CN100510614C - Large-scale forging laser radar on-line tri-dimensional measuring device and method - Google Patents
Large-scale forging laser radar on-line tri-dimensional measuring device and method Download PDFInfo
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- CN100510614C CN100510614C CNB2007101718781A CN200710171878A CN100510614C CN 100510614 C CN100510614 C CN 100510614C CN B2007101718781 A CNB2007101718781 A CN B2007101718781A CN 200710171878 A CN200710171878 A CN 200710171878A CN 100510614 C CN100510614 C CN 100510614C
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Abstract
The invention relates to a device and a method for on-line three-dimensional measuring of a laser radar of heavy forging in the measuring technical field, which comprises a two-dimensional laser radar, a servo-motor, a junction box, a rotary main shaft, a spacing and null point sensor, a bearing block which is provided with a bearing, a band brake apparatus, a back supporting stand of the laser radar, an L-shaped mounting bottom plate, a vertical mounting chassis, a movement-control card, a data collecting card and a computer which is used for processing data. Firstly, the laser radar is positioned on the horizontal surface of a forging axial cord, then four surfaces of the forging are respectively scanned by the laser radar, the two-dimensional laser scanning radar is scanned in the surface which is vertical to an axial cord of the forging, the servo-motor drives the laser radar to rotate in the horizontal surface, thereby the three-dimensional scan of the forging is realized, finally, shape and parameter of the forging are gained through data process, and deviation of the shape of the forging is gained. The invention greatly increases accuracy and speed of identification, enlarges range of application, satisfies measuring requirement of a forging, and effectively increases measuring accuracy and efficiency of the forging.
Description
Technical field
The present invention relates to a kind of apparatus and method of field of measuring technique, specifically is a kind of laser radar on-line tri-dimensional measuring device and method of large forgings.
Background technology
Large forgings is to make the indispensable blank of major technologies and equipment key components and parts, and its production cycle is long, and technical difficulty is big, costs an arm and a leg.The large forgings diameter dimension that China produces has surpassed 5m, and length dimension has reached 17m.Under the high temperature of over thousands of degree, accurately measure forging ' s block dimension and become a long-term unsolved difficult problem.Up to the present, China's heavy forging factory all adopts simple tool hot following to artificial directly contact measurement.Medium and small forged shaft is directly measured with large-scale clamp at the not enough 1m of distance forging place by the operative employee usually, and not only condition of work is abominable, and measuring error is very big.The major diameter size is measured with simple " gauge rod ", marks the size of forging drawing regulation thereon, with the naked eye at high temperature compares with forging again.This method can't guarantee that " gauge rod " by the center of circle, also can't reflect the circularity of forging, and the shape correction that is difficult to forging provides foundation; Because temperature is too high, inclement condition, measuring error is very big, has to strengthen process redundancy, and production cost increases thereupon; And forging must off-line when measuring, and Measuring Time is long, and the forging temperature drop is bigger, and production efficiency and forging quality are all had certain influence.Therefore, the Chinese large-sized forging ' s block dimension is measured has become the key technical problem that presses for solution in the production, and the accurate on-line measurement that effectively solves large forgings is significant to the technical progress that promotes whole big-and-middle-sized forging industry.
Though than China advanced person, also there are a lot of problems in the producer of forging abroad aspect the hot measurement of large scale.The external main following several measuring methods that adopt.The one, survey diameter with the suspension method, promptly use two ropes respectively near forging, record hangs the rope position coordinates simultaneously, to determine diameter; Or replacing ropes with two laser beam, method and suspension method are similar.Though this method is simple, can't reflect form variations, and need outside water pressure engine, to install very big device.The 2nd, detect the seamed edge of forging end face with a movable camera, thereby calculate diameter; But all need the complete off-line of forging, Measuring Time is long.The 3rd, utilize the photographic measurement technology, can obtain face size and shape information simultaneously, but need make workpiece break away from various accessories fully, Measuring Time is longer.
