新型智能球罐焊接机器人视觉传感器的研究

为实现智能球罐焊接机器人的自主运动与焊缝自动跟踪 ,研制了一种新型视觉传感器。该传感器以高分辨率线阵 CCD芯片为核心 ,由光源、滤光片、透镜等光学系统及 CCD驱动电路、光电信号处理电路等组成 ,其中光电处理电路全部由硬件实现。整个视觉传感系统可以避免焊接时弧光的干扰 ,实时、准确地检测出焊缝轨迹线偏差信号 ,具有实时性强、鲁棒性好、成本低、重量轻等优点。借助所研制的视觉传感器 ,球罐焊接机器人能够实现沿焊缝的自主运动和焊炬与焊缝的自动对中 ,满足球罐多层多道焊接工艺要求 ,实现球罐焊接作业的智能化、自动化     

A detailed analysis of the MIG spectrum for the development of laser-based seam tracking sensors

This paper presents a detailed series of measurements of the spectrum of the light emitted from a MIG welding arc. This work was done in the framework of a larger project concerning the development of a seam tracking sensor. Detailed measurements and analysis of the spectrum produced from welding arcs have been performed. The measurements extend from the ultraviolet region of the spectrum (150 nm) to the near infrared region (970 nm) and have revealed the presence of many strong emission lines in the spectrum. The results are of great importance for the design of any optical or vision system working close to a welding arc, because the wavelength of the optical system can be selected to be close to a value where the spectrum of the arc causes the minimum interference to the laser light.     

大功率光纤激光焊焊缝跟踪偏差红外检测方法

精确控制激光束使其始终对准并跟踪焊缝是保证激光焊接质量的前提.针对大功率(激光功率10 kW)光纤激光焊接304型不锈钢紧密对接焊缝(间隙为0-0.1 mm),研究一种基于红外热像的焊缝跟踪偏差检测新方法. 采用红外传感高速摄像机摄取焊接区域熔池红外动态热像,分析激光束对准和偏离焊缝中心时的熔池温度分布和红外辐射特性,以熔池匙孔形变参数和热堆积效应参数作为激光束与焊缝中心偏差检测特征值,通过图像识别技术研究和分析特征值与焊缝偏差之间的关系. 激光焊接试验结果表明,熔池匙孔形变参数和热堆积效应参数与焊缝偏差 关键词： 大功率光纤激光焊 焊缝跟踪偏差 红外热像 检测     

Mathematical model for light scanning system based on circular laser

A novel light scanning system based on circular laser trajectory for welding robot is developed. With the help of image processing technique, intelligent laser welding could be realized. According to laser triangulation algorithm and Scheimpflug condition, mathematical model for circular laser vision is built.This scanning system projects circular laser onto welded seams and recovers the depth of the welded seams,escapes from shortcomings of less information, explains ambiguity and single tracking direction inherent in "spot" or "line" type laser trajectory. Three-dimensional (3D) model for welded seams could be recognized after depth recovery. The imaging error is investigated also.     

利用环形激光视觉传感的焊缝三维恢复

为了实现复杂条件下的焊缝检测与跟踪,通过激光扫描技术,开发了环形激光视觉传感器,与机器人手爪一起构成焊接机器人"手-眼"系统,从而获得焊缝三维信息。改善了传统的点状或线条状激光视觉传感器信息量少、解释模糊以及跟踪方向单一等问题。研究了用于焊缝定位与跟踪的环形激光视觉传感器系统的内外参量标定,提出了实现焊缝三维计算的模型,最后,以对接接头、搭接接头、角接接头为对象进行了试验验证,并对标定精度进行了分析。结果表明:环形激光在不同的焊缝表现了不同的形态,结合标定试验结果,能够计算被检测焊缝的三维坐标,计算精度能够满足试验要求。     

