A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning...A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning level, a motion control level and a servo control level. The last three levels form a local real-time open robot controller, which realizes motion planning and motion control of a robot. A camera calibration method based on the relative movement of the end-effector connected to a robot is proposed and a method for tracking weld seam based on the structured light stereovision is provided. Combining the parameters of the cameras and laser plane, three groups of position values in Cartesian space are obtained for each feature point in a stripe projected on the weld seam. The accurate three-dimensional position of the edge points in the weld seam can be calculated from the obtained parameters with an information fusion algorithm. By calculating the weld seam parameter from position and image data, the movement parameters of the robot used for tracking can be determined. A swing welding experiment of type V groove weld is successfully conducted, the results of which show that the system has high resolution seam tracking in real-time, and works stably and efficiently.展开更多
To track the narrow butt welding seams in container manufacture, a visual tracking system based on smart camera is proposed in this paper. A smart camera is used as the sensor to detect the welding seam. The feature e...To track the narrow butt welding seams in container manufacture, a visual tracking system based on smart camera is proposed in this paper. A smart camera is used as the sensor to detect the welding seam. The feature extraction algorithm is designed with the consideration of the characteristics of the smart caraera, which is used to compute the error between the welding torch and the welding seam. Visual control system based on image is preseated, which employs a programmable controller to control a stepper motor to eliminate the tracking error detected by the smart camera. Experiments are conducted to demonstrate the effectiveness of the vision system.展开更多
Tandem gas metal arc welding ( T-GMAW) process shows a high deposition rate that up to three times o f the single electrode GMAW, so the welding speed could be significantly increased in this process. H...Tandem gas metal arc welding ( T-GMAW) process shows a high deposition rate that up to three times o f the single electrode GMAW, so the welding speed could be significantly increased in this process. However, the majority o f this process applications are based on the pre-programmed robotic welding, which does not allow them to track the seam real-time during welding. Rotating arc sensor, sensing the seam position by detecting the changing of welding currents, has been widely adopted in the automatic robot welding process. It is proposed in this paper to integrate the rotating arc sensor with a trailing torch to develop a new approach of rotating arc lead tandem gas metal arc welding (RLT-GMAW) process. The characteristics of the welding currents in the proposed new welding process were firstly studied, and then a self-turning fuzzy control seam tracking strategy was developed for the mobile robot automatic welding. The experimental results showed that the proposed RLT-GMAW process had an excellent seam tracking performance and high welding deposition rate. Even if there were some electromagnetic interactions between the two arcs, the deviation of the welding seam could also be reflected by the fluctuation of the welding currents on the leading arc once the correct welding parameters were selected. Based on the detected deviation, the welding tracking experiments showed that the proposed self-turning fuzzy controller had a good performance for the RLT-GMAW process seam tracking.展开更多
A novel hybrid visual servoing control method based on structured light vision is pro-posed for robotic arc welding with a general six degrees of freedom robot. It consists of a positioncontrol inner-loop in Cartesian...A novel hybrid visual servoing control method based on structured light vision is pro-posed for robotic arc welding with a general six degrees of freedom robot. It consists of a positioncontrol inner-loop in Cartesian space and two outer-loops. One is position-based visual control inCartesian space for moving in the direction of weld seam, i.e., weld seam tracking, another is image-based visual control in image space for adjustment to eliminate the errors in the process of tracking.A new Jacobian matrix from image space of the feature point on structured light stripe to Cartesianspace is provided for dierential movement of the end-e?ector. The control system model is simplifiedand its stability is discussed. An experiment of arc welding protected by gas CO2 for verifying iswell conducted.展开更多
为实现工业机器人自动跟踪曲线焊缝,提出了协调焊枪运动和视觉跟踪的视觉伺服控制方法.建立了特征点的数学模型,并在此基础上确定机器人运动的旋转轴.设计了一种双层结构的模糊视觉伺服控制器,通过动态确定控制量有效范围来保证图像特...为实现工业机器人自动跟踪曲线焊缝,提出了协调焊枪运动和视觉跟踪的视觉伺服控制方法.建立了特征点的数学模型,并在此基础上确定机器人运动的旋转轴.设计了一种双层结构的模糊视觉伺服控制器,通过动态确定控制量有效范围来保证图像特征存在于视场中.为准确确定有效范围,设计了带模型动态补偿的K a lm an滤波器.曲线焊缝的自动跟踪实验验证了所提方法的有效性.展开更多
基金This work was supported by the National High Technology Research and Development Program of China under Grant 2002AA422160 by the National Key Fundamental Research and the Devel-opment Project of China (973) under Grant 2002CB312200.
