CN114800574A - Robot automatic welding system and method based on double three-dimensional cameras - Google Patents
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Abstract
本发明提供了一种双三维相机的机器人自动化焊接系统及方法。该系统包括,机器人、机器人外部安装的第一三维相机、机器人末端安装的第二三维相机和焊接装备、控制机器人运动的控制箱以及系统上位机;所述第一三维相机用于拍摄获取完整工件点云;所述系统上位机用于系统坐标系对齐、第二三维相机的拍摄轨迹规划、焊缝寻位和焊接路径规划,其中,所述第二三维相机的拍摄轨迹规划包括,根据完整工件点云规划第二三维相机的拍摄点位,形成机器人的拍摄运动轨迹;所述第二三维相机用于根据拍摄运动轨迹,获取当前拍摄点位视野内的工件点云;所述焊接装备用于根据当前拍摄点位视野内的工件点云和焊接轨迹,完成焊接任务。
The invention provides a robot automatic welding system and method with dual three-dimensional cameras. The system includes a robot, a first three-dimensional camera installed outside the robot, a second three-dimensional camera installed at the end of the robot and welding equipment, a control box for controlling the movement of the robot, and a system host computer; the first three-dimensional camera is used to photograph and obtain a complete workpiece point cloud; the system host computer is used for system coordinate system alignment, shooting trajectory planning of the second three-dimensional camera, welding seam locating and welding path planning, wherein the shooting trajectory planning of the second three-dimensional camera includes, according to the complete workpiece The point cloud plans the shooting points of the second three-dimensional camera to form the shooting motion trajectory of the robot; the second three-dimensional camera is used to obtain the workpiece point cloud within the field of view of the current shooting point according to the shooting motion trajectory; the welding equipment is used for The welding task is completed according to the workpiece point cloud and welding trajectory within the field of view of the current shooting point.
Description
技术领域technical field
本发明属于焊接技术领域,具体涉及一种基于双三维相机的机器人自动化焊接系统及方法。The invention belongs to the technical field of welding, and in particular relates to a robot automatic welding system and method based on dual three-dimensional cameras.
背景技术Background technique
本部分的陈述仅仅是提供了与本发明相关的背景技术信息,不必然构成在先技术。The statements in this section merely provide background information related to the present invention and do not necessarily constitute prior art.
虽然焊接机器人目前应用较为广泛,但是焊接前复杂的编程工作一直是焊接机器人的发展阻碍。焊接机器人的编程方式主要有人工示教编程和离线编程。人工示教编程需要在一定的时间间隔重新编程,以保证在工件装夹误差下的焊接精度;离线编程实现的方式是将机器人和工件建模,在软件上实现路径规划,对于工件的三维模型依赖性大。对于小批量、多品种、非标准的工件焊接场景,以上两种编程方式适用性较差。Although welding robots are widely used at present, the complex programming work before welding has always been an obstacle to the development of welding robots. The programming methods of welding robots mainly include manual teaching programming and offline programming. Manual teaching programming needs to be reprogrammed at a certain time interval to ensure the welding accuracy under the workpiece clamping error; the way of offline programming is to model the robot and the workpiece, realize the path planning on the software, and for the 3D model of the workpiece Dependence is great. For small batch, multi-variety, and non-standard workpiece welding scenarios, the above two programming methods are less applicable.
为解决上述问题,随着机器视觉的发展,利用三维相机进行焊接轨迹的自动寻位可实现免编程示教的机器人的自动化焊接。但是,该过程需要对三维相机拍摄点位进行规划,当前工业场景下仍采用手动方式进行拍摄点位规划。In order to solve the above problems, with the development of machine vision, the use of three-dimensional cameras to automatically locate the welding trajectory can realize the automatic welding of robots without programming and teaching. However, this process requires the planning of the shooting point of the 3D camera, and the shooting point planning is still carried out manually in the current industrial scene.
此外,现有的使用软件进行眼在手上的三维相机的拍摄轨迹规划,其弊端在于:In addition, the existing software is used to plan the shooting trajectory of the 3D camera with eyes on the hand, and the disadvantages are:
1.依赖工件的三维模型,若工件不存在三维模型,则实现比较困难;1. It depends on the 3D model of the workpiece. If the workpiece does not have a 3D model, it will be difficult to realize;
2.对操作者的素质要求较高,专业软件的学习需要一定的成本;3.自动化程度低,使用软件进行规划,避免不了人工干预。2. The quality of the operator is high, and the learning of professional software requires a certain cost; 3. The degree of automation is low, and the use of software for planning cannot avoid manual intervention.
