Detailed Description
Figures 1-15 and the following description depict alternative embodiments of the invention to teach those skilled in the art how to make and reproduce the invention. In order to teach the technical solution of the present invention, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations or alternatives derived from these specific embodiments that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. Thus, the invention is not limited to the following alternative embodiments, but only by the claims and their equivalents.
Example 1.
The metal welding on-line detection method based on the LIBS technology in the embodiment of the invention, as shown in figure 1, comprises the following steps:
(S1) the identification unit identifies the position of the welding line by using an image identification technology.
(S2) the driving unit 31 drives the light emitting module 11 to move until the outgoing light of the light emitting module 11 is focused at the weld.
The detection light at the welding seam is received by the light receiving module, and the relative light intensity corresponding to various elements is obtained.
(S3) correcting the relative light intensity of the element to be measured.
(S4) obtaining the relative content of each element by using the relative light intensity.
(S5) obtaining the content of the element to be detected according to the relative content.
In order to accurately identify the weld position, further, the identification mode is as follows:
And respectively obtaining a background image without a welding workpiece and an acquisition image of the welding workpiece, and converting the background image and the identification area in the acquisition image into a gray level image.
And subtracting the background by using the gray value of the image to obtain the identification image.
The workpiece contour is extracted from the recognition image, and an upper boundary line is obtained in the contour.
A weld is obtained in the upper boundary line.
In order to accurately obtain the upper boundary line, further, the upper boundary line is obtained in such a manner that:
Dividing the workpiece contour image into a plurality of columns, and searching the mutation points of each column from top to bottom, wherein the upper boundary line is the connecting line of the mutation points of all columns.
In order to improve the accuracy of the correction, further, the light intensity is corrected by:
and according to the material type of the welding seam, selecting a correction mode corresponding to the interference element in the material in a database, wherein the interference element in the material type and the correction mode are in one-to-one correspondence in the database.
In order to more purposefully correct the light intensity of the sample to be tested, further, the corresponding relationship in the database is obtained in the following manner:
And detecting standard samples of various material types, and obtaining coefficients corresponding to the additive interference correction mode and the multiplicative interference correction mode of the interference element by using the obtained light intensity values and nominal content values of the measuring element and the interference element.
For interference elements of a standard sample of any material type, detecting results of the interference elements in the material type are processed by comparing an additive interference correction mode, a multiplicative interference correction mode and a mixed correction mode, a correction mode with the optimal detection result is selected to correspond to the interference elements of the material type and is stored, the additive interference correction mode is inti=inti0+Σ(fij·Cj, the multiplicative interference correction mode is that inti=inti0·(1+Σ(fij·Aj)),inti0、inti is light intensity before and after correction of an ith element to be detected, Cj is content of the jth interference element, fij is interference coefficient of the jth interference element to the ith element to be detected, and Aj is product of the content of the interference element and the light intensity.
The hybrid correction mode is to utilize an additive interference correction mode and then a multiplicative interference correction mode.
In order to improve the accuracy of the correction mode, further, after obtaining the coefficient once, the light intensity is obtained by using the correction mode, the coefficient is obtained again, and after a plurality of iterations, the coefficient is obtained in average a plurality of times as the coefficient in the correction mode.
In order to accurately obtain the interference coefficient, a nonlinear correction model is further established by using a correction mode, wherein the content Cˊi =Σ(ak·intik),ak of the element to be detected is a coefficient, k is a non-negative integer, and the interference coefficient of each interference element to the element to be detected is fitted by using the light intensity value of the element to be detected in the standard sample and the nominal content value of each element.
In order to obtain the percentage content of the element to be detected, in the step (S5), the calculation mode is as follows:
C%= 100·C/ (100+ΣCj),C%, C are the percentage content and the relative content of the element to be measured, respectively, Σcj is the sum of the relative contents of the other elements.
In order to implement the above detection method, further, as shown in fig. 2, the present invention implements detection by using an apparatus including:
A LIBS detection unit including a light emitting module 11, a light receiving module 12, and an analyzing module 13, the light emitting module 11 including a light source and a condensing lens. The light receiving module 12 includes a light converging device and a spectrometer. When the welding device works, emergent light emitted by the light source passes through the converging lens and then is focused on the welding workpiece, and the part of the welding workpiece is vaporized by photoablation to form transient plasma and emit light radiation. The optical radiation is converged by the optical converging device and then enters the spectrometer, and an electric signal output by a detector of the spectrometer is sent to the analysis module 13, and the analysis module 13 analyzes the electric signal by utilizing the LIBS technology.
The first recognition unit 21, the first recognition unit 21 is used for recognizing the position of the metal weld.
And a driving unit 31, wherein the driving unit 31 is used for driving the light source to move, so that the emergent light of the light source is focused at the welding seam.
In order to ensure that the outgoing light is accurately focused at the weld, the device further comprises:
a second recognition unit 22, the second recognition unit 22 is used for recognizing whether the emergent light is focused at the welding seam.
