Adaptive welding control vision head

Abstract: An adaptive welding control vision head with a metal enclosure (4) for attachment to a welding head (15). The side (1) of the enclosure facing the workpiece is angled away from the welding head, has two apertures (10, 11) and its external surface is coated with oil (19). Mounted inside the enclosure is a means (20) of projecting a strucutural light pattern (22) onto a workpiece (17) and a means (21) of monitoring the resulting scattered light (23). The inside of the enclosure is maintained at a positive air pressure to prevent welding fumes from entering and is cooled to prevent heat accumulation.

Description: Robot vision systems are becoming very important in the application of adaptive control of automated welding systems. A serious problem which these systems must overcome is the harshness of the welding environment. Optical equipment used in adaptive control of the welding process is at a high risk of being damaged or rendered useless because of the spatter of particles of molten metal which are projected outward from the welding arc, fumes from the welding process that can leave a sooty residue on optical lenses and heat from the arc that can distort optical equipment. Methods of protecting optical equipment in environments of high temperature and flying particles are mentioned in United States patent no. 3,321,265 issued May 23, 1967 to Serge and Marcel Clavé, and United States patent no. 3,310,356 issued March 21, 1967 to Willy Borberg. These patents are examples of specific enclosures used to protect optical equipment. Another example is found in United States patent no. 4,450,339 issued May 22, 1984 to Nelson R. Corby, Jr. These patents do not provide for the projection of a light which is required of an active vision system. United States patent no. 4,497,996 issued February 5, 1985 to Charles J. Libby, Jr. provides for the projection of light but is constructed in such a way that it would require frequent cleaning. Technische Rundschau, volume 77, no. 34, August 1985, Bern, pages 45-51, 53 and 55; P. Drew et al. "Sensoren für das Lichtbogen-schweissen mit Handhabungssystemen" describes a sensor for an adaptive welding control system, in which the vision head is positioned in front of the welding head to protect it from damage or contamination by dust and spatters. EP-A1-0 179 505 describes a device for protecting optical means from contaminated gases, in which a laminar gas flow is passed over the outer surface of a window to prevent aggresive gases and oxides from reaching the outer surface of the window. Technisches Messen T.M. volume 51, nos 7/8, July/August 1984, München, pages 270-275, P. Drew et. al. "Optisch-elektronischer Nahtführungssensor zur Schweissnahtverfolgung" describes an optical sensor for seam tracking in an automated arc welding system. Welding and Metal Fabrication volume 51, no. 6, July/August 1983, Haywards Heath, Sussex G.B., page 260 "The Robot's other half" describes an optical sensor for an adaptive welding system which is protected from fumes and spatter by means of a filtered air stream and two replaceable shielding glasses. Welding Journal volume 65, no. 11, November 1986, Miami, FL, U.S.A., pages 33-41; J. E. Agapakis et. al. "Joint tracking and adaptive robotic welding using vision sensing of the weld joint geometry" describes an adaptive welding control system. A vision sensor including a television camera is housed in a rugged enclosure where a dust-free, constant temperature and positive air pressure environment is maintained. Object of Invention It is the object of the present invention to provide a device which will allow optical equipment, in the form of a light source and a light monitor, to be attached to the welding head and be such as to require infrequent cleaning. A further object of the present invention is to provide a device to protect the optical equipment from the flying particles, fumes and heat of the welding process. Summary of the invention According to the present invention there is provided a vision head to supply the electrical signals required for visual control of an adaptive welding control system with a welding head, which produces a weld pool on a workpiece being welded, comprising: a metal enclosure for attachment to the welding head having a side facing the workpiece, the said side slanting away from the said welding head so as to form an angle with a plane tangent to the workpiece and passing through the weld pool, projecting means mounted in said enclosure for projecting a structured light pattern onto the workpiece, monitoring means mounted in said enclosure for monitoring scattered light of the said structured light pattern on the workpiece and converting said scattered light into electrical signals required for visual control; characterised in that the side of the enclosure has an antispatter oil coating, a first aperture through which the structured light pattern is projected onto the workpiece and a second aperture through which the scattered light is monitored, the first aperture being a slit up to 30 mm long and from 0.5 to 2 mm wide and the second aperture being a hole from 0.5 to 2 mm in diameter, and the first and second apertures being orientated to direct air flowing through them away from the welding site, the vision head further comprising pressurizing means for maintaining a positive air pressure in the enclosure, and cooling means for maintaining the temperature of the enclosure. One embodiment of the present invention provides for a vision head to supply the signals required for visual control of an adaptive welding control system. Said vision head comprises a metal enclosure for attachment to a welding head. The welding head produces a welding pool of molten metal on the workpiece. Said enclosure has a side facing a workpiece, the said side slanting away from the welding head so as to form an angle with a plane tangent to the workpiece and passing