R&D Of Automatic Micro-spot Welding System Based On Machine Vision

Welding technology is widely used in industrial production; it is an important process in the modern manufacturing. In recent years, with the development of miniaturization and high-performance of the electronic products, the demands of Welding quality and performance of tiny pieces become higher and higher, so how to improve the precision of Welding is the key to the success of some small products. But how to use Machine Vision in spot Welding system is still in the research. It’s a unstoppable trend that manual or semi-Automatic System of Micro-spot Welding will be gradually replaced by Automatic System because Automatic System of Micro-spot Welding has the advantages of high precision and efficiency. An automatic micro system of spot Welding Based on Machine Vision is proposed in this paper, it introduces the widely used Machine Vision technology into Micro-spot Welding system which realizes the image acquisition, image processing and image location of Welding pieces, and receives the work piece’s location information through PLC controller to control three-dimensional platform to reposition the Welding torch and then gives the order to weld.This main research content of paper is following:(1) the design of Architecture of Automatic System of Micro-spot Welding Firstly, we introduce the basic principles of automatic Micro-spot Welding system Based on Machine Vision, and then give out the system structure and functional module of system according to the functional requirements and performance indicators.(2) hardware design of automatic Micro-spot Welding system According to the Architecture and performance indicators of automatic Micro-spot Welding system, we introduce the main content of each functional module including the hardware selection of PLC controller and visual subsystem.(3) software design of automatic Micro-spot Welding system First we introduce the software design requirements, development environment and development process of this system.Then according to the system functional requirements we introduce the process of software design in detail which mainly introduce the center positional algorithm of the vision subsystem and control algorithm of PLC in the main control system.(4) debugging of automatic Micro-spot Welding system Debug the image processing algorithm of the visual system, including image display, image filtering, image threshold segmentation and image positioning. And then test the performance of Welding system by concrete experiment, and analyze the results of experiment.At the end of the paper we make a summary and illustrate the research results of this study and the innovation points, point out the shortages and the direction of improvement of this topic. This study improves the production quality and efficiency of the Micro-spot Welding effectively which can be generalized to other similar production process.