Study+on+welded+seam+recognition+using+circular+laser+vision+sensor
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Study+on+welded+seam+recognition+using+circular+laser+vision+sensor
328
CHINESEOPTICS
LETTERS/V01.5,No.6/June
10,2007
Study
on
weldedseamrecognitionusing
●
●
circularlaserVlSlonSenSor
Peiquan
1
Xu(徐培全)1,XinhuaTang(唐新华)2,RiNa(娜日)3,and
2
Shun
Yao(姚舜)2
201620
CollegeofMaterialsEngineering,ShanghaiUniversityofEngineering
Science,Shanghai
WeldingEngineeringInstitute.Shanghai
Jja0Tong
University,Shanghai200030
BuMness
3SchoolofComputer&Electronic
Engineering,ShanghaiSch001.Shanghai200235
ReceivedNovember1,2006
arcweldingsystembasedoncircularlaservisionsensorisdeveloped.Afterimage
de—noising,imagesegmentation,andimagethinning,therelationofdepthvalueofworkpieceandoff-axisangle7,three-dimensional(3D)calculation,andseamtrackingexperimentsarecarriedout.Finally,theerrorforseamtrackingsystemisanalyzed.Theresultsshowthat113Dinformationcallbeobtainedusing
Anovelvisualrobotic
proposedvisualroboticarcweldingsystemandthereal-timeseatlltrackingisrealized;2)theseamtrackingerrorissmallenoughforgastungstenarcwelding(GTAw)process,andthissystemcanbeusedforseamlocationandseamtrackingorsealnfinder.
the
DC昭codes:100.0100.080.0080.
A
rapiddevelopmentincomputertechnologyandrobottechnologyhasgreatlypromotedtheautomatie-ityofweldingprocess.Thereweremanyfactorsthatinfluencedtheweldingquality,whichnotonlyincludethicknessofthematerialstobewelded,thechemicalele—
computesthelocationoftheweldingseamwithrespecttothevisionsensor.Inordertocompensateforvari-ationsinpartorjointgeometry,thisprocessingresultwasthenusedintherobotcontrolmoduletocorrectthe
weldingpath.
Forhardware.theoverallsystemwascomposedoftwomodules:arobotcontrolmoduleandavisionprocessingmodule.Therobotcontrolsystemconsistsoftwounits:
mentcompositionoftheweldedmaterial,surfacestatusoftheworkpiece,butalsoincludesuchparametersas
weldingvoltage,weldingspeed,weldingpath,andthree-dimensional(3D)ofworkpiece,whetherornotwerede-tectedinrealtime.Theautomationandartificialintell[-gencecontroloftheweldingprocessrequirethedevelop—
mentofboththejointshapeandtheseamtrackingcon-tr01.sothattherobotmayselectcorrectpathautomat[一
callywhenthedeviationbetweenweldingpathandactualseamhasbeenfound.Inordertomeettherequirementof
mainprocessingunitandjointservounit.ThemainprocessingunitfINTELPentiumIIICPUoperatingat780MHzloperatesmajorprocessingsucha8coordinatetransformationfortraiectorycontrol。sensoryfeedbackcontrolforseamlocationandseamtracking,andsoon.
Thevisionprocessingmodulegrabsandanalyzestheim-agedataobtainedfromthevisionsensortorecognizethetypeofweldjointandcomputethepositionoftheweld
automaticweldingprocess,allkindsofsensorshavebeeninvestigated[1,引.Amongthem.“spotlaser’’wasthesire-plestmeasurementmethodamongactivevisionsensors
andothervisionsensors.Accordingtolasertriangularrules,differentpatternlaservisionsensorswereputfor—wardtoapplystructuredlightandscanninglightusingsinglelaserstripe,twolaserstripes,fivelaserstripes,andcircularlaserstripeaslightsource.However.‘‘spot’’or“line”typelasersensorshavesuchshortcomingsaslessinformation,explanationambiguity,andonlybeusedtosingleortwodirectionseamtracking[。一….Xueta1.setupawholeofcircularlaservisionsensorsystem[7J.Onthebasis,anovelvisionsensorwasdeveloped.Basedon“radius-depthrelation”oflaserconeandimaginglawof
joint
center.
