatic adjustment method.
背景技术Background technique
网架结构产品作为新型建筑结构产品，在大型建筑项目中得到广泛应用。在众多网架结构产品中，焊接球网架结构以其整体重量轻，材料用量少，结构刚度大等优势备受青睐。As a new type of building structure product, grid structure products are widely used in large-scale construction projects. Among the many grid structure products, the welded ball grid structure is highly favored for its advantages such as light overall weight, less material consumption, and high structural rigidity.
目前，焊接球的制造方法是先制造两个空心的半球，之后工艺装配焊接成整体，最后进行整体焊接。由于两个空心球之间的缝隙较宽较深，在焊接时需要重复焊接多次以保证焊缝平整。在网架球焊接过程中，准确地追踪焊缝是至关重要的。传统的焊接方式通常需要熟练的操作员使用手动方法进行焊接，对操作员的焊接技术水平要求较高，且在复杂焊缝的情况下，难以保证焊接质量和效率，且长期操作会对视力产生不良影响，同时设备运行时需要人员近距离操作，有生产安全隐患。At present, the manufacturing method of welding balls is to first manufacture two hollow hemispheres, then assemble and weld them into a whole, and finally weld the whole. Since the gap between the two hollow balls is wider and deeper, welding needs to be repeated many times during welding to ensure that the weld is smooth. In the process of grid ball welding, it is crucial to accurately track the weld. Traditional welding methods usually require skilled operators to use manual methods for welding, which requires a high level of welding technology from the operator. In the case of complex welds, it is difficult to ensure welding quality and efficiency, and long-term operation will have an adverse effect on eyesight. At the same time, personnel need to operate at close range when the equipment is running, which poses a potential safety hazard to production.
现有的焊缝跟踪系统几乎全部是针对直线焊缝进行设计，直线焊缝现场可利用空间很大，直线焊缝的激光器与相机在空间上有很大的距离，从而使相机获取到清晰的焊缝图像，另外，用于直线焊缝的焊缝跟踪系统与焊枪距离较远，从而几乎避免焊接过程中强弧光、焊渣等对焊缝图像的影响。然而，对于网架球焊接现场来说，现场可利用空间很小，要求相机与激光器必须安装在狭小的范围内，另外，焊接过程中强弧光、焊渣飞溅等对网架球焊缝图像的高质量获取有非常大的影响，因此，目前市场上鲜有性能优良的焊缝跟踪系统广泛应用。Almost all existing weld tracking systems are designed for straight welds. There is a lot of available space on the site for straight welds. The laser and camera of the straight weld are far apart in space, so the camera can obtain a clear weld image. In addition, the weld tracking system for straight welds is far away from the welding gun, which almost avoids the influence of strong arc light, welding slag, etc. on the weld image during welding. However, for the grid ball welding site, the available space is very small, requiring the camera and laser to be installed in a small range. In addition, strong arc light, welding slag splashing, etc. during welding have a great impact on the high-quality acquisition of grid ball weld images. Therefore, there are few weld tracking systems with excellent performance widely used in the market.
随着技术的不断进步，线激光相机应运而生。线激光相机是一种集成激光成像技术和计算机视觉技术的设备。它通过激光投射出一条线形光束，然后利用相机拍摄激光的反射图像，并通过计算机进行图像处理和分析，从而实现对焊缝的实时跟踪和监测。With the continuous advancement of technology, line laser cameras have emerged. Line laser cameras are a type of equipment that integrates laser imaging technology and computer vision technology. It projects a linear beam through laser, then uses a camera to capture the reflected image of the laser, and performs image processing and analysis through a computer, thereby achieving real-time tracking and monitoring of the weld.
然而，线激光相机在实际应用中存在一些挑战：首先，相机的分辨率和帧率需要高于一般相机，以能够捕捉焊接过程中的细微变化。其次，激光投射的焦点极大的影响了成像的质量，需要保证激光合焦点靠近反射平面，以避免影响图像质量和测量精度。此外在长时间焊接后，相机的镜头由于飞溅的焊渣和火花，会产生磨损甚至是嵌入焊渣，在长时间的焊接过程中也可能导致相机或者激光器部分过热而无法工作。最后针对于网架球，线激光相机需要对球面的激光照射角度进行控制，如，对于大型球有合适的角度拍摄到焊缝，但在面对小型球时，可能由于直径小的原因使激光照射不到球面焊缝，从而拍摄不到焊缝，进而不能进行焊缝跟踪。However, there are some challenges in the actual application of line laser cameras: First, the resolution and frame rate of the camera need to be higher than those of general cameras in order to capture subtle changes in the welding process. Secondly, the focus of laser projection greatly affects the quality of imaging. It is necessary to ensure that the laser focus is close to the reflection plane to avoid affecting the image quality and measurement accuracy. In addition, after a long period of welding, the camera lens will be worn or even embedded with welding slag due to splashing slag and sparks. During a long welding process, it may also cause the camera or laser to overheat and fail to work. Finally, for the grid ball, the line laser camera needs to control the laser irradiation angle of the spherical surface. For example, for large balls, there is a suitable angle to capture the weld, but when facing a small ball, the laser may not be able to irradiate the spherical weld due to the small diameter, so the weld cannot be captured, and the weld cannot be tracked.