发明内容SUMMARY OF THE INVENTION
本发明为了解决上述问题,提出了一种基于双三维相机的机器人自动化焊接系统及方法,本发明针对焊接前安装在机器人末端的相机的拍摄点位规划,使用安装在机器人工作台外部的俯拍相机,结合三维视觉技术,实现了焊接前相机拍摄点位的自动规划;针对焊接工件,使用安装在机器人末端的相机,结合三维视觉技术,实现了以拍摄点位为单元的焊缝寻位和自动化焊接。In order to solve the above problems, the present invention proposes a robot automatic welding system and method based on dual three-dimensional cameras. The present invention aims at the planning of the shooting point of the camera installed at the end of the robot before welding, and uses the overhead shooting installed outside the robot workbench. The camera, combined with 3D vision technology, realizes the automatic planning of camera shooting points before welding; for welding workpieces, the camera installed at the end of the robot is used, combined with 3D vision technology, to realize the welding seam location and the shooting point as a unit. Automated welding.
根据一些实施例,本发明采用如下技术方案:According to some embodiments, the present invention adopts the following technical solutions:
第一个方面,本发明提供了一种双三维相机的机器人自动化焊接系统。In a first aspect, the present invention provides a robot automatic welding system with dual three-dimensional cameras.
一种双三维相机的机器人自动化焊接系统,包括:机器人、机器人外部安装的第一三维相机、机器人末端安装的第二三维相机和焊接装备、控制机器人运动的控制箱以及系统上位机;A robot automatic welding system with dual three-dimensional cameras, comprising: a robot, a first three-dimensional camera installed outside the robot, a second three-dimensional camera installed at the end of the robot and welding equipment, a control box for controlling the movement of the robot, and a system host computer;
所述第一三维相机用于拍摄获取完整工件点云;The first three-dimensional camera is used to capture and obtain a complete workpiece point cloud;
所述系统上位机用于系统坐标系对齐、第二三维相机的拍摄轨迹规划、焊缝寻位和焊接路径规划,其中,所述第二三维相机的拍摄轨迹规划包括,根据完整工件点云规划第二三维相机的拍摄点位,形成机器人的拍摄运动轨迹;The system host computer is used for system coordinate system alignment, shooting trajectory planning of the second three-dimensional camera, welding seam locating and welding path planning, wherein the shooting trajectory planning of the second three-dimensional camera includes planning according to the complete workpiece point cloud. The shooting point of the second 3D camera forms the shooting trajectory of the robot;
所述第二三维相机用于根据拍摄运动轨迹,获取当前拍摄点位视野内的工件点云;The second three-dimensional camera is used to obtain the workpiece point cloud within the field of view of the current shooting point according to the shooting motion trajectory;
所述焊接装备用于根据当前拍摄点位视野内的工件点云和焊接轨迹,完成焊接任务。The welding equipment is used to complete the welding task according to the workpiece point cloud and the welding track in the field of view of the current shooting point.
第二个方面,本发明提供了一种双三维相机的机器人自动化焊接方法。In a second aspect, the present invention provides a robot automatic welding method with dual three-dimensional cameras.
一种双三维相机的机器人自动化焊接方法,采用第一个方面所述的双三维相机的机器人自动化焊接系统,包括:A robot automatic welding method with dual three-dimensional cameras, using the robot automatic welding system with dual three-dimensional cameras described in the first aspect, comprising:
标定焊枪工具坐标系、两个相机坐标系与机器人基坐标系之间的关系;Calibrate the relationship between the welding gun tool coordinate system, the two camera coordinate systems and the robot base coordinate system;
采用第一三维相机拍摄获取完整工件点云;Use the first three-dimensional camera to capture the complete workpiece point cloud;
根据完整工件点云规划第二三维相机的拍摄点位,形成机器人的拍摄运动轨迹;Plan the shooting point of the second 3D camera according to the complete workpiece point cloud to form the shooting trajectory of the robot;
采用第二三维相机,根据拍摄运动轨迹,获取当前拍摄点位视野内的工件点云;The second three-dimensional camera is used to obtain the workpiece point cloud within the field of view of the current shooting point according to the shooting motion trajectory;
根据当前拍摄点位拍摄得到的点云,进行焊缝寻位,规划机器人的焊接轨迹;According to the point cloud captured by the current shooting point, the welding seam is located and the welding trajectory of the robot is planned;
采用焊接装备,根据当前拍摄点位视野内的工件点云和焊接轨迹,完成焊接任务。Using welding equipment, the welding task is completed according to the workpiece point cloud and welding trajectory in the field of view of the current shooting point.
