基于光栅投影的焊后焊缝表面三维测量

杨国威; 张金丽

doi:10.12073/j.hjxb.20210724001

基于光栅投影的焊后焊缝表面三维测量

天津科技大学，天津，300222

基金项目: 天津市自然科学基金项目(20JCQNJC00120)

详细信息

作者简介:
杨国威，博士，讲师；主要从事激光与光电测试、焊接智能化方面研究；Email: yangguowei@tust.edu.cn

中图分类号: TG 441.7
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出版历程
- 收稿日期: 2021-07-23
- 网络出版日期: 2022-05-31
- 刊出日期: 2022-04-24

Three-dimensional measurement of post-weld surface based on grating projection

Tianjin University of Science and Technology, Tianjin, 300222, China

摘要

摘要: 焊缝表面三维轮廓是评价焊后焊缝质量的重要指标，针对常用线结构光扫描进行焊缝测量时无法兼顾测量速度与精度等问题，设计并搭建了一种基于面结构光光栅投影的焊缝三维轮廓测量系统. 首先，通过数字光处理(digital light processing,DLP)投影仪向焊缝表面投射面结构光光栅条纹图像，摄像机获取变形调制条纹，利用四步相移法结合多频外差时域解相算法准确地实现了变形光栅条纹相位主值的解算和相位的展开.然后，利用平面靶标结合精密平移台获取空间点阵列的方法实现了对模型参数的标定，该标定方法精度高、可操作性强、结构稳定.最后，采用空间相位映射模型实现焊缝相位信息到高度信息的转换，实现焊缝三维轮廓的测量.结果表明，该测量方法能很好的表现焊缝细节信息，测量结果准确，测量精度能达到0.0968 mm，可以为焊后焊缝外观检测与评价提供可靠数据.
- 光栅投影 /
- 三维测量 /
- 标定 /
- 空间相位映射
Abstract: The three-dimensional contour of the weld surface is an important index to evaluate the quality of the weld. In response to the problem that the measurement speed and accuracy cannot be balanced when the weld is measured by the commonly used line structured light scanning, a weld three-dimensional profile measurement system based on the surface structured light grating projection is designed and built. Firstly, the grating fringe is projected onto the weld through a digital light processing(DLP) projector, and the camera acquires the deformation modulation fringe. The phase of the deformed grating fringe is accurately calculated and unwrapped by using the four-step phase-shifting method combined with the multi-frequency heterodyne time-domain phase-resolving algorithm. Then, using a planar target combined with a high precision moving platform to obtain space coordinate data to calibrate the model parameters. The calibration method has high precision, strong operability and stable structure. Finally, the spatial phase mapping model is used to convert the phase information of the weld to the height information, and the measurement of the three-dimensional profile of the weld is realized. The test results show that this measurement method can well represent the detailed information of the weld, the measurement results are accurate, and the measurement accuracy can reach 0.096 8 mm, which can provide reliable data for the appearance inspection and evaluation of the post-weld.
- grating projection /
- three-dimensional measurement /
- calibration /
- spatial phase mapping

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图 1 焊后焊缝表面测量系统示意图

Figure 1. Schematic of post-weld seam measurement system

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图 2 外差原理示意图

Figure 2. Schematic of heterodyne principle. (a) wrapped phase; (b) heterodyned phase

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图 3 三频外差展开示意图

Figure 3. Schematic of unwrapping process of three frequency heterodyne method

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图 4 系统标定示意图

Figure 4. Calibration diagram

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图 5 系统实物图

Figure 5. System physical diagram

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图 6 光栅条纹图像

Figure 6. Granting fringe image

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图 7 ${\varphi _{1}}$解相结果

Figure 7. Phase calculation results of ${\varphi _{1}}$. (a) wrapped phase of ${\varphi _{1}}$; (b) unwrapped phase of ${\varphi _{_1}}$

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图 8 量块三维测量结果

Figure 8. 3D measurement results of gauge block

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图 9 焊后焊缝工件

Figure 9. Welding seam workpiece after welding. (a) workpiece1; (b) workpiece 2

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图 10 滤波后的焊缝条纹图

Figure 10. Weld fringe images after welding filter

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图 11 焊缝三维测量结果

Figure 11. 3D measurement results of welding seam.(a) results of workpiece 1 with three frequency heterodyne method; (b) results of workpiece 1 with branch cutting method; (c) results of workpiece 2 by three frequency heterodyne method; (d) results of workpiece 2 with branch cutting method

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表 1 模型参数

Table 1 Model parameters

$ {p_i} $	$ {q_i} $	$ {r_i} $
1245.56 −5.121770628 0.006729067 −0.00000289 −0.534082009 0.001769769 −0.00000146 −0.0000131 0.0000000202 −0.000000000627 −1.557448492 0.004277788 −0.00000259 0.000586622 −0.000000972 0.00000000907 0.000635451 −0.000000674 −0.000000162 −0.0000000495	−2470.71 11.28448568 −0.017017439 0.00000842 0.589600969 −0.001643752 0.00000149 −0.0000196 0.000000024 0.00000000394 4.139785184 −0.012510248 0.00000931 −0.000603428 0.00000109 0.00000000779 −0.002287981 0.00000341 0.000000195 0.000000416	4683.44 −23.02690587 0.03843155 −0.0000217 0.014012346 −0.0000564 0.00000005 0.0000135 −0.0000000185 0.00000000112 −7.670646446 0.025792839 −0.0000221 0.000000366 0.00000000464 −0.0000000098 0.004336764 −0.00000746 −0.00000000206 −0.000000839

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表 2 量块表面某点高度值

Table 2 Height value of a certain point of gauge block

量块长度x/mm	量块宽度y/mm	量块高度z/mm
45.655 45.113 55.112 60.220 65.138 68.786	50.370 55.640 55.463 55.381 55.308 49.997	5.019 4.923 4.939 5.010 4.939 4.978

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表 3 焊件焊缝表面某点高度值

Table 3 Height value of a certain point of welding seam

焊件编号	检测位置编号	焊缝检验尺值 h/mm	系统检测值 h₀/mm	误差 δ/mm
1	1	5.2	5.121	0.079
	2	4.8	4.716	0.084
	3	4.7	4.828	0.128
	4	4.8	4.879	0.079
	5	5.1	5.013	0.087
2	1	5.5	5.571	0.071
	2	3.4	3.482	0.082
	3	4.6	4.487	0.113
	4	4.9	4.993	0.093
	5	4.8	4.917	0.117

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