For accurate identification, further, the second identification unit 22 employs a visual identification unit or a ranging unit provided on the driving unit 31 for a distance between the light source and the weld so that the distance is equal to a focal length of the converging lens.
In order to provide the real-time correction function, the apparatus further comprises.
The bearing seat is used for bearing a plurality of standard samples, and the driving unit 31 is used for driving the light source to move, so that the emergent light of the light source is focused on the standard samples, and the LIBS detection unit is corrected in real time.
Example 2.
According to the application example of the LIBS technology-based metal welding on-line detection method in the welding of the steel pipe 1 in the embodiment 1 of the invention.
In this application example, as shown in fig. 2, in the implementation device of the detection method, the LIBS detection unit includes a light emitting module 11, a light receiving module 12, and an analyzing module 13, and the light emitting module 11 includes a laser and a converging lens, and is disposed on a driving unit 31 (the present embodiment employs a three-dimensional mechanical arm, providing vertical up-down movement, horizontal rotation). The light receiving module 12 includes a light converging device and a spectrometer in which a line detector is employed.
The first recognition unit 21 adopts a visual recognition unit for recognizing the weld positions between the steel pipes 1.
The second recognition unit 22 is a distance measuring unit, specifically a laser distance meter, and is disposed on the three-dimensional mechanical arm, so as to obtain the distance between the light source (or the converging lens) and the welding seam.
The gas supply unit 41 includes an argon gas tank and a pipe, and argon gas discharged from the pipe purges the excitation of the weld.
The bearing seat is provided with various brands of steel standard samples, and the three-dimensional mechanical arm drives the light source, so that emergent light of the laser is converged on the standard samples.
The embodiment of the invention discloses a metal welding on-line detection method based on LIBS technology, which specifically detects 316 percent of manganese content in a steel pipe 1, as shown in figure 1, and comprises the following steps:
(S0) establishing a correspondence between the interference elements and the correction patterns in the material type. The method comprises the following steps:
The nonlinear correction models are built by using (additive interference and multiplicative interference) correction modes respectively, wherein the content Cˊi=Σ(ak·intik),ak of the element to be detected is a coefficient, and k is a non-negative integer, in the embodiment, k=0, 1 and 2.
In the additive interference correction mode, inti=inti0+Σ(fij·Cj). In the multiplicative interference correction mode, inti=inti0·(1+Σ(fij·Aj)).inti0、inti is the light intensity before correction (i.e. the original light intensity) and the light intensity after correction of the ith element to be detected, Cj is the content of the jth interference element, and fij is the interference coefficient of the jth interference element to the ith element to be detected. In this example, nickel and chromium were selected as interfering elements for the manganese 293 channel.
And detecting standard samples of various material types to obtain the relative light intensity (the ratio of the light intensity of the interference element to the light intensity of the iron) and the relative content (the ratio of the content of the interference element to the content of the iron) of the element to be detected and the interference element in the standard samples.
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And fitting the interference coefficients corresponding to the additive interference correction mode and the multiplicative interference correction mode by using correction models corresponding to the additive interference correction mode and the multiplicative interference correction mode respectively corresponding to each interference element.
Such as the additive interference coefficient of nickel, the multiplicative interference coefficient, the additive interference coefficient of chromium and the multiplicative interference coefficient.
For each interference element, the corrected light intensity is obtained by using an additive interference correction mode, a multiplicative interference correction mode and a mixed correction mode (the corrected light intensity is obtained by using the additive interference correction mode firstly, then the corrected light intensity is substituted into the multiplicative interference correction mode as the original light intensity to obtain the final corrected light intensity), and then the relative content of the measurement element is obtained by using the mapping relation between the relative content and the relative light intensity.
And selecting a correction mode corresponding to the relative content closest to the nominal value of the standard sample as the correction mode corresponding to the interference element in the material type.
For example, the effect of the multiplicative interference correction mode corresponding to the interference element nickel is optimal, so that the multiplicative interference correction mode corresponding to the interference element nickel is optimal, and the effect of the additive interference correction mode corresponding to the interference element chromium is optimal, so that the additive interference correction mode corresponding to the interference element chromium is optimal.
After the interference coefficient is obtained, the correction light intensity is obtained by using the correction mode, and then the correction light intensity is substituted into the correction model, and the interference coefficient is fitted again. For example, iterating 199 times, obtaining 200 groups of interference coefficients, averaging, taking the average value as the interference coefficient, and storing.
Data to be used was regressed 1 st.
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Data to be used was regressed 2 nd time.
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Data for use was regressed 200 th time.
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The interference coefficient fitted out by each regression.
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And establishing the corresponding relation between the interference elements in the material types, the correction modes and the correction coefficients, and storing the corresponding relation.
(S1) the first recognition unit 21 recognizes the position of the weld by using an image recognition technique in such a manner that:
As shown in fig. 3, a background image is obtained when there is no welded steel pipe 1, and as shown in fig. 4, an acquired image of the welded steel pipe 1 is obtained.