发明内容Summary of the invention
现有的焊缝跟踪装置在进行焊接工作时，存在相机焦距不可调，激光焦距不可调，相机镜头易磨损，相机与球体距离可变范围小的问题，然而，在网架球焊接过程中，球体直径变化范围大，球体直径在160mm—1000mm内有很多种直径规格，不同的直径规格的球体在焊接时，要求相机焦距、相机与激光器的夹角是完全不一样的，但当前焊缝跟踪装置中都不能实现这些参数的调节。针对现有焊缝跟踪装置的这些问题，本发明的目的在于提供一种网架球焊缝跟踪系统装置及自动调节方法，本发明通过对相机焦距的精确控制，以及线激光器的角度的精确控制，能够实现对不同直径的网架球焊缝清晰准确的自动识别与跟踪。When performing welding, the existing weld tracking device has the problems of non-adjustable camera focal length, non-adjustable laser focal length, easy wear of camera lens, and small variable range of distance between camera and sphere. However, in the process of mesh ball welding, the diameter of the sphere varies greatly, and there are many diameter specifications of the sphere within 160mm-1000mm. When welding spheres of different diameter specifications, the camera focal length and the angle between camera and laser are required to be completely different, but the current weld tracking device cannot adjust these parameters. In view of these problems of the existing weld tracking device, the purpose of the present invention is to provide a mesh ball weld tracking system device and an automatic adjustment method. The present invention can realize clear and accurate automatic identification and tracking of mesh ball welds of different diameters through precise control of the camera focal length and the angle of the line laser.
为实现上述目的，本发明提供技术方案如下：To achieve the above object, the present invention provides the following technical solutions:
一种网架球焊缝跟踪系统装置，包括外壳和外壳盖板，外壳盖板安装在一体式结构的外壳侧面，外壳盖板与外壳形成腔体式结构，所述腔体式结构内部设有用于拍摄焊缝图像的相机组件和用于调节线激光器的激光组件，所述相机组件位于激光组件的上方，相机组件的安装面与激光组件的安装面之间通过光滑圆弧曲面连接；所述相机组件包括工业变焦相机、相机固定组件和相机保护组件，外壳设有用于工业变焦相机拍摄图像的第一通孔，所述相机保护组件安装在外壳上；所述激光组件包括线激光器、激光器保护镜片和激光器调节组件，外壳在线激光器的激光发射方向设有第二通孔，激光器保护镜片通过激光器外盖板和螺丝固定在第二通孔外围的外壳外壁；通过激光器调节组件调节线激光器的角度；所述激光器调节组件包括激光器安装支架、用于调整线激光器角度偏转的推杆和推杆电机，线激光器固定在激光器安装支架上，激光器安装支架一端与外壳转动连接，激光器安装支架另一端的侧面设置槽口；所述推杆的末端设置凸起结构，所述凸起结构与激光器安装支架的槽口滑动配合，利用PWM信号控制推杆电机驱动推杆纵向移动，推杆带动激光器安装支架转动实现线激光器角度的精确调整。A grid ball weld tracking system device comprises a shell and a shell cover plate, wherein the shell cover plate is mounted on the side of the shell of an integrated structure, the shell cover plate and the shell form a cavity structure, wherein a camera assembly for photographing weld images and a laser assembly for adjusting a line laser are arranged inside the cavity structure, wherein the camera assembly is located above the laser assembly, and the mounting surface of the camera assembly is connected to the mounting surface of the laser assembly via a smooth arc surface; the camera assembly comprises an industrial zoom camera, a camera fixing assembly and a camera protection assembly, the shell is provided with a first through hole for the industrial zoom camera to photograph images, and the camera protection assembly is mounted on the shell; the laser assembly comprises a line laser, a laser protection lens and a laser adjustment assembly, and the shell is provided with a line laser A second through hole is provided in the laser emission direction of the device, and the laser protection lens is fixed to the outer wall of the shell outside the second through hole through the laser outer cover plate and screws; the angle of the line laser is adjusted by the laser adjustment component; the laser adjustment component includes a laser mounting bracket, a push rod and a push rod motor for adjusting the angle deflection of the line laser, the line laser is fixed on the laser mounting bracket, one end of the laser mounting bracket is rotatably connected to the shell, and a notch is provided on the side of the other end of the laser mounting bracket; a protruding structure is provided at the end of the push rod, and the protruding structure is slidably matched with the notch of the laser mounting bracket, and the PWM signal is used to control the push rod motor to drive the push rod to move longitudinally, and the push rod drives the laser mounting bracket to rotate to achieve precise adjustment of the angle of the line laser.
进一步，所述相机保护组件包括相机保护镜片和相机滤光片，相机保护镜片通过相机外盖板和螺丝固定在开设第一通孔位置处的外壳外壁，相机滤光片通过相机内盖板和螺丝固定在第一通孔位置处的外壳内壁。Furthermore, the camera protection assembly includes a camera protection lens and a camera filter. The camera protection lens is fixed to the outer wall of the shell at the position of the first through hole through a camera outer cover plate and screws, and the camera filter is fixed to the inner wall of the shell at the position of the first through hole through a camera inner cover plate and screws.
进一步，所述相机外盖板贴近外壳一面的中心位置设有用于固定相机保护镜片的凹槽，凹槽底部开设镜头通孔，通孔的孔径小于相机保护镜片的外径。Furthermore, a groove for fixing the camera protective lens is provided at the center of one side of the camera outer cover plate close to the shell, and a lens through hole is provided at the bottom of the groove, and the aperture of the through hole is smaller than the outer diameter of the camera protective lens.