Theprincipleofvisionsensorwasthat:circularlasertrajectorywasusedasaactivelighttoprojectontotheworkpiecetobewelded,andwhenthetasksofseamloca,tionandseamtrackingwerecarriedoutbyweldingtorch,the3Dofweldmentcanbemeasuredbyvisionsensorus—ingcalibrationmodelanddepthcalculationalgorithm,andtheerrorofweldingtorchandweldmentcanbefur.therdetectedandsentbacktorobotg].Thevision
sensorsensor
(CCD)image
consistsofchargecoupledeviceandlightscanningsystembasedon
rotatedlensthatgeneratescircularlaserbeam,a18showninFig.1.Thecamerawasfittedwithanarrow—bandop—ticalinterferencefilterhavinganarrowbandpassof0.99amcenteredat611.49am.Thenarrow—bandinterfer—fliterefficientlyremovesmuchoftheambientand
weldingarclight矗omtheimage.Thecameracircuitry
ence
camera,3Dmodel
arc
forfeaturepointsofweldseams
undergastungstenwelding(GTAw)processwas
es—
tablished.Subsequently,seamlocationandtrackinginroboticweldingprocesscanberealized.
proposedsystem,anarticulatedrobotwithsix
degreesoffreedomwascarryingaweldingtorchandavi-sionsensorsystem.Thevisionsensorviewstheweldingjointaheadoftheweldingtorchwhiletherobottravels
our
In
generatesanNTSCstandardvideosignalthatwasstoredinthevisiongrabberasa768×576arrayof8一bitpixel.Onepixelintheimageplanecorrespondsapproximately
alongtheweldingseam.Theimagesfromthevisionsen-sorwereanalyzedbyanimagegrabbercardandusedtoreconstructthedimensionsoftheweldingseam,which
8.3越monafocusedobject。Thesensorfieldofviewandresolutionwerereconfigurabledependingontheap-
to
plicationrequirements.Asalightsource,the
10一mW
laserdiodeemittingat
万方数据
1671—7694/2007/060328-04⑥2007ChineseOptics
Letters
June
10,2007/V01.5,No.6/CHINESE
OPTICSLETTERS
329
Fig.1.Configurationofthevision
sensor
byscanningtechnique.
635nmwasused.Themainadvantageofilluminationbythelightsourceinthisbandwasitsvisibilityandintell-sitv.whichconsiderablyfacilitatestheeahbrationofthesensorinthestageofdevelopmentofthevisionsensor.Simultaneously,itstillfacilitatesthesegmentationofthelaserlightfromtheweldingseamimagebecausemostsignificantspectralcomponentsofscatteredlightfromthearcexistintheultravioletfUV)andvisiblebands.Also.itguaranteesgoodtransmissionofthelaserlightthroughthesmokeandfumegeneratedduringwelding.Thesensoroperatesonaprincipleofproposed3Dcal-culationmodelbasedon“radius—depthrelationoflaserconeandcameraamplificationcoefficient”.
Theexperimentwascarriedoutincomputerizednu-mericalcontrol(CNC)platform,andIRB2400weldingrobotwasusedtoholdoiltheproposedvisionsensorbasedoncircularlaser.GTAWmethodwasoperated.andtheparametersusedinthissensorysystemwereshowninTable1.
DuringthecourseofimageacquisitionIimperfectcir-cularlasertrajectoryalwaysappearedbecauseofthelimitationofscanningmotorandchargecoupleddevice
based
on
1/3
valueratherthan
mid-whie.Incontrast
withlinearfiltermethod,order-statisticfiltercouldbet—tersolvecertaintypesofimageprocessingproblems.Thisfiitermethodmakesthecircularlasertrajectoryperfect.Inaddition.itsabilitytoreducerandomDOisewithoutblurringedgeswasasmuchasacomparablelinearlowpassfilter.Thelaser—strengtheningandnoise-reducingeffectsthatorder-statisticfilterhasonallimagedependontworelatirethings:thespatialextentofthe
maskandthenumberofPixelsinvolvedinthemedian
computation.Here,theywereinthefive-by-fivemask,and9pointswereselectedforthemask.
