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Automatic calibration of work coordinates for robotic wire and arc additive re-manufacturing with a single camera

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Abstract

Industrial robots are increasingly applied in the automatic die repair welding via the prevalent wire and arc additive manufacturing (WAAM) technology. However, the precise calibration of work coordinates is indispensable for the off-line programming of robotic welding paths, which often results in positioning error, path deviation, or even tool collisions. The die is pre-heated at about 500 °C before the robotic WAAM processes. Thus, it is challenging to calibrate work coordinates by touch sensing because those points on the X-axis and the Y-axis to determine the location of the part need to be caught by human eyes. In this paper, a camera vision calibration (CVC) method based on stereo vision is developed. Image feature points are extracted by a multi-saliency fusion algorithm based on the human visual attention mechanism. Through stereo vision, 3D information of the feature points is obtained, and the workpiece coordinate system (WCS) is finely calibrated. Compared with the random error of human vision calibration (HVC), the proposed method could improve the workpiece’s calibration accuracy, reduce the unexpected collisions in limited space, and improve the dimensional precision of the welding layer.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This study was funded by the Hubei Province Technology Innovation Project (No. 2018AAA021).

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Authors and Affiliations

  1. School of Automotive Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Qiang Wu, Xunpeng Qin, Yifeng Li & Zeqi Hu

  2. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan, 430070, China

    Qiang Wu, Xunpeng Qin, Yifeng Li & Zeqi Hu

  3. Hubei Shenli Forging Co., LTD., Danjiangkou, 442700, China

    Congming Liang

Authors
  1. Qiang Wu
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  2. Xunpeng Qin
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Contributions

Xunpeng Qin contributed to the conception of the study; Qiang Wu designed the study and contributed to analysis and manuscript preparation; Yifeng Li and Zeqi Hu contributed to the data analysis; Congming Liang provided the experimental platform; and both authors contributed equally to the writing of the paper.

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Correspondence to Xunpeng Qin.

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The authors declare that they have no conflict of interest. All procedures performed in studies involving human participants were in accordance with the ethical standards of the institutional and/or national research committee and with the 1964 Helsinki Declaration and its later amendments or comparable ethical standards. This article does not contain any studies with animals performed by any of the authors. Informed consent was obtained from all individual participants included in the study.

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Wu, Q., Qin, X., Li, Y. et al. Automatic calibration of work coordinates for robotic wire and arc additive re-manufacturing with a single camera. Int J Adv Manuf Technol 114, 2577–2589 (2021). https://doi.org/10.1007/s00170-021-06664-9

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