风机叶片角焊缝识别与跟踪视觉系统设计  

Design of Vision System for Recognition and Tracking of Fillet Welds of Fan Blade

作　　者：王浩东 韩建海[1,2] 王军华 刘继鹏 WANG Haodong;HAN Jianhai;WANG Junhua;LIU Jipeng(School of Mechatronics Engineering,Henan University of Science and Technology,Luoyang 471003,China;Henan Provincial Key Laboratory of Robotics and Intelligent Systems,Luoyang 471003,China;Luoyang Merik Robot Technology Co.,Ltd.,Luoyang 471000,China)

机构地区：[1]河南科技大学机电工程学院,河南洛阳471003 [2]河南省机器人与智能系统重点实验室,河南洛阳471003 [3]洛阳美瑞克机器人科技有限公司,河南洛阳471000

出　　处：《热加工工艺》2024年第3期62-67,共6页Hot Working Technology

摘　　要：工业风机具有叶轮结构和叶片型面复杂、加工精度要求高的特点,一直以来实现叶片自动化焊接是个难题。本文设计了由机器人本体、移动导轨和变位机组成的多轴联动机器人风机叶片焊接工作站,通过激光视觉传感器扫描定位焊缝位置实现高精度自动焊接。采用一种新的相机标定方法,计算特制标定板上标定点在图像坐标系和机器人坐标系下的位置得到标定矩阵。编写LoG滤波和形态学运算图像处理算法,消除反射光及噪音点,采用几何中心法和改进的灰度重心法得到亚像素级激光条纹中心点;通过RANSAC算法拟合直线,根据直线相交法得到焊缝特征点;最后根据手眼标定矩阵得到特征点的三维坐标,从而引导机器人实现自动焊接。焊接实验结果表明,焊缝成型良好,无明显缺陷,焊点位置误差控制在±1.5 mm以内,满足实际焊接工艺需求。Industrial fans have the characteristics of complex impeller structure and blade profile,and high machining accuracy requirements.So it has always been a difficult problem to realize automatic welding of blades.A multi-axis linkage robot fan blade welding workstation composed of a robot body,a moving guide and a positioner was designed,which can realize high-precision automatic welding by scanning and locating the weld seam position by laser vision sensor.A new camera calibration method was used to calculate the positions of calibration points on the special calibration board in the image coordinate system and the robot coordinate system to obtain the calibration matrix.LoG filtering and morphological operation image processing algorithms were written to eliminate reflected light and noise points,geometric center method and improved gray centroid method were used to obtain sub-pixel laser stripe center points;straight lines were fitted through RANSAC algorithm and the feature points of the weld were obtained according to the straight line intersection method.Finally,the three-dimensional coordinates of the feature points were obtained according to the hand-eye calibration matrix,so as to guide the robot to realize automatic welding.The welding test results show that the weld seam is well formed without obvious defects,and the position error of the weld is controlled within±1.5 mm,which meets the actual welding process requirements.

关 键 词：风机叶轮 自动焊接 焊缝识别 相机标定 图像处理 

分 类 号：TG409[金属学及工艺—焊接]