进一步，所述相机固定组件包括相机固定底板和若干固定柱，工业变焦相机固定安装在相机固定底板朝向第一通孔一面的中心位置，相机固定底板通过若干固定柱安装在腔体式结构内部。Furthermore, the camera fixing assembly includes a camera fixing base plate and a plurality of fixing columns, the industrial zoom camera is fixedly installed at the center position of the camera fixing base plate facing the first through hole, and the camera fixing base plate is installed inside the cavity structure through the plurality of fixing columns.
一种网架球焊缝跟踪系统装置的自动调节方法，基于上述的网架球焊缝跟踪系统装置，根据已知的工业变焦相机的当前焦距 0，以及当前状态下相机光轴与线激光器之间的夹角A0，通过激光反射的光线在工业变焦相机的CMOS面上投射的坐标位置，计算线激光器的调节角度和工业变焦相机的焦距，利用调整后的线激光器和工业变焦相机获取清晰的网架球焊缝特征图像具体步骤如下：An automatic adjustment method for a grid ball weld seam tracking system device is based on the above-mentioned grid ball weld seam tracking system device and according to the current focal length of a known industrial zoom camera. 0 , and the angle A 0 between the camera optical axis and the line laser in the current state, and the coordinate position of the light reflected by the laser projected on the CMOS surface of the industrial zoom camera, calculate the adjustment angle of the line laser and the focal length of the industrial zoom camera , using the adjusted line laser and industrial zoom camera to obtain a clear grid ball weld feature image. The specific steps are as follows:
步骤1. 根据当前状态下已知的工业变焦相机的当前焦距 0，以及当前状态下相机光轴与线激光器之间的夹角A0，通过线激光器发射的激光反射到工业变焦相机的CMOS面上投射的坐标位置，计算出CMOS的中心点和成像点之间的距离即光轴偏移d：Step 1. Based on the known current focal length of the industrial zoom camera in the current state 0 , and the angle A 0 between the camera optical axis and the line laser in the current state, the coordinate position projected on the CMOS surface of the industrial zoom camera by the laser emitted by the line laser , calculate the distance between the center point of the CMOS and the imaging point, that is, the optical axis offset d :
其中，X r 和Y r 分别为相机的横向分辨率和纵向分辨率，时，光轴偏移d取正，反之取负；Among them, X r and Y r are the horizontal resolution and vertical resolution of the camera respectively. When , the optical axis offset d is positive, otherwise it is negative;
步骤2. 利用步骤1获得的光轴偏移d计算工业变焦相机到网架球焊缝表面的物距F：Step 2. Use the optical axis offset d obtained in step 1 to calculate the object distance F from the industrial zoom camera to the mesh ball weld surface:
其中，D是工业变焦相机与线激光器之间的距离；Where, D is the distance between the industrial zoom camera and the line laser;
步骤3. 根据步骤2获得的物距F，利用如下公式计算调节后线激光器与工业变焦相机的光轴之间的夹角A：Step 3. According to the object distance F obtained in step 2, use the following formula to calculate and adjust the angle A between the rear-line laser and the optical axis of the industrial zoom camera:
其中，C为工业变焦相机和线激光器连线所在直线与工业变焦相机的光轴的夹角，根据线激光器与工业变焦相机的光轴之间的夹角A，得到航空插头的信号线向推杆电机输入的PWM信号的占空比duty：Among them, C is the angle between the straight line connecting the industrial zoom camera and the line laser and the optical axis of the industrial zoom camera. According to the angle A between the line laser and the optical axis of the industrial zoom camera, the duty cycle of the PWM signal input from the signal line of the aviation plug to the push rod motor is obtained:
其中，K 1为二阶变换系数，K 2为一阶变换系数，K 1和K 2为依照电机齿比与激光器支架长度确定的常数，B表示占空比duty为0时，线激光器与工业变焦相机的光轴之间的夹角；Wherein, K1 is the second-order transformation coefficient, K2 is the first-order transformation coefficient, K1 and K2 are constants determined according to the motor gear ratio and the length of the laser bracket, and B represents the angle between the line laser and the optical axis of the industrial zoom camera when the duty cycle is 0;
步骤4. 通过航空插头的信号线向推杆电机输入占空比为步骤3计算所得占空比duty的PWM信号，完成线激光器和工业变焦相机的光轴之间的夹角A的调节，根据步骤2获得的物距F，计算工业变焦相机在线激光器调节角度后的焦距，焦距计算公式如下：Step 4. Input a PWM signal with a duty cycle calculated in step 3 to the push rod motor through the signal line of the aviation plug to adjust the angle A between the line laser and the optical axis of the industrial zoom camera. According to the object distance F obtained in step 2, calculate the focal length of the industrial zoom camera after adjusting the angle of the line laser. ,focal length Calculated as follows:
其中，cmossize为工业变焦相机的CMOS传感器尺寸，objsize为被测区域尺寸，K 3画幅占比系数；利用调整后的线激光器和工业变焦相机获取清晰的网架球焊缝特征图像。Among them, cmossize is the CMOS sensor size of the industrial zoom camera, objsize is the size of the measured area, and K 3 is the frame ratio coefficient. The adjusted line laser and industrial zoom camera are used to obtain clear grid ball weld feature images.