与现有技术相比,本发明的有益效果为:Compared with the prior art, the beneficial effects of the present invention are:
(1)本发明实现了机器人焊接系统的全过程自动化。目前,三维相机引导机器人进行焊接前,需要手动规划相机的拍摄点位。本发明使用双三维相机,通过三维视觉技术和机器人技术的结合,解决了拍摄点位的手动规划问题。(1) The present invention realizes the whole process automation of the robot welding system. At present, before the 3D camera guides the robot to weld, it is necessary to manually plan the shooting point of the camera. The invention uses dual three-dimensional cameras, and solves the problem of manual planning of shooting points through the combination of three-dimensional vision technology and robot technology.
(2)本发明使用三维视觉信息进行手上相机的拍摄点位规划,效率高,普适性强。适用对多品种、多焊缝、加工一致性差的工件焊接。(2) The present invention uses three-dimensional visual information to plan the shooting point of the hand camera, which has high efficiency and strong universality. It is suitable for welding workpieces with multiple varieties, multiple welds and poor processing consistency.
(3)本发明使用三维相机采集精度高,使用寻位方法拾取的焊缝精度高,保证了焊接的高质量。(3) The present invention uses a three-dimensional camera to acquire high precision, and uses a positioning method to pick up the welding seam with high precision, which ensures high quality of welding.
附图说明Description of drawings
构成本发明的一部分的说明书附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。The accompanying drawings forming a part of the present invention are used to provide further understanding of the present invention, and the exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention.
图1是本发明实施例一示出的双三维相机的机器人自动化焊接系统的示意图;1 is a schematic diagram of a robotic automatic welding system with dual three-dimensional cameras shown in Embodiment 1 of the present invention;
图2是本发明实施例二示出的双三维相机的机器人自动化焊接方法的流程图;FIG. 2 is a flowchart of a robot automatic welding method for dual three-dimensional cameras shown in Embodiment 2 of the present invention;
其中,1、多自由度机器人,2、手外相机,3、手上相机,4、焊接装备,5、控制箱,6、系统上位机。Among them, 1. Multi-DOF robot, 2. Camera outside the hand, 3. Camera on hand, 4. Welding equipment, 5. Control box, 6. System host computer.
具体实施方式Detailed ways
下面结合附图与实施例对本发明作进一步说明。The present invention will be further described below with reference to the accompanying drawings and embodiments.
应该指出,以下详细说明都是示例性的,旨在对本发明提供进一步的说明。除非另有指明,本文使用的所有技术和科学术语具有与本发明所属技术领域的普通技术人员通常理解的相同含义。It should be noted that the following detailed description is exemplary and intended to provide further explanation of the invention. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图限制根据本发明的示例性实施方式。如在这里所使用的,除非上下文另外明确指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说明书中使用术语“包含”或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。It should be noted that the terminology used herein is for the purpose of describing specific embodiments only, and is not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly dictates otherwise, the singular is intended to include the plural as well, furthermore, it is to be understood that when the term "comprising" or "comprising" is used in this specification, it indicates the presence of a characteristic , steps, operations, devices, components and/or combinations thereof.
本发明中,术语如“相连”、“连接”等应做广义理解,表示可以是固定连接,也可以是一体地连接或可拆卸连接;可以是直接相连,也可以通过中间媒介间接相连。对于本领域的相关科研或技术人员,可以根据具体情况确定上述术语在本发明中的具体含义,不能理解为对本发明的限制。In the present invention, terms such as "connected" and "connected" should be understood in a broad sense, indicating that it can be a fixed connection, an integral connection or a detachable connection; it can be directly connected or indirectly connected through an intermediate medium. For the relevant scientific research or technical personnel in the field, the specific meanings of the above terms in the present invention can be determined according to the specific situation, and should not be construed as a limitation of the present invention.
实施例一Example 1
本实施例提供了一种双三维相机的机器人自动化焊接系统。This embodiment provides a robot automatic welding system with dual three-dimensional cameras.
如图1,一种基于双三维相机的机器人自动化焊接系统,包括多自由度机器人1,机器人外部安装的三维相机,机器人末端安装的三维相机以及焊接装备4,控制机器人运动的控制箱5,系统上位机6;其中系统上位机6分别与多自由度机器人1、机器人外部安装的三维相机、机器人末端安装的三维相机以及焊接装备、控制机器人运动的控制箱5连接,控制箱5连接机器人。As shown in Figure 1, a robot automatic welding system based on dual 3D cameras includes a multi-degree-of-freedom robot 1, a 3D camera installed outside the robot, a 3D camera installed at the end of the robot and welding equipment 4, a control box 5 that controls the movement of the robot, and the
所述的机器人外部安装的三维相机,与机器人的组合方式是眼在手外(Eye-to-Hand),本实施例叙述将其简称为手外相机2。The three-dimensional camera installed outside the robot is combined with the robot in an Eye-to-Hand, which is simply referred to as the out-of-hand camera 2 in the description of this embodiment.