through said weld pool, said side having a first and second aperture. The range of angles found to give the preferred results was from 5° to 45°. Mounted in the metal enclosure is a projecting means for projecting a structured light pattern onto the workpiece through the first aperture. Also mounted in the enclosure is a monitoring means for monitoring, through the second aperture, the structured light after it has been scattered by the workpiece and converting the scattered light images into electrical signals required for visual control of an adaptive welding control system. The vision head also includes a pressurizing means for maintaining a positive air pressure in the enclosure and a cooling means for maintaining the temperature of the enclosure. In another embodiment of the present invention, the external surface of the side facing the enclosure is covered with an oil coating to prevent particles of molten metal thrown from the welding torch from adhering to the surface. Brief Description of the Drawings Figure 1 shows a cross-section of the vision head. Figure 2 is a block diagram of the adaptive welding control system. Figure 3 shows the advantage of the particular geometry of the vision head. Description of the Preferred Embodiment Figure 1 shows a cross-section of the vision head. The side 1 of the enclosure 4 facing the workpiece 17 is slanted away from the welding head 15 so as to form an angle of 14° with the plane 18 tangent to the workpiece 17 passing through the weld pool 16. In said side 1, there is a first aperture 10 and a second aperture 11. These apertures 10 and 11 are oriented perpendicular to the said side 1. The external surface of the said side 1 is covered with an oil coating 19 which is the same as the antispatter coating commonly used in the protection of welding heads. A projecting means 20 is mounted in the enclosure 4 so that a light pattern 22 of well defined geometry, in this case a line, can be projected onto the workpiece. The projecting means 20 comprises a light source 7 which projects through a cylindrical lens 8 and a protective plate 9 to protect the lens from foreign particles, and finally through the first aperture 10 which is 0.5 mm by 15 mm and onto the workpiece 17. The light source 7 can be selected from the group consisting of a fiber optic bundle and a laser diode. The range of dimensions for the first aperture 10 is up to 30 mm in length and from 0.5 mm to 2.0 mm in width. Also mounted in the enclosure is a monitoring means 21 for monitoring the scattered light 23 of the structured light pattern 22 after it has struck the workpiece 17. Upon leaving the workpiece 17 the scattered light 23 passes through the second aperture 11 which has a diameter of 1.5 mm and passes through a protective plate 12 which prevents any particles thrown from the welding torch 15 from striking the lens 2. The range of dimensions for the second aperture 11 is from 0.5 mm to 2.0 mm in diameter. The scattered light 23 then passes through a precision lens 2 and then through an interference filter 3 which prevents light other than the scattered light of the projected light source from passing to the detector 5 which is a two dimensional array charge coupled device mounted in the enclosure to convert the scattered light images 23 into electrical signals. A printed circuit 6 transmits the electrical signals to the adaptive welding control system. The arrangement of the second aperture 11, lens 2 and filter 3 are such that they form a telecentric configuration. This configuration ensures complete collimation of the light before it reaches the filter 3. This prevents vignetting and permits the use of a 2.5 nanometer as opposed to the usual 10 nanometer filter. As seen in Figure 3, the minimum distance 30 between the second aperture 11 the the lens 2 should be small enough to give a sufficiently wide field of vision and great enough to allow for the dispersion of flying metal particles that may find their way through the second aperture. This distance has been found to be from 10 to 40 mm with 20 mm giving the preferred results. This will ensure that the most probable point of impact 40 of any small metal particle will occur on that part of the lens 2 that is least used. A connection 13 for air provides a pressurizing means by allowing air to flow into the enclosure 4 at an approximate rate of 3 liters per minute and results in a small positive air pressure within the enclosure 4 which prevents fumes from entering the enclosure 4 through the apertures 10 and 11. As seen in Figure 3, the direction 50 of the air flow resulting from the small internal positive air pressure is away from the welding arc and its surrounding weld pool inert gas shield 60. The air pressure is used to protect the optical equipment from fumes and not to stop spatters. A connection 14 for cooling provides a cooling means. The flow of coolant, usually water, prevents heat accumulation in the enclosure. Figure 2 is a block diagram of the adaptive control system. The light source 45 mounted in the enclosure 65 projects a structured light pattern 95 onto the workpiece 75. The scattered light 85 is sensed by the monitoring means 55 which produces a typical image as seen in block A of Figure 2. At the centre of block A is the characteristic angle joint profile 25. The image is distorted by a spot 35 at the left caused by the light from the welding arc and by the trace 15 of two particles of molten metal which have crossed the field of vision. The image is sent to the video processor for analysis. Block B shows the digitized profile generated in real time by the video processor from the video signal supplied by the monitoring means 55. The processor transmits its results to the micro-computer which performs the calculations required to provide the welding parameters: position and orientation of the joint, distance between edges etc. Block C shows a cross indicating the calculated centre of the weld joint.

