Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor
To solve the problems of low teaching programming efficiency and poor flexibility in robot welding of complex box girder structures, a method of seam trajectory recognition based on laser scanning displacement sensing was proposed for automated guidance of a welding torch in the skip welding of a sp...
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| Format: | Article |
| Language: | English |
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MDPI AG
2020-06-01
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| Series: | Sensors |
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| Online Access: | https://www.mdpi.com/1424-8220/20/13/3657 |
| _version_ | 1827713970803310592 |
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| author | Gaoyang Li Yuxiang Hong Jiapeng Gao Bo Hong Xiangwen Li |
| author_facet | Gaoyang Li Yuxiang Hong Jiapeng Gao Bo Hong Xiangwen Li |
| author_sort | Gaoyang Li |
| collection | DOAJ |
| description | To solve the problems of low teaching programming efficiency and poor flexibility in robot welding of complex box girder structures, a method of seam trajectory recognition based on laser scanning displacement sensing was proposed for automated guidance of a welding torch in the skip welding of a spatially intermittent welding seam. Firstly, a laser scanning displacement sensing system for measuring angles adaptively is developed to detect corner features of complex structures. Secondly, a weld trajectory recognition algorithm based on Euclidean distance discrimination is proposed. The algorithm extracts the shape features by constructing the characteristic triangle of the weld trajectory, and then processes the set of shape features by discrete Fourier analysis to solve the feature vector used to describe the shape. Finally, based on the Euclidean distance between the feature vector of the test sample and the class matching library, the class to which the sample belongs is identified to distinguish the weld trajectory. The experimental results show that the classification accuracy rate of four typical spatial discontinuous welds in complex box girder structure is 100%. The overall processing time for weld trajectory detection and classification does not exceed 65 ms. Based on this method, the field test was completed in the folding special container production line. The results show that the system proposed in this paper can accurately identify discontinuous welds during high-speed metal active gas arc welding (MAG) welding with a welding speed of 1.2 m/min, and guide the welding torch to automatically complete the skip welding, which greatly improves the welding manufacturing efficiency and quality stability in the processing of complex box girder components. This method does not require a time-consuming pre-welding teaching programming and visual inspection system calibration, and provides a new technical approach for highly efficient and flexible welding manufacturing of discontinuous welding seams of complex structures, which is expected to be applied to the welding manufacturing of core components in heavy and large industries such as port cranes, large logistics transportation equipment, and rail transit. |
| first_indexed | 2024-03-10T18:48:17Z |
| format | Article |
| id | doaj.art-442190e824aa4649b685e7e608527132 |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-03-10T18:48:17Z |
| publishDate | 2020-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj.art-442190e824aa4649b685e7e6085271322023-11-20T05:20:30ZengMDPI AGSensors1424-82202020-06-012013365710.3390/s20133657Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision SensorGaoyang Li0Yuxiang Hong1Jiapeng Gao2Bo Hong3Xiangwen Li4Key Laboratory in Hunan Provincial for Welding Robot and Its Application, Xiangtan University, Xiangtan 411105, ChinaCollege of Mechanical and Electrical Engineering, China Jiliang University, Hangzhou 310018, ChinaKey Laboratory in Hunan Provincial for Welding Robot and Its Application, Xiangtan University, Xiangtan 411105, ChinaKey Laboratory in Hunan Provincial for Welding Robot and Its Application, Xiangtan University, Xiangtan 411105, ChinaKey Laboratory in Hunan Provincial for Welding Robot and Its Application, Xiangtan University, Xiangtan 411105, ChinaTo solve the problems of low teaching programming efficiency and poor flexibility in robot welding of complex box girder structures, a method of seam trajectory recognition based on laser scanning displacement sensing was proposed for automated guidance of a welding torch in the skip welding of a spatially intermittent welding seam. Firstly, a laser scanning displacement sensing system for measuring angles adaptively is developed to detect corner features of complex structures. Secondly, a weld trajectory recognition algorithm based on Euclidean distance discrimination is proposed. The algorithm extracts the shape features by constructing the characteristic triangle of the weld trajectory, and then processes the set of shape features by discrete Fourier analysis to solve the feature vector used to describe the shape. Finally, based on the Euclidean distance between the feature vector of the test sample and the class matching library, the class to which the sample belongs is identified to distinguish the weld trajectory. The experimental results show that the classification accuracy rate of four typical spatial discontinuous welds in complex box girder structure is 100%. The overall processing time for weld trajectory detection and classification does not exceed 65 ms. Based on this method, the field test was completed in the folding special container production line. The results show that the system proposed in this paper can accurately identify discontinuous welds during high-speed metal active gas arc welding (MAG) welding with a welding speed of 1.2 m/min, and guide the welding torch to automatically complete the skip welding, which greatly improves the welding manufacturing efficiency and quality stability in the processing of complex box girder components. This method does not require a time-consuming pre-welding teaching programming and visual inspection system calibration, and provides a new technical approach for highly efficient and flexible welding manufacturing of discontinuous welding seams of complex structures, which is expected to be applied to the welding manufacturing of core components in heavy and large industries such as port cranes, large logistics transportation equipment, and rail transit.https://www.mdpi.com/1424-8220/20/13/3657automated skip weldingspatially intermittent welding seamcomplex box girder structureslaser scanning displacement sensorEuclidean distance discrimination |
| spellingShingle | Gaoyang Li Yuxiang Hong Jiapeng Gao Bo Hong Xiangwen Li Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor Sensors automated skip welding spatially intermittent welding seam complex box girder structures laser scanning displacement sensor Euclidean distance discrimination |
| title | Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor |
| title_full | Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor |
| title_fullStr | Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor |
| title_full_unstemmed | Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor |
| title_short | Welding Seam Trajectory Recognition for Automated Skip Welding Guidance of a Spatially Intermittent Welding Seam Based on Laser Vision Sensor |
| title_sort | welding seam trajectory recognition for automated skip welding guidance of a spatially intermittent welding seam based on laser vision sensor |
| topic | automated skip welding spatially intermittent welding seam complex box girder structures laser scanning displacement sensor Euclidean distance discrimination |
| url | https://www.mdpi.com/1424-8220/20/13/3657 |
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