综上所述，发明具有以下有益效果：In summary, the invention has the following beneficial effects:
本发明采用GigE工业变焦相机，通过控制相机焦距变化，在面对不同直径网架球焊接时产生的网架球表面与相机距离变化过大情况下，提高网架球焊缝的成像质量，进而提高焊缝跟踪精度，保证焊接质量；本发明采用PWM信号控制推杆电机改变线激光器的角度，既能够稳定控制激光的光路，也便于调整激光器与相机的合焦点，对不同直径的网架球焊缝进行清晰且准确的自动识别与追踪；本发明采用手拧螺丝配合两个外部盖板安装保护镜片，杜绝了焊渣火花对镜头的损伤，降低了更换保护镜片的难度，且相机与激光器保护镜片的规格一致，进一步降低维修成本；本发明采用三角定位法进行网架球距离计算，全自动完成变焦合焦与夹角调整工作，快速高效的针对不同直径网架球的工况进行调节，极大的减少了工人的使用难度和生产成本。本发明只采用一套跟踪装置适应不同直径网架球焊接时焊缝的清晰且准确的自动识别与追踪，完全改善了当前焊缝跟踪系统只能在固定小范围距离内进行焊缝识别与跟踪，以及针对不同距离需要频繁更换跟踪系统的问题。The present invention adopts a GigE industrial zoom camera, and by controlling the change of the camera focal length, when the distance between the grid ball surface and the camera changes too much during the welding of grid balls with different diameters, the imaging quality of the grid ball weld is improved, thereby improving the weld tracking accuracy and ensuring the welding quality; the present invention adopts a PWM signal to control the push rod motor to change the angle of the line laser, which can not only stably control the optical path of the laser, but also facilitate the adjustment of the focal point of the laser and the camera, and clearly and accurately automatically identify and track the grid ball welds of different diameters; the present invention adopts a hand-tightened screw in conjunction with two external cover plates to install a protective lens, which prevents the damage of welding slag sparks to the lens, reduces the difficulty of replacing the protective lens, and the specifications of the camera and laser protective lenses are consistent, further reducing the maintenance cost; the present invention adopts a triangulation positioning method to calculate the grid ball distance, automatically completes the zoom focus and angle adjustment work, and quickly and efficiently adjusts the working conditions of grid balls with different diameters, greatly reducing the difficulty of use and production costs for workers. The present invention uses only one set of tracking devices to adapt to the clear and accurate automatic identification and tracking of welds when welding grid balls of different diameters, which completely improves the problem that the current weld tracking system can only identify and track welds within a fixed small range and needs to frequently replace the tracking system for different distances.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明外侧相机盖板与激光器盖板结构示意图；FIG1 is a schematic diagram of the structure of the outer camera cover and the laser cover of the present invention;
图2为本发明内侧相机组件与激光组件位置示意图；FIG2 is a schematic diagram of the positions of the inner camera assembly and the laser assembly of the present invention;
图3为航空插头及装置固定孔位置示意图；Figure 3 is a schematic diagram of the location of the aviation plug and the device fixing hole;
图4为本发明的相机组件位置及拆解示意图；FIG4 is a schematic diagram of the position and disassembly of the camera assembly of the present invention;
图5为本发明激光组件位置及拆解示意图；FIG5 is a schematic diagram of the position and disassembly of the laser assembly of the present invention;
图6为本发明的线激光器角度变化示意图；FIG6 is a schematic diagram of the angle change of the line laser of the present invention;
图7为本发明激光器安装支架的转动轴固定点位示意图；FIG7 is a schematic diagram of the fixed points of the rotating shaft of the laser mounting bracket of the present invention;
图8为本发明在当前状态下的三角测距法示意图；FIG8 is a schematic diagram of the triangulation distance measurement method of the present invention in the current state;
图9为线激光器与工业变焦相机的光轴之间的夹角A求解示意图。FIG9 is a schematic diagram showing the solution of the angle A between the line laser and the optical axis of the industrial zoom camera.
图中：1-外壳、2-外壳盖板、3-第一通孔、4-第二通孔、5-相机外盖板、6-激光器外盖板、7-相机外盖板螺丝、8-激光器外盖板螺丝、9-相机安装螺孔、10-外壳盖板固定螺丝、11-航空插头安装孔位、12-装置固定螺孔、13-相机内盖板螺丝、14-相机保护镜片、15-相机滤光片、16-相机内盖板、17-固定柱、18-工业变焦相机、19-相机固定底板、20-激光器保护镜片、21-激光器固定架、22-线激光器、23-激光器推杆、24-推杆电机。In the figure: 1-housing, 2-housing cover, 3-first through hole, 4-second through hole, 5-camera outer cover, 6-laser outer cover, 7-camera outer cover screw, 8-laser outer cover screw, 9-camera mounting screw hole, 10-housing cover fixing screw, 11-aviation plug mounting hole, 12-device fixing screw hole, 13-camera inner cover screw, 14-camera protection lens, 15-camera filter, 16-camera inner cover, 17-fixing column, 18-industrial zoom camera, 19-camera fixing base plate, 20-laser protection lens, 21-laser fixing frame, 22-line laser, 23-laser push rod, 24-push rod motor.
具体实施方式Detailed ways
下面结合附图对本发明作进一步详细说明。The present invention will be further described in detail below in conjunction with the accompanying drawings.