三维形貌柔性测量系统标定方法及验证

为了避免机器人模型误差对三维形貌柔性测量系统手眼标定的影响,对手眼关系的标定方法进行了研究。提出了一种融合特征点拟合的手眼标定方法。将三维形貌扫描仪安装在工业机器人末端搭建三维形貌柔性测量系统。标定时,首先利用激光跟踪仪对工业机器人末端法兰盘坐标系进行测量,得到两者转换关系;然后,利用三维形貌扫描仪和激光跟踪仪对空间固定的特征点组进行测量,利用特征点约束和基于罗德里格矩阵的算法求解两者转换关系即可间接地求解出手眼关系。基于ATOS三维扫描仪、安川HP20D机器人和API公司生产的激光跟踪仪进行了手眼标定实验,并进行了精度验证。结果表明:标定后的三维形貌柔性测量系统,其重复性测量精度(3σ)不超过0.1 mm,长度测量精度的均方根误差在0.2 mm以内,点云拼接精度优于±0.7 mm。该方法有效避免了传统手眼标定过程中会引入机器人模型误差的问题,在求解手眼关系解时采用了线性的解法,并且适用于三维形貌柔性测量系统。     

基于标准温度法的电弧高温区自动判别研究

在电弧等离子体的光谱诊断中,标准温度法测温原理与目前先进的图像传感技术相结合,通过特征谱图像完成电弧全场温度信息采集,因其良好的时、空分辨率而被广泛应用于电弧温度测量。但是谱线的发射系数与等离子体温度不是单调变化关系,传统标准温度法选取一条ArⅠ谱线完成对电弧等离子体的测量,在电弧内部的高温电离区域产生谱线辐射强度降低的现象,需要人为判定电弧不同位置所处的温度区间才能完成温度的计算,整个过程无法通过软件自主完成。针对此问题,根据电弧等离子体的局部热力学平衡条件,探索一种基于双特征谱线的标准温度法测温原理,通过融合电弧在外层低温区域聚集的Ar原子发出的ArⅠ谱线发射系数场,和在高温区域的Ar一次电离离子所发出的ArⅡ特征谱线发射系数场,将达到ArⅠ谱线标准温度的位置处的ArⅡ谱线发射系数作为电弧不同温度区域的判定依据,完成电弧等离子体高温区域的自动判别,继而应用ArⅠ谱线发射系数与温度对应关系在电弧高、低温区域分别计算电弧温度,消除单一的ArⅠ谱线发射系数场暗区给计算带来的不利影响;设计并搭建了一种镜前分幅采集系统,其中分光镜将弧光等能量分成两束,利用两组反射镜和窄带滤光片建立起两路光学通道,使CMOS在一次曝光中完成两组电弧特征谱图像的采集,并且两幅图像的采集时刻、焦距、光圈等拍摄参数完全一致,达到良好的时间、空间一致性,从而减小谱线融合时误差的输出,满足了原位获取两组电弧特征谱图像的需求;为验证测量系统可行性以及后期的电弧图像提取,以黑白棋盘为标靶,用Harris算子对系统采集的图像进行扫描,根据角点坐标证明系统所采集的两幅图像具有良好的一致性,并且据此将两幅图像做归一化处理,以便后期的电弧特征谱图像的提取;通过假设所测电弧等离子具有轴对称属性,以CMOS所采集的特征谱图像亮度信息作为电弧发射系数场在不同角度下的投影依据,经过中值滤波降噪后,利用ML-EM迭代重建算法求解电弧的三维发射系数分布。实验中,选择受自吸收效应影响较小的ArⅠ696.5 nm谱线和ArⅡ480.6 nm谱线为测量目标,并且在696.5 nm谱线的光通路中加入OD0.4的中性减光片,使两幅特征谱图像的最高亮度值保持一致。选取150A焊接等离子弧为测量对象,经ML-EM法三维还原后,将两条谱线发射系数场等像素融合,在ArⅠ谱线发射系数达到最大值的像素点位置处,ArⅡ谱线发射系数达到ε_rp,判定ArⅡ谱线发射系数大于ε_rp的像素点位置为电弧高温区域,其余位置为低温区域,最终在不同温度区域自动完成焊接等离子弧的温度计算。实验结果表明696.5 nm谱线和480.6 nm谱线发射系数场融合后可以自动识别电弧高温区域,继而完成电弧等离子体的自动测量,为电弧温度实时监测的实现提供更多可能。     