所述的机器人末端安装的三维相机,与机器人的组合方式是眼在手上(Eye-in-Hand),本实施例叙述将其简称为手上相机3。The three-dimensional camera installed at the end of the robot is combined with the robot in an Eye-in-Hand, which is referred to as the camera 3 on the hand for short in the description of this embodiment.
所述的焊接装备,根据不同的焊接工艺,不限于使用多种品牌的焊枪,焊机和送丝器。The welding equipment described is not limited to the use of various brands of welding torches, welding machines and wire feeders according to different welding processes.
所述的手外相机用于手上相机的拍摄点位规划,根据焊接场景需求,通常安装在机器人工作场景上方,安装方式包含但不限于龙门式。该装置的视野较大,能获取完整的工件点云。The out-of-hand camera is used for the shooting point planning of the on-hand camera. According to the requirements of the welding scene, it is usually installed above the working scene of the robot, and the installation method includes but is not limited to the gantry type. The device has a large field of view and can obtain a complete workpiece point cloud.
所述的手上相机用于焊缝寻位,该装置选择视野较小的相机,能够获取当前拍摄点位视野内的工件点云。The hand-held camera is used for welding seam locating, and the device selects a camera with a smaller field of view, and can acquire the workpiece point cloud within the field of view of the current shooting point.
所述的三维相机,具备获取扫描物体表面点云的功能,其测量精度小于1mm,获取深度图的帧速率大于1帧每秒,通常选择使用高精度的三维面阵结构光相机,但选择不限于使用多种品牌、多结构、相似原理且具有相同功能的三维视觉扫描装置。The 3D camera has the function of acquiring the point cloud on the surface of the scanned object, its measurement accuracy is less than 1mm, and the frame rate of acquiring the depth map is greater than 1 frame per second. Usually, a high-precision 3D area array structured light camera is used, but no It is limited to three-dimensional visual scanning devices that use multiple brands, multiple structures, similar principles and have the same function.
所述的多自由度机器人,用于搭载焊枪和手上相机,执行手上相机的拍摄运动和焊枪的焊接运动,不限于使用多种品牌的工业机器人。The multi-degree-of-freedom robot is used for carrying a welding gun and a camera on hand, and performing the shooting motion of the camera on the hand and the welding motion of the welding gun, and is not limited to the use of industrial robots of various brands.
所述的系统上位机,包含系统坐标系对齐功能、点云处理功能、通信功能、交互功能、文件读取和存储功能、模型可视化功能等一切满足本焊接系统需求的功能,运行在包含但不限于Windows和Linux的系统平台上。The system host computer includes system coordinate system alignment function, point cloud processing function, communication function, interactive function, file reading and storage function, model visualization function and other functions that meet the needs of the welding system. Limited to Windows and Linux system platforms.
所述的系统坐标系对齐功能,主要的目的是将整个系统的坐标系统一到多自由度机器人基坐标系下,包含对多自由度机器人基坐标系和焊枪工具坐标系的空间转换关系标定,多自由度机器人基坐标系和手外相机坐标系的空间转换关系标定,以及多自由度机器人基坐标系和手上相机坐标系的空间转换关系标定,三个标定关系无先后关系,具体为:The main purpose of the system coordinate system alignment function is to calibrate the coordinate system of the entire system from one to the base coordinate system of the multi-degree-of-freedom robot, including the spatial transformation relationship between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the welding gun tool. The calibration of the spatial transformation relationship between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the camera outside the hand, and the calibration of the spatial transformation relationship between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the camera on the hand, the three calibration relationships have no sequence relationship, specifically:
首先,三维相机本身经过精确的内参标定,且已知相机的内参;First, the 3D camera itself is calibrated with precise internal parameters, and the internal parameters of the camera are known;
其次,对多自由度机器人基坐标系和焊枪工具坐标系标定:引导机器人带动焊枪末端多次指到一个固定的空间点,改变每一次指点的机器人末端的姿态,不改变末端的位置,经过计算得到焊枪工具坐标系相对于多自由度机器人基座的空间转换关系BaseTTool。Secondly, calibrate the base coordinate system of the multi-degree-of-freedom robot and the welding gun tool coordinate system: guide the robot to drive the end of the welding gun to point to a fixed space point for many times, change the posture of the robot end for each pointing, without changing the position of the end, after calculating The spatial transformation relationship Base T Tool of the welding gun tool coordinate system relative to the multi-degree-of-freedom robot base is obtained.
