Narrow gap welding seam deflection correction study based on passive vision
Abstract
Purpose
The purpose of this study is to establish a method for accurately extracting torch and seam features. This will improve the quality of narrow gap welding. An adaptive deflection correction system based on passive light vision sensors was designed using the Halcon software from MVtec Germany as a platform.
Design/methodology/approach
This paper proposes an adaptive correction system for welding guns and seams divided into image calibration and feature extraction. In the image calibration method, the field of view distortion because of the position of the camera is resolved using image calibration techniques. In the feature extraction method, clear features of the weld gun and weld seam are accurately extracted after processing using algorithms such as impact filtering, subpixel (XLD), Gaussian Laplacian and sense region for the weld gun and weld seam. The gun and weld seam centers are accurately fitted using least squares. After calculating the deviation values, the error values are monitored, and error correction is achieved by programmable logic controller (PLC) control. Finally, experimental verification and analysis of the tracking errors are carried out.
Findings
The results show that the system achieves great results in dealing with camera aberrations. Weld gun features can be effectively and accurately identified. The difference between a scratch and a weld is effectively distinguished. The system accurately detects the center features of the torch and weld and controls the correction error to within 0.3mm.
Originality/value
An adaptive correction system based on a passive light vision sensor is designed which corrects the field-of-view distortion caused by the camera’s position deviation. Differences in features between scratches and welds are distinguished, and image features are effectively extracted. The final system weld error is controlled to 0.3 mm.
Keywords
Acknowledgements
Since submission of this article, the following authors have updated their affiliations: Wang Zhang is at the School of Mechanical Engineering, Shanghai Dianji University, Shanghai, China and Yanbin Guo is at School of Ocean Science and Engineering, Institute of Marine Materials Science and Engineering, Shanghai Maritime University, Shanghai, China.
Funding: This study was supported by the National Natural Science Foundation of China (51975346 and 51505271).
Conflict of interest statement: I guarantee that there is no conflict of interest in this article.
Data availability statement: This data cannot be disclosed due to technical advantages. Data cannot be shared openly but available on request form authors.
Citation
Zhang, W., Fan, L., Guo, Y., Liu, W. and Ding, C. (2024), "Narrow gap welding seam deflection correction study based on passive vision", Industrial Robot, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/IR-10-2023-0252
Publisher
:Emerald Publishing Limited
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