基于线结构光的型钢自动焊接位置检测技术

Automatic welding position detection technology

  • 摘要: 针对现有H型钢现场焊接过程中多为人工焊接、劳动强度大、操作环境恶劣且人工测量随意性大等问题,提出了一种基于视觉与图像处理的型钢自动焊接位置检测技术。该技术主要基于线结构光测量法来实现对型钢轮廓的检测从而确定焊接位置,利用激光线的位置确定焊缝位置,结合焊接机器人达到自动焊接的目的。先利用张正友标定法获得相机内参数和畸变系数,再通过最小二乘法拟合激光平面的方法实现激光平面的标定,结合两者实现整个测量系统的标定,然后基于OpenCV编程接口实现图像处理,最后利用ABB机器人工具坐标系对该测量方法的检测精度进行评价。针对检测点深度方向坐标误差较大问题提出一种误差拟合方法,应用此方法进行多种型号H型钢测量试验。试验结果表明,采用上述方法标定后的线结构光视觉测量系统测量误差小于1 mm,达到了较高的标定精度,明显降低了坐标误差,能够满足焊接使用要求。创新点: 利用标准量块提出一种误差拟合方法,可有效降低坐标误差。

     

    Abstract: For the existing problems in welding process of H section steel, such as mostly manual welding, high labor intensity, poor operation environment and high randomness of manual measurement, an automatic welding position detection technology based on vision and image processing was proposed. This technology was mainly based on line structured light measurement method to realize outline detection of section steel to determine welding position, and the position of weld was determined by the position of laser line, and then the purpose of automatic welding was achieved by combining with welding robot. Firstly, Zhang’s calibration algorithm was used to obtain the camera internal parameter and distortion coefficient. Then, the laser plane was calibrated by fitting the laser plane with the least square method and the whole measurement system was calibrated by combining the two methods. And then, based on OpenCV programming interface, image processing was realized. Finally, ABB robot tool coordinate system was use to evaluate the accuracy of the measurement method. For the large coordinate error problem of detection point in the depth direction, an error fitting method was put forward and it was applied to various types of H section steel measurement test. The test results showed that the measurement error of the line structured light visual measurement system calibrated by the above method was less than 1 mm, which achieved high calibration accuracy, significantly reduced the coordinate error, and met the requirements of welding.Highlights: A method of error fitting based on standard measuring block can effectively reduce coordinate error.

     

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