example.theoriginalwelded
imageduringG墨&粕processusingcircularlaservisionsensorasweldingseamdetectorwasillustratedinFig.2(a).Becauseofthehigh-intensityarclightinterference,
process
as
蹦ngGTAW
novelbarrierlayerwasadoptedtoremovemostofthearclight.Therefore.theweldingseamwasseparatedintotwoparts:onewasforcircularlaserzone;theother
one
was
arc
lightzone.De—noisemethodbased
on
3一level
(CCD)camera.Here,weaddressorder-statisticfilter
Table1.SpecificationofSensorySystemUsedfor
SeamTrackingExperiment
Item
Distance
and
Specification
betweenTorchTip
Coordinate8ofLaserCone
Center
W=84
mm;H=5
ITIITI
DistancebetweenLens
and
CoordinatesofLaserCone
178mm
FocalLengthofLens
(afterCalibration)
Heightof
6.21mm
ImagePlane
4.8mm6。4mm
12.88。39.250300
Width
ofImagePlane
ot
ConeAngle
SeparationAngle口SeamTrackingSpeed
Detect
mm/min
millmmA
Fig.2.Results
RangeY
z
士20士2552928
DetectRange
WjldCurrent
ArgonFlowRateSamplingRate
for“imagepre-processing”.(a)Originalim-
L/rain
frame/s
age;(b)3Dimage;(c)histogram;(d)imagesegumntation;(e)5×5imagethinning;(f)histogramafterimage
内容需要下载文档才能查看equalizing.
万方数据
330CHINESEOPTICS
LETTERS|V01.5,No.6
June1012007
Fig.3.De-noiseparametersandresultforcircularlaserseamimageof3-levelwavelet.(a)Waveletgraph;(b)originalim—
age(1eft)(Ijoint,butt,GTAwelding,I=52A,v=5mm/s,100kgf/cm2)andde—noiseimage(right).
wavelettechniquewasputfcIrwardtode—noisetheweld-ingseamimage,whichisillustratedinFig.3.Figure3(a)illustratesthewaveletgraphforde—noiseprocess,thecontrasteffectimageoforiginalimageandde—noised
imageisshowninFig.3(b),theweldingparameters
are:
,=52A.v=5mm/s.100kgf/cm2.
In
addition,“two—stepsegmentation(TTS)”andim-
agethinningtechniquewereusedforfeatureextractionofweldimagesunderGTAWcondition.asshowninFigs.
2(d)and(e).Theresultsshowthatthistechnique
can
be
tosegmentweldingseamimagefrombackground
accurately.
Afterimagesegmentationandimagethinning,the3DexperimentcanberealizedbytheproposedvisionsensorandmathematicalmodelIsJ,includ—buttweldingseamwithgap,buttweldingseamwith
weldingseam,filletweldingseam,andrampseametc..Figure4illustratestheprocessof
trackingforbothI—typebuttjointandsinewelded
Here.takingI—typebuttweldedseamasanexample.lasertrajectorywasproiectedtoI-typeweldmentactivelight;the3Dcalculationcanberealized.Onewasgrabbedusingcircularlaservisionsensorandpositionsweremeasuredatthesametime.The3D
ofseamtrackingbased
on
circularlaser
sensor.(a)Ion
string
welded
joint;(b)sine
welded
万
方数据119
舍7邑5
毋3
1
一l
吕u
吕
壬如
Fig.5.ExperimentalresultsforI-typebuttweldedjointus-ingcircularlaservisionsensorasseamguider.(a)RelationofdepthvalueZLand7angle;(b)3Dcalculation;(c)seaJn
tracking.
calculationresultwasshownin
Fig.5(a).The
relationof
depthinformationofworkpiecetobedetectedandoff-axisangle吖wasillustratedinFig.5(b).
Guidedbycircularlaservisionsensor,seamtrackingexperimentforbuttweldjointwascarriedoutinABBl40robotplatform.Seamtrackingcanberealizedbytwo
types
seamtrackingmodel.Onewasoff-lineprogram-
mingseamtracking,thatistosay,seamtrackingprocess
wasdividedintotwo
stages.Stage
1:3Dcalculation
ofweldediointcharacteristicpointfl‘om2Dinsensitiv-
ity
planethroughlinageacquisition,imageprocessing,and
3Dcalculationalgorithm;stage2:seamtracking
accordingtotheobtained3Dpositiondataoftheweld.ingseam.Theotherwasseamtrackinginrealtime,thatistosay,seamtrackingwassimultaneouswiththe3Dpositiondatacalculationoftheweldingseam.When
seamtrackingwasinprocess,twothreadswereoccurring:computerthreadusedforimageacquisition,imagepro—cessingand3Dcalculationfrom2Dinsensitivityplane,robotthreadusedforcommunicationwithcomputerand
guidanceformanipulatoralongtherealweldingseam.TheseamtrackingresultswereshowninFig.5(c1.Developedseamtrackingsystembasedoncircularlaservisionsensorwasamulti—hardwareconsistingofimagegrabber,visionsensor,androbot;amulti-taskdatapro—cessingwithimageprocessing,weldseam3Dcalcula-tion,andcommunicationbetweenrobotandcomputer;evenamulti—nodeinformationtransfercomplexsystem.Theprecisionofthesystemwasaffectedbykindsoffac—tors,includinglightscanningsystem,cameracalibrationandrobotcalibration,imageprocessingandevenweld—ingseam3Dalgorithm.Themainerroranalysiswas
asfollows.1)Cahbrationerror.Intheseamtrackingsystem,calibrationconsistsoftwoparts:onewascall—brationforABBrobot;theotherwascameracalibration.