然后,对多自由度机器人基坐标系和手外相机坐标系标定:将标定板固定安装在机器人末端,相机多次拍摄不同机器人位姿下的标定板,记录多自由度机器人每次拍摄时的位置和姿态。定义机器人末端到基座的齐次转换矩阵为EndTBase,三维相机到标定板坐标系的齐次转换矩阵为CameraATObject。由于机器人末端和标定板的相对位置不变,两次不同的拍摄之间可以表示为:Then, calibrate the base coordinate system of the multi-degree-of-freedom robot and the camera coordinate system outside the hand: the calibration plate is fixedly installed at the end of the robot, and the camera shoots the calibration plate in different robot poses multiple times, and records the multi-degree-of-freedom robot. position and attitude. Define the homogeneous transformation matrix from the robot end to the base as End T Base , and the homogeneous transformation matrix from the 3D camera to the calibration plate coordinate system as CameraA T Object . Since the relative position of the robot end and the calibration plate does not change, the time between two different shots can be expressed as:
EndTBase2·Base2TCameraA2·CameraA2TObject=EndTBase1·Base1TCameraA1·CameraA1TObject End T Base2 · Base2 T CameraA2 · CameraA2 T Object = End T Base1 · Base1 T CameraA1 · CameraA1 T Object
又因为相机到机器人基座的位置相对不变,即:And because the position of the camera to the robot base is relatively unchanged, namely:
Base2TCameraA2=Base1TCameraA1=BaseTCameraA, Base2 T CameraA2 = Base1 T CameraA1 = Base T CameraA ,
可得:Available:
通过多次拍摄,求解上述方程,得到多自由度机器人基坐标系和手外相机坐标系之间的空间转换关系BaseTCameraA;Through multiple shots, the above equations are solved, and the spatial transformation relationship Base T CameraA between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the out-of-hand camera is obtained;
最后,对自由度机器人基坐标系和手上相机坐标系标定:标定板固定位置不变,改变机器人的姿态,手上相机对标定板实现多次不同位姿的拍摄。定义三维相机到标定板坐标系的齐次转换矩阵为CameraBTObject。由于机器人基座和标定板的相对位置不变,两次不同的拍摄之间可以表示为:Finally, the base coordinate system of the degree-of-freedom robot and the coordinate system of the camera on the hand are calibrated: the fixed position of the calibration board is unchanged, the posture of the robot is changed, and the camera on the hand can shoot multiple times of different poses on the calibration board. Define the homogeneous transformation matrix from the 3D camera to the calibration board coordinate system as CameraB T Object . Since the relative position of the robot base and the calibration plate does not change, the time between two different shots can be expressed as:
BaseTEnd2·End2TCameraB2·CameraB2TObject=BaseTEnd1·End1TCameraB1·CameraB1TObject Base T End2 · End2 T CameraB2 · CameraB2 T Object = Base T End1 · End1 T CameraB1 · CameraB1 T Object
又因为三维相机到机器人末端的相对位置不变,即:And because the relative position of the 3D camera to the end of the robot does not change, that is:
End2TCameraB2=End1TCameraB1=EndTCameraB, End2 T CameraB2 = End1 T CameraB1 = End T CameraB ,
有:Have:
通过多次拍摄,求解上述方程,得到多自由度机器人基坐标系和手外相机坐标系之间的空间转换关系EndTCameraB;Through multiple shots, the above equations are solved, and the spatial transformation relationship End T CameraB between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the out-of-hand camera is obtained;
最终得到手上相机和机器人基座之间的手眼关系矩阵为:Finally, the hand-eye relationship matrix between the camera on the hand and the robot base is obtained as:
BaseTCameraB=BaseTEnd EndTCameraB Base T CameraB = Base T End End T CameraB
为了能够让相机较为准确的拍摄工件的焊缝部分,需要确定相机的拍摄位置,该位置可能不止一个,这些点位加上焊接过程中的中间位置构成机器人的拍摄轨迹。目前的拍摄轨迹获取方法,主要是人工示教和一些专用的软件设定,这两种方法自动化程度不高。In order to allow the camera to accurately photograph the welding seam of the workpiece, it is necessary to determine the shooting position of the camera. There may be more than one position. These points plus the intermediate position during the welding process constitute the shooting trajectory of the robot. The current acquisition method of shooting track is mainly manual teaching and some special software settings, and the degree of automation of these two methods is not high.