Claims: A vision head to supply the electrical signals required for visual control of an adaptive welding control system with a welding head (15), which produces a weld pool (16) on a workpiece (17) being welded, comprising: a metal enclosure (4) for attachment to the welding head having a side (1) facing the workpiece, the said side slanting away from the said welding head (15) so as to form an angle with a plane (18) tangent to the workpiece and passing through the weld pool, projecting means (20) mounted in said enclosure (4) for projecting a structured light pattern onto the workpiece, monitoring means (21) mounted in said enclosure (4) for monitoring scattered light of the said structured light pattern on the workpiece and converting said scattered light into electrical signals required for visual control; characterised in that the side (1) of the enclosure (4) has an antispatter oil coating (19), a first aperture (10) through which the structured light pattern is projected onto the workpiece (17) and a second aperture (11) through which the scattered light is monitored, the first aperture (10) being a slit up to 30 mm long and from 0.5 to 2 mm wide and the second aperture being a hole from 0.5 to 2 mm in diameter, and the first and second apertures being orientated to direct air flowing through them away from the welding site, the vision head further comprising pressurizing means (13) for maintaining a positive air pressure in the enclosure (4), and cooling means (14) for maintaining the temperature of the enclosure. A vision head according to claim 1, wherein the said first and second apertures (10,11) are oriented perpendicularly to said side (1). A vision head as in claim 2, wherein said projecting means (20) comprises: a light source (7) mounted within the enclosure (4), a lens (8) mounted in the enclosure in such a way as to focus the light from said light source (7) onto the workpiece (17) as the said structured light pattern through the first aperture (10), and a protector plate (9) mounted in the enclosure between the lens (8) and the first aperture (10) to protect the lens from foreign particles. A vision head as in claim 2 wherein said monitoring means (21) comprises: circuit means (6) for transmitting electrical signals to the adaptive welding control system, converting means (5) mounted in the enclosure (4) for converting the scattered light of the structured light pattern into electrical signals, a lens (2) mounted in the enclosure to focus the scattered light onto said converting means (5), an interference filter (3) mounted in the enclosure between the converting means (5) and the lens (2) to prevent any light other than the scattered light from the structured light pattern from striking said converting means, a protector plate (12) mounted in the enclosure between the lens (2) and the second aperture (11) to protect the lens from foreign particles. A vision head according to claim 3 wherein the light source (7) is selected from a group consisting of an optic fibre bundle, and a laser diode. A vision head according to claim 4 wherein the converting means (5) is a two-dimensional array charge coupled device. A vision head according to any one of the preceding claims, wherein the first aperture (10) is a slit 15 mm long and 0.5 mm wide. A vision head according to any one of the preceding claims, wherein the second aperture (11) is a hole 1.5 mm in diameter. A vision head as in claim 2 wherein the side (1) facing the workpiece (17) forms an angle of 5° to 45° with a plane (18) tangent to the workpiece (17) and passing through the weld pool (16).

Inventors: DUFOUR L MARC, DUFOUR, L. MARC
Applicants: CANADA NAT RES COUNCIL, NATIONAL RESEARCH COUNCIL OF CANADA
Application year: 1988
Main classification: B23K9
IPC codes: B23K9, B23K31