The background image and the identified region (including the weld region) in the captured image are taken, respectively, as shown in fig. 5 and 6.
The recognition areas in the background image and the captured image are converted into grayscale images, respectively, as shown in fig. 7 and 8.
The background is subtracted by subtracting the gray values of the images to obtain an identification image, where the same is black and the different is white, as shown in fig. 9.
The identification image is binarized as shown in fig. 10.
Noise points are eliminated using a morphological erosion dilation operation, as shown in fig. 11.
The profile of the steel pipe 1 was extracted to obtain the diameter of the steel pipe 1 as shown in fig. 12.
And extracting the outline of the steel pipe 1 from the identification image, and obtaining an upper boundary line in the outline, wherein the outline image of the steel pipe 1 is divided into a plurality of columns, and the mutation points of each column are searched from top to bottom, and the upper boundary line is the connecting line of the mutation points of all columns.
The weld was obtained in the upper boundary line by obtaining all maximum points on the upper boundary line, 20 points on the left and right, and peak heights or peak areas, where two or more pixels at the peak heights were regarded as the center of the weld, and 15 pixels on the left and right of the center of the peak were regarded as the weld. As shown in fig. 13, the red spot area is the weld position.
(S2) the driving unit 31 drives the light emitting module 11 to move until the outgoing light of the light emitting module 11 is focused at the weld. The specific method is as follows:
The first recognition unit 21 recognizes the position of the weld using an image recognition technique;
The driving unit 31 drives the light emitting module 11 to move according to the position, and at the same time, the laser range finder obtains the distance between the light source and the weld, and when the distance between the converging lens and the weld is the focal length of the converging lens, the driving unit 31 stops moving.
The outgoing light emitted by the laser is focused on the welding seam through the converging lens, the light at the welding seam is received by the light receiving module 12, is split by a spectrometer and is converted into an electric signal through the linear array detector, and the electric signal is sent to the analysis module 13.
During the excitation, the laser rangefinder outputs a distance in real time, and when the distance between the converging lens and the weld deviates from the focal length of the converging lens, the driving unit 31 drives the light source to move so that the distance between the converging lens and the weld is equal to the focal length. The argon gas supplied from the gas supply unit 41 purges the excitation of the weld.
The detection light at the weld is received by the light receiving module 12, obtaining (original) relative light intensities corresponding to the respective elements.
The light intensity data is that the relative light intensity of manganese is 0.236124120043884, the relative light intensity of chromium is 3.02214616341552, and the relative light intensity of nickel is 24.2685493177653.
And (S3) selecting a correction mode and an interference coefficient corresponding to the type of the material of the current welded steel pipe 1 according to the corresponding relation in the database, and correcting the original relative light intensity of the element to be detected. The correction light intensity of the manganese after the influence of the (additive) interference element is removed is obtained by using the additive interference correction mode, and then the correction light intensity of the manganese after the (additive) interference element is removed is obtained by substituting the correction light intensity into the multiplicative interference correction mode.
In the embodiment, the corrected light intensity of Mn is 0.253568212352195, and the corrected light intensity of Mn is searched in a database, and in the material model corresponding to the steel pipe 1, the interference element nickel corresponds to the multiplicative interference correction mode, and the interference element chromium corresponds to the additive interference correction mode.
And S4, obtaining the relative content of each element according to the relative light intensity of the element to be detected and other elements by using the mapping relation between the relative content and the relative light intensity. The relative content of manganese 1.10827089728167.
And (S5) obtaining the content of the element to be detected according to the relative content and the following formula, wherein the percentage content of manganese is 1.51348291632582%.
C%= 100·C/ (100+ΣCj),C% and C are the percentage content and the relative content of the element to be detected, respectively, and ΣCj is the sum of the relative contents of other elements in the sample.
After a period of use, the drive unit 31 drives the light source to move, in cooperation with the laser range finder, so that the distance between the converging lens and the standard sample is equal to the focal length. The outgoing light emitted by the laser is focused on the standard sample through the converging lens, and the excitation light on the standard sample is received by the light receiving module 12 and sent to the analysis module 13. The correction coefficient is obtained according to the measured value output by the analysis module 13 and the nominal value of the standard sample, and is used for detecting the welding seam. The derivation of correction coefficients is prior art in the field of analytical instrumentation.
After using the correction pattern of the present invention, as shown in fig. 14, in the fitted curve (between relative content and relative light intensity), the offset point is significantly close to the curve.
In contrast, as shown in fig. 15, in the related art, the offset point is significantly deviated from the curve.
Example 3.
According to the application example of the LIBS technology-based metal welding on-line detection method in copper pipe welding in embodiment 1 of the present invention, the difference from embodiment 2 is that:
1. The second recognition unit 22 recognizes whether the outgoing light is focused at the weld or on the standard sample by an image recognition technique using a visual recognition unit.
2. Various standard samples matched with the copper pipe are configured.
3. The three-dimensional robotic arm provides translational motion in the fore-aft, side-to-side, and up-and-down directions.