Find that through literature search Nie Shaomin etc. have delivered " based on the large forgings dimensional measurement research of CCD " on " plastic engineering journal " [(2005) 12 (7): 85-88] to prior art.Point out in the literary composition, in recent years the Chinese first heavy-duty machinery company cooperates with the University On The Mountain Of Swallows, developed a kind of large forgings Size Measuring System based on CCD, this system can realize hot, long-range non-cpntact measurement, the measuring error of large diameter is less than 2mm, the measuring error of stock size is less than 1mm, simple, convenient, good reliability, but in the literary composition only at axle class, tube forging, its xsect is considered as ellipse, on the accuracy of the cross section of measuring object type and measurement, also can further improve, and aspect such as its rapidity is still to be strengthened.Find also in the retrieval that Zheng Dehua etc. have delivered " three-dimensional laser scanner and measuring error analysis of Influential Factors thereof " on " Surveying Engineering " [(2005) 14 (2): 32-34,56].The document is divided into radially three types of three-dimensional laser scanner, phase interference method scanning system and trigonometry scanning systems with three-dimensional laser scanning technique.And analyzed the influence factor of three-dimensional laser scanning system error from three aspects such as instrument error, sum of errors external environmental condition influence relevant with the target object reflecting surface.The measuring error influence factor of three-dimensional laser scanner device has radially been carried out comparatively comprehensively theoretical analysis, and pointed out that range error and scan angle error are the main error source of 3 D laser scanning error.Yet this literary composition is just studied at the topography and geomorphology direction of measurement, does not relate to high warm forging fields of measurement.
Summary of the invention
The objective of the invention is at the deficiencies in the prior art, a kind of laser radar on-line tri-dimensional measuring device and method of large forgings is provided.The present invention adopts the laser radar vertical sweep to drive the rotation of laser radar in horizontal plane in conjunction with servomotor, realizes the 3-D scanning of two dimensional laser scanning radar.By processing, identify the shape of on-line measurement object, thereby realize remote, the noncontact on-line measurement of large forgings scan-data.This measurement mechanism and method have measures advantage fast and accurately.
The present invention is achieved by the following technical solutions:
The laser radar on-line tri-dimensional measuring device of the large forgings that the present invention relates to comprises two-dimensional laser radar, servomotor, shaft joint, rotary main shaft, spacing and zero point sensor, the bearing seat that contains bearing, band brake apparatus, laser radar back bracket, L shaped installation base plate, the vertical computing machine of mounting seat, motion control card, data collecting card, data processing.Laser radar is connected to data collecting card by communication cable, data collecting card directly links to each other with data handling machine, servomotor is connected to motion control card by the motion control cable, motion control card directly links to each other with data handling machine, the two-dimensional laser radar is fixed on the rotary main shaft by the laser radar back bracket, rotary main shaft is installed on the L shaped installation base plate by the bearing seat that contains bearing, servomotor is installed on the L shaped installation base plate, and be connected with rotary main shaft by shaft coupling, spacing and zero point sensor and band brake apparatus are installed in the rotary main shaft end, L shaped installation base plate is fixed on the vertical mounting seat, drive laser radar rotation horizontal plane in the scanning of vertical direction in conjunction with servomotor by the two dimensional laser scanning radar, realize the 3-D scanning of two dimensional laser scanning radar.
Described two dimensional laser scanning radar, its plane of scanning motion is vertical with the Plane of rotation of rotary main shaft.
The data that described two dimensional laser scanning radar collects are transferred to data collecting card in the computing machine by communication cable.The point cloud range data of the measuring workpieces that the two dimensional laser scanning radar collects and this moment be laser radar internal vertical level angle data accordingly, simultaneity factor itself obtains the level angle data of servomotor in the same mechanical hook-up constantly, by communication cable with above-mentioned data transmission to data collecting card and be ultimately delivered to data handling machine.
Described data handling machine receives the data that data collecting card transmits, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, the final forging shape information that obtains, and then calculate the real surface pattern and the dimensional parameters of large forgings to be measured and form variations.