使用手上相机引导机器人焊接的流程如下:The process of guiding robot welding with the camera in hand is as follows:
1、焊缝寻位1. Weld seam locating
在拍摄点位拍摄获取点云,对点云进行算法处理,获取焊缝特征,然后根据焊接的工艺要求规划焊接轨迹。最后,将焊接轨迹从相机坐标系下转换到机器人基坐标系下。The point cloud is obtained by shooting at the shooting point, the point cloud is processed by algorithm, the characteristics of the welding seam are obtained, and then the welding trajectory is planned according to the welding process requirements. Finally, the welding trajectory is transformed from the camera coordinate system to the robot base coordinate system.
2、机器人焊接2. Robot welding
对焊接轨迹进行分析,生成不同机器人的控制脚本或程序,控制机器人完成焊接。Analyze the welding trajectory, generate control scripts or programs for different robots, and control the robot to complete the welding.
因此,本实施例针对上述问题,提出了外加一台三维相机实现拍摄点位自动规划的方案,提高现有方案的自动化程度。Therefore, in order to solve the above problems, the present embodiment proposes a solution of adding a three-dimensional camera to realize automatic planning of shooting points, so as to improve the automation degree of the existing solution.
本实施例中,系统上位机根据完整工件点云规划第二三维相机的拍摄点位,形成机器人的拍摄运动轨迹;所述第二三维相机用于根据拍摄运动轨迹,获取当前拍摄点位视野内的工件点云;所述焊接装备用于根据当前拍摄点位视野内的工件点云和焊接轨迹,完成焊接任务。In this embodiment, the system host computer plans the shooting point of the second 3D camera according to the complete workpiece point cloud to form the shooting motion trajectory of the robot; the second 3D camera is used to obtain the current shooting point field of view according to the shooting motion trajectory. The point cloud of the workpiece; the welding equipment is used to complete the welding task according to the point cloud of the workpiece and the welding track within the field of view of the current shooting point.
实施例二Embodiment 2
本实施例提供了一种双三维相机的机器人自动化焊接方法。This embodiment provides a robot automatic welding method with dual three-dimensional cameras.
一种双三维相机的机器人自动化焊接方法,采用实施例一所述的双三维相机的机器人自动化焊接系统包括:A robot automatic welding method with dual 3D cameras, the robot automatic welding system using the dual 3D cameras described in Embodiment 1 includes:
(一)标定焊枪工具坐标系、两个相机坐标系与机器人基坐标系之间的关系;(1) To calibrate the relationship between the welding gun tool coordinate system, the two camera coordinate systems and the robot base coordinate system;
(二)使用手外相机拍摄获取完整工件点云;(2) Use an off-hand camera to capture the complete workpiece point cloud;
(三)根据完整工件点云规划手上相机的拍摄点位,形成机器人的拍摄运动轨迹;(3) Plan the shooting point of the camera on the hand according to the complete workpiece point cloud to form the shooting trajectory of the robot;
(四)使用手上相机获取当前拍摄点位视野内的工件点云;(4) Use the hand-held camera to obtain the workpiece point cloud within the field of view of the current shooting point;
(五)通过焊缝寻位方法,获取并生成焊接轨迹;(5) Obtain and generate the welding track through the welding seam locating method;
(六)机器人完成当前拍摄点位的焊接任务;(6) The robot completes the welding task of the current shooting point;
(七)重复步骤(四)到步骤(六),直至完成所有拍摄点位的焊接任务。(7) Repeat steps (4) to (6) until the welding tasks of all shooting points are completed.
所述步骤(一),对多自由度机器人基坐标系和焊枪工具坐标系的空间转换关系标定,多自由度机器人基坐标系和手外相机坐标系的空间转换关系标定,以及多自由度机器人基坐标系和手上相机坐标系的空间转换关系标定,三个标定过程无先后关系,具体为:The step (1) is to calibrate the space conversion relationship between the multi-degree-of-freedom robot base coordinate system and the welding torch tool coordinate system, the multi-degree-of-freedom robot base coordinate system and the space conversion relationship calibration of the out-of-hand camera coordinate system, and the multi-degree-of-freedom robot. For the calibration of the spatial transformation relationship between the base coordinate system and the hand-held camera coordinate system, the three calibration processes have no sequence relationship, specifically:
首先,三维相机本身经过精确的内参标定,且已知相机的内参;First, the 3D camera itself is calibrated with precise internal parameters, and the internal parameters of the camera are known;
其次,对多自由度机器人基坐标系和焊枪工具坐标系标定:引导机器人带动焊枪末端多次指到一个固定的空间点,改变每一次指点的机器人末端的姿态,不改变末端的位置,经过计算得到焊枪工具坐标系相对于多自由度机器人基座的空间转换关系BaseTTool。Secondly, calibrate the base coordinate system of the multi-degree-of-freedom robot and the welding gun tool coordinate system: guide the robot to drive the end of the welding gun to point to a fixed space point for many times, change the posture of the robot end for each pointing, without changing the position of the end, after calculating The spatial transformation relationship Base T Tool of the welding gun tool coordinate system relative to the multi-degree-of-freedom robot base is obtained.