Automatic teaching of welding robot for free-formed seam using laser vision sensor

In order to enhance the flexibility of the robotic welding, it is necessary to generate the robot path automatically. In this paper, the automatic teaching of the welding robot for free-formed seam was implemented through the range data acquired by the laser vision sensor. The geometric modeling of objects such as the worktable and weld joint were performed from sequential range data. The orientation as well as the position of the torch was determined by the geometric models, and the path of the welding robot was automatically generated. Experiments for the free-formed seam showed that the proposed method performed sucessfully.     

Laser systems in modern production environments

The present situation in production engineering is characterized by a need to create organizational structures and production methods which enable a reduction of the product development time and continuously improved product quality. Together with an improvement in productivity, cost savings and quality assurance, the success of a company will increasingly depend on shortened throughput times, flexibility and the full utilization of its employees' creativity. Laser technology offers important contributions to these aims, if its related technical and organizational advantages can be fully exploited.On an organizational level, the simultaneous development of product, process and production system and multilevel quality control loops enables preventive quality assurance and continuous improvement of product quality. Simulation tools for process, process flow and laser systems allow reliable planning data at a very early stage in product design and operations planning.On the manufacturing level, e.g. in the field of prototype building, the laser is used as a flexible tool for cutting two- and three-dimensional body panels. Owing to the need for programming, the downtimes for 3D laser cutting systems can be quite considerable. Computer-aided, comprehensive process chains enabling off-line programming are therefore increasingly being adopted. The use of the laser in prototype shops makes it possible to provide production-equivalent components at a high level of reproducibility and with much shorter lead times.System status monitoring tools enable full operator control and fast fault rectification. Seam tracking sensors with moving laser beam and moving workpiece allow compensation of tolerances in part shape and position. By measuring the gap distance during seam tracking, suitable adaptation of process parameters makes it possible to achieve a controlled welding process. As a continuation of preventive quality assurance measures, process monitoring using characteristics of the laser-induced plasma during welding reveals defects in the weld seam.     

Regeneration of elemental images in integral imaging for occluded objects using a plenoptic camera

In this Letter, we propose an elemental image regeneration method of three-dimensional(3D) integral imaging for occluded objects using a plenoptic camera. In conventional occlusion removal techniques, the information of the occlusion layers may be lost. Thus, elemental images have cracked parts, so the visual quality of the reconstructed 3D image is degraded. However, these cracked parts can be interpolated from adjacent elemental images. Therefore, in this Letter, we try to improve the visual quality of reconstructed 3D images by interpolating and regenerating virtual elemental images with adjacent elemental images after removing the occlusion layers. To prove our proposed method, we carry out optical experiments and calculate performance metrics such as the mean square error(MSE) and the peak signal-to-noise ratio(PSNR).     

直升机旋翼三维动态变形测量与可视化分析

针对直升机旋翼动载荷飞行试验测试需求,提出一种直升机旋翼三维动态变形测量与可视化分析方法。首先,根据直升机旋翼的结构特点和高速旋转特性,设计了以一组双目高清摄像头为核心的旋翼动态变形影像测量与监控及分析系统;其次,基于双目立体视觉测量理论,论述了测量系统标定、实时单点变形测量、散斑影像匹配、旋翼表面三维重建与三维动态变形可视化分析原理/方法;最后,在地面进行了模拟实测环境的仿真试验,实现了试验系统搭建、试验数据采集、处理与分析。试验结果证明,该方法可获得最大误差优于4 mm的定位测量精度,能很好地实现直升机旋翼三维动态变形测量,为飞行试验旋翼载荷测试数据分析等提供直观、可靠的数据与技术支撑。     