如图1~7所示，本发明公开了一种网架球焊缝跟踪系统装置，包括外壳1和外壳盖板2，外壳盖板2安装在一体式结构的外壳1侧面，外壳盖板2与外壳1形成腔体式结构，腔体式结构内部设有用于拍摄焊缝图像的相机组件和用于调节线激光器22的激光组件，相机组件位于激光组件的上方，相机组件的安装面与激光组件的安装面之间通过光滑圆弧曲面连接，外壳1的相机组件安装面与激光组件安装面之间存在圆弧曲线的连接过渡，优点在于圆弧曲线方便加工，降低生产成本且更美观，同时加强外壳1正面结构强度，方便前面板粘连焊渣的清理。As shown in Figures 1 to 7, the present invention discloses a grid ball weld tracking system device, including a shell 1 and a shell cover 2, the shell cover 2 is installed on the side of the shell 1 of an integrated structure, the shell cover 2 and the shell 1 form a cavity structure, and a camera component for shooting weld images and a laser component for adjusting a line laser 22 are arranged inside the cavity structure, the camera component is located above the laser component, and the mounting surface of the camera component and the mounting surface of the laser component are connected by a smooth arc surface, and there is an arc curve connection transition between the camera component mounting surface and the laser component mounting surface of the shell 1, which has the advantage that the arc curve is easy to process, reduces production costs and is more beautiful, and at the same time strengthens the front structural strength of the shell 1, which is convenient for cleaning welding slag adhered to the front panel.
相机组件包括工业变焦相机18、相机固定组件和相机保护组件，外壳1设有用于工业变焦相机18拍摄图像的第一通孔3，相机保护组件安装在外壳1上；相机保护组件包括相机保护镜片14和相机滤光片15，相机保护镜片14通过相机外盖板5和相机外盖板螺丝7固定在开设第一通孔3位置处的外壳1外壁，相机滤光片15通过相机内盖板16和相机内盖板螺丝13固定在第一通孔3位置处的外壳1内壁；工业变焦相机18的镜头贴紧相机内盖板16；相机外盖板5贴近外壳1的一面的中心位置设有用于固定相机保护镜片14的凹槽，凹槽底部开设镜头通孔，通孔的孔径小于相机保护镜片14的外径。The camera assembly includes an industrial zoom camera 18, a camera fixing assembly and a camera protection assembly. The housing 1 is provided with a first through hole 3 for the industrial zoom camera 18 to shoot images, and the camera protection assembly is installed on the housing 1; the camera protection assembly includes a camera protection lens 14 and a camera filter 15. The camera protection lens 14 is fixed to the outer wall of the housing 1 at the position of the first through hole 3 through a camera outer cover 5 and a camera outer cover screw 7, and the camera filter 15 is fixed to the inner wall of the housing 1 at the position of the first through hole 3 through a camera inner cover 16 and a camera inner cover screw 13; the lens of the industrial zoom camera 18 is close to the camera inner cover 16; a groove for fixing the camera protection lens 14 is provided at the center position of one side of the camera outer cover 5 close to the housing 1, and a lens through hole is provided at the bottom of the groove, and the aperture of the through hole is smaller than the outer diameter of the camera protection lens 14.
相机固定组件包括相机固定底板19和若干固定柱17，在图4所示实施例中，固定柱17一端安装在相机固定底板19的四角，固定柱17的另一端安装在外壳1的相机安装螺孔9，工业变焦相机18固定安装在相机固定底板19朝向第一通孔3一面的中心位置，相机固定底板19通过若干固定柱17安装在腔体式结构内部。The camera fixing assembly includes a camera fixing base plate 19 and a plurality of fixing columns 17. In the embodiment shown in FIG. 4 , one end of the fixing column 17 is installed at the four corners of the camera fixing base plate 19, and the other end of the fixing column 17 is installed at the camera mounting screw hole 9 of the outer shell 1. The industrial zoom camera 18 is fixedly installed at the center position of the side of the camera fixing base plate 19 facing the first through hole 3, and the camera fixing base plate 19 is installed inside the cavity structure through a plurality of fixing columns 17.
激光组件包括线激光器22、激光器保护镜片20和激光器调节组件，外壳1在线激光器22的激光发射方向设有第二通孔4，激光器保护镜片20通过激光器外盖板6和激光器外盖板螺丝8固定在第二通孔4外围的外壳1外壁；通过激光器调节组件调节线激光器22的角度。The laser assembly includes a line laser 22, a laser protection lens 20 and a laser adjustment assembly. The housing 1 is provided with a second through hole 4 in the laser emission direction of the line laser 22. The laser protection lens 20 is fixed to the outer wall of the housing 1 outside the second through hole 4 through a laser outer cover plate 6 and a laser outer cover plate screw 8; the angle of the line laser 22 is adjusted by the laser adjustment assembly.
激光器调节组件包括激光器安装支架21、用于调整线激光器22角度偏转的推杆23和推杆电机24，线激光器22固定在激光器安装支架21上，激光器安装支架21一端与外壳1转动连接，激光器安装支架21另一端的侧面设置槽口；所述推杆23的末端设置凸起结构，所述凸起结构与激光器安装支架21的槽口滑动配合，利用PWM信号控制推杆电机24驱动推杆23纵向移动，推杆23带动激光器安装支架21转动实现线激光器22角度的精确调整。The laser adjustment component includes a laser mounting bracket 21, a push rod 23 and a push rod motor 24 for adjusting the angle deflection of the line laser 22. The line laser 22 is fixed on the laser mounting bracket 21. One end of the laser mounting bracket 21 is rotatably connected to the housing 1, and a notch is arranged on the side of the other end of the laser mounting bracket 21. A protruding structure is arranged at the end of the push rod 23, and the protruding structure is slidably matched with the notch of the laser mounting bracket 21. The push rod motor 24 is controlled by a PWM signal to drive the push rod 23 to move longitudinally. The push rod 23 drives the laser mounting bracket 21 to rotate to realize precise adjustment of the angle of the line laser 22.