然后,对多自由度机器人基坐标系和手外相机坐标系标定:将标定板固定安装在机器人末端,相机多次拍摄不同机器人位姿下的标定板,记录多自由度机器人每次拍摄时的位置和姿态。定义机器人末端到基座的齐次转换矩阵为EndTBase,三维相机到标定板坐标系的齐次转换矩阵为CameraATObject。由于机器人末端和标定板的相对位置不变,两次不同的拍摄之间可以表示为:Then, calibrate the base coordinate system of the multi-degree-of-freedom robot and the camera coordinate system outside the hand: the calibration plate is fixedly installed at the end of the robot, and the camera shoots the calibration plate in different robot poses multiple times, and records the multi-degree-of-freedom robot. position and attitude. Define the homogeneous transformation matrix from the robot end to the base as End T Base , and the homogeneous transformation matrix from the 3D camera to the calibration plate coordinate system as CameraA T Object . Since the relative position of the robot end and the calibration plate does not change, the time between two different shots can be expressed as:
EndTBase2·Base2TCameraA2·CameraA2TObject=EndTBase1·Base1TCameraA1·CameraA1TObject End T Base2 · Base2 T CameraA2 · CameraA2 T Object = End T Base1 · Base1 T CameraA1 · CameraA1 T Object
又因为相机到机器人基座的位置相对不变,即:And because the position of the camera to the robot base is relatively unchanged, namely:
Base2TCameraA2=Base1TCameraA1=BaseTCameraA, Base2 T CameraA2 = Base1 T CameraA1 = Base T CameraA ,
可得:Available:
通过多次拍摄,求解上述方程,得到多自由度机器人基坐标系和手外相机坐标系之间的空间转换关系BaseTCameraA;Through multiple shots, the above equations are solved, and the spatial transformation relationship Base T CameraA between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the out-of-hand camera is obtained;
最后,对多自由度机器人基坐标系和手上相机坐标系标定:标定板固定位置不变,改变机器人的姿态,手上相机对标定板实现多次不同位姿的拍摄。定义三维相机到标定板坐标系的齐次转换矩阵为CameraBTObject。由于机器人基座和标定板的相对位置不变,两次不同的拍摄之间可以表示为:Finally, the multi-degree-of-freedom robot base coordinate system and the hand camera coordinate system are calibrated: the fixed position of the calibration board is unchanged, the robot's posture is changed, and the hand camera can shoot the calibration board with different poses for many times. Define the homogeneous transformation matrix from the 3D camera to the calibration board coordinate system as CameraB T Object . Since the relative position of the robot base and the calibration plate does not change, the time between two different shots can be expressed as:
BaseTEnd2·End2TCameraB2·CameraB2TObject=BaseTEnd1·End1TCameraB1·CameraB1TObject Base T End2 · End2 T CameraB2 · CameraB2 T Object = Base T End1 · End1 T CameraB1 · CameraB1 T Object
又因为三维相机到机器人末端的相对位置不变,即:And because the relative position of the 3D camera to the end of the robot does not change, that is:
End2TCameraB2=End1TCameraB1=EndTCameraB, End2 T CameraB2 = End1 T CameraB1 = End T CameraB ,
有:Have:
通过多次拍摄,求解上述方程,得到多自由度机器人基坐标系和手外相机坐标系之间的空间转换关系EndTCameraB;Through multiple shots, the above equations are solved, and the spatial transformation relationship End T CameraB between the base coordinate system of the multi-degree-of-freedom robot and the coordinate system of the out-of-hand camera is obtained;
最终得到手上相机和机器人基座之间的手眼关系矩阵为:Finally, the hand-eye relationship matrix between the camera on the hand and the robot base is obtained as:
BaseTCameraB=BaseTEnd EndTCameraB Base T CameraB = Base T End End T CameraB
所述的步骤(三)中,规划手上相机拍摄点位目的在于,使得手上相机通过多个点位的拍摄,完整得到手外相机获得的工件部分的所有焊缝区域点云。In the step (3), the purpose of planning the shooting points of the camera on the hand is to make the camera on the hand complete the point cloud of all the weld areas of the workpiece obtained by the camera outside the hand by shooting at multiple points.
