基于机器视觉的智能定位与识别系统及其在激光焊接中的应用研究

Research on Intelligent Positioning and Recognition System Based on Machine Vision and Its Application in Laser Welding

摘要: 在传统生产方式中，机箱混料及螺柱缺失主要依赖人工目检，存在准确性低、生产成本高的问题，会导致错误产品流入焊接工序引发批量报废；同时，机器人焊接依赖预设轨迹，但机箱来料位姿偏差普遍存在，远超激光焊接的精度容限，造成焊偏等工艺缺陷。本文设计了一套基于机器视觉的智能定位与识别系统，并将其应用在机箱的激光焊接领域。工位一通过字符识别、卡尺工具和灰度值标准差算法，实现了对产品线上的机箱混料识别以及目标螺柱有无识别。工位二通过形状模板匹配算法，实现了视觉引导激光焊接。经过大量的实验测试，混料识别和螺柱有无识别的准确性均达到99.5%以上，视觉引导激光焊接的定位误差在±0.1 mm左右，满足现场实际的生产需求。该系统操作简单、准确性高、稳定性强，极大地提高了现场的生产效率，为激光焊接领域的高质量发展提供了强大的技术支撑。

Abstract: In traditional production methods, the mixing of chassis materials and the absence of studs mainly rely on manual visual inspection, which has problems of low accuracy and high production costs. This can lead to incorrect products flowing into the welding process and causing batch scrapping. Meanwhile, robot welding relies on preset trajectories, but the orientation deviation of incoming materials from the chassis is widespread, far exceeding the precision tolerance of laser welding, resulting in process defects such as welding deviation. This paper designs a set of intelligent positioning and recognition systems based on machine vision and applies it to the field of laser welding of chassis. At Workstation One, through character recognition, caliper tools and the standard deviation algorithm of gray values, the identification of mixed materials in the chassis of the product line and the identification of whether there are target studs or not have been achieved. Station Two has achieved vision-guided laser welding through a shape template matching algorithm. After extensive experimental tests, the accuracy of both mixed material identification and stud presence identification has reached over 99.5%, and the positioning error of vision-guided laser welding is approximately ±0.1 mm, meeting the actual production requirements on site. This system is easy to operate and highly accurate. It has strong stability, which greatly improves the on-site production efficiency and provides strong technical support for the high-quality development of the laser welding field.