本发明还公开了一种网架球焊缝跟踪系统装置的自动调节方法，基于上述的网架球焊缝跟踪系统装置，根据已知的工业变焦相机18的当前焦距 0，以及当前状态下相机光轴与线激光器22之间的夹角A0，通过激光反射的光线在工业变焦相机18的CMOS面上投射的坐标位置，计算线激光器22的调节角度和工业变焦相机18的焦距，利用调整后的线激光器22和工业变焦相机18获取清晰的网架球焊缝特征图像具体步骤如下：The present invention also discloses an automatic adjustment method for a grid ball weld seam tracking system device. Based on the above grid ball weld seam tracking system device, according to the current focal length of the known industrial zoom camera 18, 0 , and the angle A 0 between the camera optical axis and the line laser 22 in the current state, and the coordinate position of the light reflected by the laser projected on the CMOS surface of the industrial zoom camera 18, calculate the adjustment angle of the line laser 22 and the focal length of the industrial zoom camera 18 The specific steps of obtaining a clear grid ball weld feature image using the adjusted line laser 22 and the industrial zoom camera 18 are as follows:
步骤1. 根据当前状态下已知的工业变焦相机18的当前焦距 0，以及当前状态下相机光轴与线激光器22之间的夹角A0，通过线激光器22发射的激光反射到工业变焦相机18的CMOS面上投射的坐标位置，计算出CMOS的中心点和成像点之间的距离即光轴偏移d：Step 1. Based on the known current focal length of the industrial zoom camera 18 in the current state 0 , and the angle A 0 between the camera optical axis and the line laser 22 in the current state, and the coordinate position projected on the CMOS surface of the industrial zoom camera 18 by the laser emitted by the line laser 22 , calculate the distance between the center point of the CMOS and the imaging point, that is, the optical axis offset d :
其中，X r 和Y r 分别为工业变焦相机18的横向分辨率和纵向分辨率，时，光轴偏移d取正，反之取负。Wherein, X r and Y r are the lateral resolution and longitudinal resolution of the industrial zoom camera 18, respectively. When , the optical axis offset d is positive, otherwise it is negative.
步骤2. 利用步骤1获得的光轴偏移d计算工业变焦相机18到网架球焊缝表面的物距F：Step 2. Calculate the object distance F from the industrial zoom camera 18 to the mesh ball weld surface using the optical axis offset d obtained in step 1:
其中，D是工业变焦相机18与线激光器22之间的距离。Wherein, D is the distance between the industrial zoom camera 18 and the line laser 22 .
步骤3. 根据步骤2获得的物距F，利用如下公式计算调节后线激光器22与工业变焦相机18的光轴之间的夹角A：Step 3. According to the object distance F obtained in step 2, the angle A between the rear-line laser 22 and the optical axis of the industrial zoom camera 18 is calculated and adjusted using the following formula:
其中，C为工业变焦相机18和线激光器22连线所在直线与工业变焦相机18的光轴的夹角，根据线激光器22与工业变焦相机18的光轴之间的夹角A，得到航空插头11的信号线向推杆电机24输入的PWM信号的占空比duty：Wherein, C is the angle between the straight line connecting the industrial zoom camera 18 and the line laser 22 and the optical axis of the industrial zoom camera 18. According to the angle A between the line laser 22 and the optical axis of the industrial zoom camera 18, the duty cycle duty of the PWM signal input from the signal line of the aviation plug 11 to the push rod motor 24 is obtained:
其中，K 1为二阶变换系数，K 2为一阶变换系数，K 1和K 2为依照电机齿比与激光器支架长度确定的常数，B表示占空比duty为0时，线激光器22与工业变焦相机18的光轴之间的夹角。Wherein, K1 is a second- order transformation coefficient, K2 is a first-order transformation coefficient, K1 and K2 are constants determined according to the motor gear ratio and the length of the laser bracket, and B represents the angle between the line laser 22 and the optical axis of the industrial zoom camera 18 when the duty cycle is 0.
步骤4. 通过航空插头11的信号线向推杆电机24输入占空比为步骤3计算所得占空比duty的PWM信号，完成线激光器22和工业变焦相机18的光轴之间的夹角A的调节，根据步骤2获得的物距F，计算工业变焦相机18在线激光器22调节角度后的焦距，焦距计算公式如下：Step 4. Input a PWM signal with a duty cycle calculated in step 3 to the push rod motor 24 through the signal line of the aviation plug 11 to complete the adjustment of the angle A between the line laser 22 and the optical axis of the industrial zoom camera 18. According to the object distance F obtained in step 2, calculate the focal length of the industrial zoom camera 18 after adjusting the angle of the line laser 22. ,focal length Calculated as follows:
其中，cmossize为工业变焦相机18的CMOS传感器尺寸，objsize为被测区域尺寸，K 3画幅占比系数；利用调整后的线激光器22和工业变焦相机18获取清晰的网架球焊缝特征图像。Among them, cmossize is the CMOS sensor size of the industrial zoom camera 18, objsize is the size of the measured area, and K 3 is the frame ratio coefficient; the adjusted line laser 22 and the industrial zoom camera 18 are used to obtain a clear grid ball weld feature image.