Probability analysis of position errors using uncooled IR stereo camera

This paper analyzes the random phenomenon of 3D positions when tracking moving objects using the infrared (IR) stereo camera, and proposes a probability model of 3D positions. The proposed probability model integrates two random error phenomena. One is the pixel quantization error which is caused by discrete sampling pixels in estimating disparity values of stereo camera. The other is the timing jitter which results from the irregular acquisition-timing in the uncooled IR cameras. This paper derives a probability distribution function by combining jitter model with pixel quantization error. To verify the proposed probability function of 3D positions, the experiments on tracking fast moving objects are performed using IR stereo camera system. The 3D depths of moving object are estimated by stereo matching, and be compared with the ground truth obtained by laser scanner system. According to the experiments, the 3D depths of moving object are estimated within the statistically reliable range which is well derived by the proposed probability distribution. It is expected that the proposed probability model of 3D positions can be applied to various IR stereo camera systems that deal with fast moving objects.     

Sheet metal welding using a pulsed Nd: YAG laser-robot

This paper presents a pulsed Nd: YAG laser-robot system for spot and seam welding of mild steel sheets. The study evaluates the laser beams behaviour for welding, and then investigates pulsed Nd: YAG laser spot and seam welding processes. High pulse power intensity is needed to initiate the key-hole welding process and a threshold pulse energy to reach full penetration. In seam welding, a weld consists of successive overlapping spots. Both high pulse energy and high average power are needed to keep the key-hole welding going. A 70% overlap is used to define overlapping spot welding as seam welding and to optimize process parameters because a high tensile strength joint compatible with the strength of the base material can be obtained when the overlap is ≥70%; at the same time a smooth seam with full penetration is obtained. In these cases, the joints in pulsed Nd: YAG laser welding are comparable in strength to those obtained with CO₂ laser welding. Robot positioning and motion accuracies can meet the demands of Nd: YAG laser sheet metal welding, but its cornering accuracy affects the welding processes. The purpose of the study is to evaluate the YAG laser-robot system for production in the automotive industry.     

计算机辅助彩色立体图像生成中的误差分析与处理

柱透镜光栅的计算机辅助立体成像的基本原理是将二维序列图像进行切分和重组,使之以三维模型的形式展现,使合成的图像在柱透镜光栅下观察时具有"纵深感"。该项技术在广告、摄影、电影制作中具有广泛的应用。但是长期以来,在图像切分时并不能保证像素一定被整除,这意味着剩余像素的出现,合成的立体图像必然存在误差。如何处理剩余像素的问题一直是个难题,阻碍了该技术的推广。针对立体图像生成方法中的剩余像素问题,详尽地分析了误差的形成,并提出了强行取整算法和误差分散算法两种误差处理方法。实验表明,这两种算法能较好的处理剩余像素,增强了合成图像的立体效果,这将有助于立体成像技术的进一步推广。     

面向逆向工程的工业CT图像预处理系统开发

 为了将工业CT技术应用于逆向工程中,开发了一个面向逆向工程的工业CT图像预处理系统。该系统主要通过图像处理、轮廓拟合和数据格式转换三个步骤对工业CT切片图像进行处理,输出的IGES格式数据能直接输入到专业化的逆向工程软件中进行３维CAD模型重构,减少了重构３维模型的工作量;输出的２维DXF格式数据能直接输入到AutoCAD软件中进行处理,提高了系统的灵活性。同时,提出了用加权方法计算拟合圆弧的圆心和半径,有效提高了曲线的拟合精度。并通过实例验证了该系统的正确性。     

基于图像质量评价的手术机器人系统磁共振兼容性分析方法

为保证手术安全及操作精度,基于磁共振图像导航的手术机器人系统需具备磁共振设备兼容性. 针对这一问题,本文提出了基于磁共振图像质量评价的手术机器人系统磁共振设备兼容性分析方法,扩展了图像数据集,并结合图像信噪比、图像变化因数、磁共振图像畸变量等评价参数,逐一分析机器人系统组件通电、机器人系统运动对磁共振图像质量产生的影响,建立图像质量评价依据. 实验结果表明,该质量评价方法可充分分析手术机器人及其系统组件的磁共振兼容性,且可为医疗手术机器人系统组件的磁共振兼容性分析提供测试方法与理论依据.     