文摘A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning level, a motion control level and a servo control level. The last three levels form a local real-time open robot controller, which realizes motion planning and motion control of a robot. A camera calibration method based on the relative movement of the end-effector connected to a robot is proposed and a method for tracking weld seam based on the structured light stereovision is provided. Combining the parameters of the cameras and laser plane, three groups of position values in Cartesian space are obtained for each feature point in a stripe projected on the weld seam. The accurate three-dimensional position of the edge points in the weld seam can be calculated from the obtained parameters with an information fusion algorithm. By calculating the weld seam parameter from position and image data, the movement parameters of the robot used for tracking can be determined. A swing welding experiment of type V groove weld is successfully conducted, the results of which show that the system has high resolution seam tracking in real-time, and works stably and efficiently.
文摘To track the narrow butt welding seams in container manufacture, a visual tracking system based on smart camera is proposed in this paper. A smart camera is used as the sensor to detect the welding seam. The feature extraction algorithm is designed with the consideration of the characteristics of the smart caraera, which is used to compute the error between the welding torch and the welding seam. Visual control system based on image is preseated, which employs a programmable controller to control a stepper motor to eliminate the tracking error detected by the smart camera. Experiments are conducted to demonstrate the effectiveness of the vision system.
基金supported by the National Natural Science Foundation of China(Grant No.51465043)
文摘Tandem gas metal arc welding ( T-GMAW) process shows a high deposition rate that up to three times o f the single electrode GMAW, so the welding speed could be significantly increased in this process. However, the majority o f this process applications are based on the pre-programmed robotic welding, which does not allow them to track the seam real-time during welding. Rotating arc sensor, sensing the seam position by detecting the changing of welding currents, has been widely adopted in the automatic robot welding process. It is proposed in this paper to integrate the rotating arc sensor with a trailing torch to develop a new approach of rotating arc lead tandem gas metal arc welding (RLT-GMAW) process. The characteristics of the welding currents in the proposed new welding process were firstly studied, and then a self-turning fuzzy control seam tracking strategy was developed for the mobile robot automatic welding. The experimental results showed that the proposed RLT-GMAW process had an excellent seam tracking performance and high welding deposition rate. Even if there were some electromagnetic interactions between the two arcs, the deviation of the welding seam could also be reflected by the fluctuation of the welding currents on the leading arc once the correct welding parameters were selected. Based on the detected deviation, the welding tracking experiments showed that the proposed self-turning fuzzy controller had a good performance for the RLT-GMAW process seam tracking.
文摘A novel hybrid visual servoing control method based on structured light vision is pro-posed for robotic arc welding with a general six degrees of freedom robot. It consists of a positioncontrol inner-loop in Cartesian space and two outer-loops. One is position-based visual control inCartesian space for moving in the direction of weld seam, i.e., weld seam tracking, another is image-based visual control in image space for adjustment to eliminate the errors in the process of tracking.A new Jacobian matrix from image space of the feature point on structured light stripe to Cartesianspace is provided for dierential movement of the end-e?ector. The control system model is simplifiedand its stability is discussed. An experiment of arc welding protected by gas CO2 for verifying iswell conducted.
文摘为实现工业机器人自动跟踪曲线焊缝,提出了协调焊枪运动和视觉跟踪的视觉伺服控制方法.建立了特征点的数学模型,并在此基础上确定机器人运动的旋转轴.设计了一种双层结构的模糊视觉伺服控制器,通过动态确定控制量有效范围来保证图像特征存在于视场中.为准确确定有效范围,设计了带模型动态补偿的K a lm an滤波器.曲线焊缝的自动跟踪实验验证了所提方法的有效性.