逆向补偿下的箱涵钢筋焊接焊缝跟踪技术

Weld seam tracking technology for box culvert reinforcement welding under reverse compensation

  • 摘要:   箱涵钢筋焊接过程中,热输入引起的结构热变形会导致焊缝形态发生随机、非线性变化,由此产生跟踪误差,易造成跟踪误差累积,进而影响焊接质量与结构整体安全性。为此,提出逆向补偿下的箱涵钢筋焊接焊缝跟踪技术。
      通过二维高斯函数构建所采集焊缝图像的 Hessian 矩阵,利用其特征值特性提取激光条纹像素点,以准确计算焊缝中心坐标。将焊缝中心坐标输入至卡尔曼级联滤波算法中,通过建立状态空间模型,利用前一时刻估计值与当前测量值递归预测目标状态,实时处理坐标数据,精准计算焊接热变形导致误差累积量。由此,将焊缝中心坐标点转化为 NURBS 曲线,通过单目标点约束算法构建拉格朗日方程求解基函数权重修正量,对轨迹进行逆向补偿以最小化累积误差,从而抵消累积误差对跟踪结果的影响,实现箱涵钢筋焊接焊缝的精准跟踪。实验结果表明,所提方法能够在实现高精度焊缝跟踪的同时,RTAMS在1cm以下。可以有效抑制跟踪误差累积,显著提升焊接自动化系统的稳定性和可靠性,为工程应用提供了可靠的技术保障。

     

    Abstract: During the welding process of box culvert steel bars, the structural thermal deformation caused by heat input can lead to random and nonlinear changes in the shape of the weld seam, resulting in tracking errors, which can easily accumulate and affect the welding quality and overall structural safety. Therefore, a welding seam tracking technology for box culvert steel bars under reverse compensation is proposed. Construct a Hessian matrix of the collected weld seam images using a two-dimensional Gaussian function, and extract laser stripe pixels based on their characteristic values to accurately calculate the center coordinates of the weld seam. Input the center coordinates of the weld seam into the Kalman cascade filtering algorithm, establish a state space model, recursively predict the target state using the previous estimated value and current measured value, process the coordinate data in real time, and accurately calculate the accumulated error caused by welding thermal deformation. Therefore, the center coordinate of the weld seam is transformed into a NURBS curve. The Lagrange equation is constructed by single-target point constraint algorithm to solve the weight correction of the basis function, and the trajectory is compensated inversely to minimize the cumulative error, so as to offset the influence of the cumulative error on the tracking results, so as to realize the accurate tracking of the welded seam of the box culvert steel bar. The experimental results show that the proposed method can achieve high-precision weld seam tracking while RTAMS is below 1cm. It can effectively suppress the accumulation of tracking errors, significantly improve the stability and reliability of welding automation systems, and provide reliable technical support for engineering applications.

     

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