Mean-shift跟踪算法及其在光电跟踪系统中的应用

针对光电跟踪系统中实时提取运动目标脱靶量的应用需求,设计了一种基于灰度直方图的Mean-shift 图像跟踪算法,对算法中目标模型与候选模型的建立进行了改进,抑制了背景像素对目标跟踪产生的影响。算法在系统上位机Visual C+ + 6.0平台上实现,当光电跟踪系统捕获到运动目标后,利用Mean-shift图像跟踪算法跟踪运动目标,并实时将运动目标脱靶量作为伺服控制系统的输入信号,驱动跟踪器跟踪目标。实验结果表明：设计的算法可以实时、准确、有效地跟踪运动目标,使稳定后的脱靶量换算得到的角偏差量控制在30"之内。     

基于广义正交迭代算法的立体视觉定位

提出了一种新的基于广义正交迭代算法的立体视觉定位.该算法通过提取CenSurE局部特征和相应的U-SURF描述符,采用SAD方法进行子像素立体匹配,并利用U-SURF描述符匹配进行前后帧图像特征跟踪.在RANSAC框架下对匹配点进行3D-3D运动估计获得了运动参量的初始值.由于3D-3D运动估计使3D点集间欧式距离误差最小,而3D特征点坐标受噪音影响很大,因此运动估计误差也较大.本文把广义正交迭代算法应用到立体视觉定位方法中,得到使立体相机目标空间共线性误差最小的运动估计参量,由于共线性误差比3D-3D运动估计算法中的共点误差受噪音影响更小,从而大大较少了运动估计误差.仿真实验和户外真实实验表明：本文算法获得了较高的计算准确度、鲁棒性和实时性,优于传统方法.     

双丝脉冲MIG焊接电弧光谱诊断及热源耦合机理分析

搭建了双丝脉冲MIG焊接试验系统,为了分析研究双丝脉冲MIG焊接的热源耦合机理以及电弧温度场,采用光谱技术对其电弧进行了诊断分析,采用中空探针法进行等离子体的辐射采集,得到电弧等离子体的光信号,利用Boltzmann图法计算了双丝脉冲MIG焊接电弧等离子体的电子温度,得出了电弧等离子体的电子温度分布规律,并结合电信号采集和高速摄像技术对电弧进行了综合分析。研究创新之处在于结合了电弧的高速摄像图片信息和电弧等离子体的光信号对双电弧耦合机理进行分析,对电弧温度场进行了较为直观的分析研究。试验结果表明,在本试验条件下焊接过程实现了推挽式输出,实现了一脉一滴的过渡方式;两个电弧在焊接过程中在磁场的作用下相互吸引,向中心发生了偏移,在双电弧的几何中心形成了新的热源中心,并且电弧发生上飘现象;双电弧电子温度整体呈倒V型分布,在双电弧几何中心位置,距工件表面3 mm的位置电弧电子温度最高,为16 887.66 K,比最低温度11 963.63 K高大约4 900 K。     

活性剂等离子弧焊焊接电弧的光谱与热分析

针对活性剂等离子弧焊焊接过程,利用光谱分析方法对活性剂等离子弧焊焊接电弧进行光谱分析,采用红外热像伪着色法测定活性剂等离子弧焊焊接电弧温度场,并建立活性剂等离子弧焊焊接电弧热流密度径向分布模型,对焊接电弧的成分及焊接电弧温度场进行了研究。研究结果表明,常规等离子焊焊接电弧以氩原子和氩一次电离离子的谱线为主,金属蒸气谱线不突出,焊接电弧以气体粒子为主,属于气体电弧;活性剂等离子弧焊焊接电弧的光谱中氩原子及氩一次离子谱线的辐射强度增强,Ti,Cr,Fe金属谱线大量涌现;活性剂等离子弧焊焊接电弧的温度分布比较紧凑,温度场外形窄,温度分布范围较集中,电弧径向温度梯度较大;电弧径向温度分布呈现正态Gauss分布模式。