所述的步骤(三)中,规划手上相机的拍摄点位的方法主要包含以下两种:In the step (3), the methods for planning the shooting point of the camera on the hand mainly include the following two:
1)通过对工件点云进行几何分割,根据点云的线面特征确定手上相机的拍摄角度。结合手上相机的工作距离范围,设定手上相机的拍摄位置。对工件点云进行几何分割的方法包括但不限于使用点云处理算法分割和使用交互设备人工分割。所述的人工分割包含但不限于鼠标绘制或选择、触摸式屏幕绘制或选择等。1) By geometrically segmenting the workpiece point cloud, the shooting angle of the hand camera is determined according to the line and surface features of the point cloud. Combined with the working distance range of the hand camera, set the shooting position of the hand camera. The methods of geometrically segmenting the workpiece point cloud include but are not limited to segmentation using point cloud processing algorithms and manual segmentation using interactive equipment. The manual segmentation includes but is not limited to mouse drawing or selection, touch screen drawing or selection, and the like.
2)当存在工件的三维模型时,使用第三方建模软件在三维模型上设定拍摄点位。将拍摄得到的点云模型与三维模型做配准,将拍摄点位转换到机器人基坐标系下。2) When there is a three-dimensional model of the workpiece, use a third-party modeling software to set the shooting point on the three-dimensional model. The point cloud model obtained by shooting is registered with the three-dimensional model, and the shooting point is converted into the robot base coordinate system.
所述三维模型的来源包含但不限于:使用机器人末端的3D相机进行扫描、拼接、点云融合逆向得到;使用三维CAD软件建模;使用既有模型进行变换;按照以下方式优选数字三维模型,在具有原始CAD设计三维模型,并且工件的一致性较好的情况下,选择设计的CAD三维数字模型,否则优选逆向得到的数字三维模型。The sources of the three-dimensional model include but are not limited to: scanning, splicing, and reverse point cloud fusion using the 3D camera at the end of the robot; modeling using three-dimensional CAD software; using existing models for transformation; In the case that the original CAD design 3D model is available and the consistency of the workpiece is good, the CAD 3D digital model of the design is selected, otherwise the digital 3D model obtained in reverse is preferred.
所述的步骤(五)中,寻位方法主要包含以下两种,但只要能完成焊缝特征的拾取,都可以实现本发明的效果。In the step (5), the positioning method mainly includes the following two methods, but as long as the welding seam feature can be picked up, the effect of the present invention can be achieved.
1)通过对三维点云模型进行几何分割,通过线面特征,提取工件焊缝的特征点,对特征点进行拟合平滑得到焊缝轨迹。对工件点云进行几何分割的方法包括但不限于使用点云处理算法分割和使用交互设备人工分割。所述的人工分割包含但不限于鼠标绘制或选择、触摸式屏幕绘制或选择等。同时,利用特征点的邻域信息,规划焊枪姿势。1) By geometrically segmenting the three-dimensional point cloud model, extracting the feature points of the workpiece weld through line and surface features, and fitting and smoothing the feature points to obtain the weld track. The methods of geometrically segmenting the workpiece point cloud include but are not limited to segmentation using point cloud processing algorithms and manual segmentation using interactive equipment. The manual segmentation includes but is not limited to mouse drawing or selection, touch screen drawing or selection, and the like. At the same time, using the neighborhood information of the feature points, the welding torch pose is planned.
2)当存在可使用的三维数字模型时,直接在数字模型中拾取特征,作为焊接轨迹。所述数字三维模型的来源包含但不限于:使用机器人末端的3D相机进行扫描、拼接、点云融合逆向得到;使用三维CAD软件建模;使用既有模型进行变换;按照以下方式优选数字三维模型,在具有原始CAD设计三维模型,并且工件的一致性较好的情况下,选择设计的CAD三维数字模型,否则优选逆向得到的数字三维模型。焊枪姿态的规划同步骤1)。2) When there is a usable 3D digital model, directly pick up features in the digital model as welding tracks. The sources of the digital 3D model include, but are not limited to: scanning, splicing, and reverse point cloud fusion using the 3D camera at the end of the robot; modeling using 3D CAD software; using existing models for transformation; , in the case that the original CAD design 3D model is available and the consistency of the workpiece is good, the CAD 3D digital model of the design is selected, otherwise the digital 3D model obtained in reverse is preferred. The planning of the welding torch posture is the same as step 1).
所述步骤(六)中,将步骤(五)中获得的焊接轨迹转换成机器人控制语言,发送给机器人控制器,通过机器人实施焊接。In the step (6), the welding trajectory obtained in the step (5) is converted into a robot control language, sent to the robot controller, and the robot is used for welding.
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。The above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.
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