实施例：Example:
在本实施例中，相机外盖板5选用厚度为2.5mm的圆形金属薄片，水平方向有中心对称的两个M3开孔，通过相机外盖板螺丝7固定在外壳1上，相机外盖板螺丝7为手拧螺丝，方便拆装，竖直方向有中心对称的两个通孔，内部放置相机内盖板螺丝13，孔径为M3；相机外盖板5中心内侧为直径12mm深度1.1mm的圆柱形凹槽，可放置直径12mm，厚度1mm的相机保护镜片14，相机保护镜片14采用石英晶体材质，相机外盖板5外侧为圆台形结构，圆台形结构底部为直径10mm的圆形通孔；所述相机内盖板16通过相机内盖板螺丝13与M3螺母固定在外壳1上，相机内盖板16中心为直径10mm深度1.1mm的圆柱形凹槽，用于放置直径10mm，厚度1mm的相机滤光片15，相机滤光片15的通过波段要求与线激光器22的波段一致。In this embodiment, the camera outer cover plate 5 is made of a circular metal sheet with a thickness of 2.5 mm, and has two centrally symmetrical M3 openings in the horizontal direction, which are fixed to the housing 1 by the camera outer cover plate screws 7. The camera outer cover plate screws 7 are hand-tightened screws for easy disassembly and assembly. There are two centrally symmetrical through holes in the vertical direction, inside which the camera inner cover plate screws 13 with an aperture of M3 are placed; the inner side of the center of the camera outer cover plate 5 is a cylindrical groove with a diameter of 12 mm and a depth of 1.1 mm, which can accommodate a camera protective cover with a diameter of 12 mm and a thickness of 1 mm. The lens 14, the camera protection lens 14 is made of quartz crystal material, the outer side of the camera outer cover 5 is a truncated cone structure, and the bottom of the truncated cone structure is a circular through hole with a diameter of 10 mm; the camera inner cover 16 is fixed to the outer shell 1 by the camera inner cover screw 13 and the M3 nut, and the center of the camera inner cover 16 is a cylindrical groove with a diameter of 10 mm and a depth of 1.1 mm, which is used to place the camera filter 15 with a diameter of 10 mm and a thickness of 1 mm. The passing band of the camera filter 15 is required to be consistent with the band of the line laser 22.
在本实施例中，激光器外盖板6为圆形金属薄片，竖直方向有中心对称的两个M3开孔，通过激光器外盖板螺丝8固定在外壳1上；放置激光器保护镜片20的凹槽为直径12mm深度1.1mm的圆柱形凹槽，且激光器保护镜片20与相机保护镜片14通用；激光器外盖板6中心外侧为圆角矩形通孔，不会对激光产生遮挡；线激光器22固定在激光器安装支架21上，通过PWM信号控制推杆电机24推动激光器推杆23，激光器推杆23通过凸起结构与激光器安装支架21的槽口相耦合，通过激光器推杆23的升降带动激光器安装支架21的角度偏转。In this embodiment, the laser outer cover 6 is a circular metal sheet with two centrally symmetrical M3 openings in the vertical direction, and is fixed to the outer housing 1 by the laser outer cover screws 8; the groove for placing the laser protection lens 20 is a cylindrical groove with a diameter of 12 mm and a depth of 1.1 mm, and the laser protection lens 20 is compatible with the camera protection lens 14; the outer side of the center of the laser outer cover 6 is a rounded rectangular through hole, which will not block the laser; the line laser 22 is fixed on the laser mounting bracket 21, and the push rod motor 24 is controlled by a PWM signal to push the laser push rod 23. The laser push rod 23 is coupled to the notch of the laser mounting bracket 21 through a protruding structure, and the angle deflection of the laser mounting bracket 21 is driven by the lifting and lowering of the laser push rod 23.
外壳1后侧设有航空插头安装孔位11，固定航空插头的四个M2螺孔内有螺纹，在航空插头下方为本装置固定孔，规格为M5，两孔竖直排列，内部有螺纹，便于将本装置固定在网架球焊接系统上。An aviation plug mounting hole 11 is provided on the rear side of the housing 1. The four M2 screw holes for fixing the aviation plug have threads. Below the aviation plug is a fixing hole for the device, which is M5 in specification. The two holes are arranged vertically and have threads inside, which makes it easy to fix the device on the grid ball welding system.
外壳盖板2通过6颗沉头M3螺丝固定在外壳1上，对外壳1进行密封，拧紧后外壳盖板2表面平滑无突出，腔体结构内部组件实现有效防尘。The outer shell cover 2 is fixed to the outer shell 1 by 6 countersunk M3 screws to seal the outer shell 1. After tightening, the surface of the outer shell cover 2 is smooth without protrusions, and the internal components of the cavity structure are effectively dustproof.