pointstoolcenterpointfTCP)”calibration
methodwasusedtocalibratetheABBrobot.Conse—quently,weldingtorchcoordinatescanbedeterminedbyrobotcontroller.Thecalibrationerror,meanerror
内容需要下载文档才能查看 内容需要下载文档才能查看ofO.24
usedimagecalculationcircularinggroove,lapweldingseamjoint.
circularimage563as
Fig.4.Illustratevision
Wherein.“4
joint.
June
10,2007/V01.5,No.6/CHINESE
OPTICSLETTERS331
andmaximum
error
of0.67wasachieved.21Scanning
systemerror.Scanningsystemerrorresultsfromscan-ninglens,includingsphericalaberration(errorcausedby
differentdistancesofseverallightswhentheyillustratethescanninglens.thethicknessofwhichcannotbeomit—ted).The
error
analysismanifestthatwhilethedistance
betweentheIightandcenteroflenswaswithin40mm.themaximumerrorwas0.707mm.
ThisworkWassupportedbytheYouthFoundationofShanghaiUniversityofEngineeringScience(No.06—7),SpecializedResearchFundforExcellentYoungTeachersofShanghaifNo.06xpyql71.AndmanythankswillbegiventoDr.FengguiLu,Prof.H.L.Yu,S.B.Chen.andDr.C.J.FanfromShanghaiJiaoTongUniversityand
W.Zhang
fromShanghaiLaserManufacturingInstitute.
P.XU’Se-mailaddressisxupeiquan7810@yahoo.corn.an.
万
方数据R息fefences
1.Z.Li,Z.Jing,andZ.Sun,Chin.Opt.Lett.2,578
(2004).
2.J.-Y.JuandS.-J.Na,Mechatronics
7,599(1997).
3.H.Zhang,Z.Xiong,J.Jia,andJ.Pan,Chin.J.Mechan icalEngineering(inChinese)38,113(2002).
4.G.M.Graham,“Georgia
Institute
ofTechnology”Ph.D.
thesis(School
of
MechanicalEngineeringGeorgiaInsti-tuteofTechnology,1995).
5.A.DeandD.Parle.ScienceandTechnologyofWbldingandJoining8,340(2003).
6.H.LUOandX.Chen.InternationalJournalofAdvancedManufacturingTechnology26,1012(2005).
7.P.Xu,X.Tang,F.Lu,S.Yao,andH.Yu,Journalof
ShanghaiJiaotongUniversity(inChinese)6,902(2006).8.P.Xu,S.Yao,F.Lu,X.Tang,andW.Zhang,ChinOpt.Lett.3,640(2005).
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Study on welded seam recognition using circular laservision sensor
作者:作者单位:
Peiquan Xu, Xinhua Tang, Ri Na, Shun Yao
Peiquan Xu(College of Materials Engineering, Shanghai University of EngineeringScience, Shanghai 201620), Xinhua Tang,Shun Yao(Welding Engineering Institute,Shanghai Jiao Tong University, Shanghai 200030), Ri Na(School of Computer &Electronic Engineering, Shanghai Business School, Shanghai 200235)中国光学快报(英文版)CHINESE OPTICS OF LETTERS2007,5(6)
刊名:英文刊名:年,卷(期):
参考文献(8条)
1.Z Li;Z Jing;Z Sun Multi-sensor image fusion using discrete wavelet frame transform[期刊论文]-Chinese Optics of Letters 2004(02)2.J -Y Ju;S -J Na 查看详情 1997(07)3.H Zhang;Z Xiong;J Jia;J.Pan 查看详情 20024.G M Graham Georgia Institute of Technology 19955.A De;D Parle 查看详情 20036.H Luo;X Chen 查看详情 2005
7.P Xu;X Tang;F Lu;S.Yao,H.Yu 查看详情 2006(06)8.P Xu;S Yao;F Lu;X.Tang,W.Zhang 查看详情 2005(03)
引用本文格式:Peiquan Xu.Xinhua Tang.Ri Na.Shun Yao Study on welded seam recognition using circularlaser vision sensor[期刊论文]-中国光学快报(英文版) 2007(6)
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