固定柱17长度不小于工业变焦相机18在最大焦距状态下的相机整体长度，固定柱17的长度能够给镜头变焦产生的长度浮动留出空间，确保相机滤光片15与相机保护镜片14紧密相接，确保入射入相机的光线都经过相机滤光片15的过滤。线激光器22通过对激光器安装支架21上的螺纹孔拧入螺丝以固定线激光器22。如图7所示，激光器安装支架21通过内嵌螺纹的转动轴固定在外壳1上，且激光器安装支架21以转动轴为圆心转动，通过PWM控制的推杆电机24能够实现精确控制相机光轴与线激光器22的夹角A，如图6所示。The length of the fixing column 17 is not less than the overall length of the industrial zoom camera 18 at the maximum focal length. The length of the fixing column 17 can leave space for the length float caused by the zoom of the lens, ensure that the camera filter 15 is tightly connected to the camera protective lens 14, and ensure that all light incident on the camera is filtered by the camera filter 15. The line laser 22 is fixed by screwing screws into the threaded holes on the laser mounting bracket 21. As shown in Figure 7, the laser mounting bracket 21 is fixed to the housing 1 through a rotating shaft with an embedded thread, and the laser mounting bracket 21 rotates with the rotating shaft as the center of the circle. The push rod motor 24 controlled by PWM can achieve precise control of the angle A between the camera optical axis and the line laser 22, as shown in Figure 6.
线激光器22发出的光线经过物体表面反射回工业变焦相机18的成像面，由于推杆电机24推出长度可由占空比duty精确控制，如图8所示，通过三角测距法，首先在已知工业变焦相机18的当前焦距 0，以及当前状态下相机光轴与线激光器22之间的夹角A0的情况下，通过激光反射回来的光线在CMOS面上的投射坐标位置，计算出CMOS的中心点和成像点之间的距离即光轴偏移d：The light emitted by the line laser 22 is reflected by the surface of the object and then returned to the imaging surface of the industrial zoom camera 18. Since the push length of the push rod motor 24 can be precisely controlled by the duty cycle, as shown in FIG8 , the triangulation method is used to first determine the current focal length of the industrial zoom camera 18. 0 , and the angle A between the camera optical axis and the line laser 22 in the current state is 0 , the projection coordinate position of the light reflected by the laser on the CMOS surface , calculate the distance between the center point of the CMOS and the imaging point, that is, the optical axis offset d :
其中X r 和Y r 分别为工业变焦相机18的横向分辨率和纵向分辨率，时，光轴偏移d取正，反之取负；然后计算出工业变焦相机18到网架球焊缝表面的物距F：Where X r and Y r are the lateral resolution and longitudinal resolution of the industrial zoom camera 18, respectively. When , the optical axis offset d is positive, otherwise it is negative; then the object distance F from the industrial zoom camera 18 to the mesh ball weld surface is calculated:
其中D是工业变焦相机18与线激光器22之间的距离，D为固定值。Wherein D is the distance between the industrial zoom camera 18 and the line laser 22, and D is a fixed value.
在计算出物距F后，通过航空插头11的信号线向推杆电机24输入PWM信号，PWM信号的占空比即为步骤3计算所得的占空比duty，以调节线激光器22与工业变焦相机18的光轴之间的夹角A，调节后的夹角A和占空比duty的计算公式如下：After calculating the object distance F , a PWM signal is input to the push rod motor 24 through the signal line of the aviation plug 11. The duty cycle of the PWM signal is the duty cycle duty calculated in step 3 to adjust the angle A between the line laser 22 and the optical axis of the industrial zoom camera 18. The calculation formula of the adjusted angle A and the duty cycle duty is as follows:
其中C为工业变焦相机18和线激光器22连线所在直线与工业变焦相机18的光轴的夹角，如图9所示；duty为通过航空插头11接入的信号线向推杆电机24输入的PWM信号的占空比，K 1为二阶变换系数，K 2为一阶变换系数，具体依照电机齿比与激光器支架长度确定，K 1和K 2为常数，B为占空比duty为0时，线激光器22与工业变焦相机18的光轴之间的夹角。Wherein C is the angle between the straight line connecting the industrial zoom camera 18 and the line laser 22 and the optical axis of the industrial zoom camera 18, as shown in Figure 9; duty is the duty cycle of the PWM signal input to the push rod motor 24 through the signal line connected to the aviation plug 11, K1 is the second - order transformation coefficient, K2 is the first -order transformation coefficient, which is specifically determined according to the motor gear ratio and the length of the laser bracket, K1 and K2 are constants, and B is the angle between the line laser 22 and the optical axis of the industrial zoom camera 18 when the duty cycle duty is 0.
基于物距F，通过航空插头11接入的GigE总线控制工业变焦相机18的焦距：Based on the object distance F , the focal length of the industrial zoom camera 18 is controlled via the GigE bus connected to the aviation plug 11 :
其中cmossize为工业变焦相机18的CMOS传感器尺寸，objsize为被测区域尺寸，为画幅占比系数。cmossize is the CMOS sensor size of the industrial zoom camera 18, objsize is the size of the measured area, is the frame ratio coefficient.
最后基于调整完成的焦距与夹角A，按照实际需求的放大倍数能够获取清晰的焊缝的特征，本发明能够自适应工业现场远近大小不同的焊接工况的要求。Finally, based on the adjustment of the focal length With the angle A, clear weld features can be obtained according to the magnification factor actually required, and the present invention can adapt to the requirements of welding conditions of different sizes and distances at industrial sites.
以上所述仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，凡属于本发明思路下的技术方案均属于本发明的保护范围。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理前提下的若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.
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