Described motion control card links to each other with the driver module (support equipment of servomotor) of servomotor by the motion control cable.
The laser radar On-line Measuring Method of large forgings involved in the present invention (at the forging of the clamping on the forging manipulator) is a core with the two-dimension scanning laser radar, in conjunction with servomotor and motion control card, has realized the function of 3-D scanning.Corresponding method is at first laser radar to be positioned forging axis place horizontal plane; Laser radar scans four surfaces of forging respectively then, the two dimensional laser scanning radar with the plane interscan of forging axis normal, servomotor drives the rotation of laser radar in horizontal plane, thereby has realized the 3-D scanning of forging; Obtain forging shape and correlation parameter thereof by data processing at last,, and obtain the form variations of forging as diameter.
The inventive method specifically comprises with following steps:
(1) this measuring system is installed in the position that the visual angle faces object being measured;
(2) after end is parked in large forgings, laser radar on-line tri-dimensional measuring device carries out single pass to large forgings; Then by forging manipulator with the uniform Equidirectional overturning of forging 3 times, each 90 degree that rotate, revolution is moving once then to carry out single pass to forging respectively, and the face of four scannings produces between any two overlaps, thereby obtains whole parameters of forging shape by these four times scanning;
(3) disposal route of laser radar on-line tri-dimensional measuring device when each surface of scanning is: the clamping location by forging manipulator is within the visual field of laser radar a side surface of forging.Laser radar is from an end of forging, earlier by the cross section of two dimensional laser scanning radar at vertical direction scanning forging; Servomotor carries out the deflection of horizontal direction then, then scans next cross section, realizes the scanning on forging surface in the laser radar visual angle in this way.In the horizontal direction, limit sweep limit by the deflection angle that limits motor; At vertical direction, whether point passes through on the forging surface is judged apart from thresholding.
(4) system scan obtains some cloud range data and the corresponding horizontal and vertical two corner data of measuring workpieces, computing machine receives above-mentioned data, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, finally obtain forging shape information (can be polytypes such as ellipse, circle, rectangle), and then calculate the real surface pattern and the dimensional parameters of large forgings to be measured, and form variations.
Laser radar on-line tri-dimensional measuring device among the present invention at first obtains the forging surface information; Obtain forging shape and correlation parameter thereof then, as diameter; Draw the form variations of forging at last.The present invention uses the method for laser to high temp objects scanning identification, and software processes and hardware controls technology, has significantly improved accuracy of identification and speed, has enlarged range of application, satisfies the forging measurement requirement, has effectively improved precision and efficient that forging is measured.The measurement full accuracy of measurement range of the present invention when 8.191m is 1mm, measures a diameter 6m, and length is that the needed time of the large forgings of 12m is relevant with precision, and when elected location survey accuracy of measurement was 1mm, the required time was about 1 minute.
Description of drawings
Fig. 1 is the general structure composition frame chart of apparatus of the present invention
Layout structure and measuring principle synoptic diagram (vertical view) that Fig. 2 realizes for the inventive method
Layout structure and measuring principle synoptic diagram (right view) that Fig. 3 realizes for the inventive method
Fig. 4 is the core machinery structural representation (partial isometric) of measurement mechanism of the present invention
Fig. 5 is the synoptic diagram of measuring distance.
Embodiment
Below in conjunction with accompanying drawing embodiments of the invention are elaborated: present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 1, the present embodiment device comprises electric part and the interior mechanical part (Fig. 1 has only provided two critical components) of right frame of broken lines in the left frame of broken lines.Concrete electric part comprises: 1-data handling machine, 2-data collecting card, 3-motion control card, 4-communication cable, 5-motion control cable, mechanical part includes, but are not limited to: 10-servomotor, 13-two-dimensional laser radar.The connection of electric part of the present invention as shown in Figure 1, laser radar 13 is connected to data collecting card 2 by communication cable 4, data collecting card 2 directly links to each other with data handling machine 1, servomotor 10 is connected to motion control card 3 by motion control cable 5, and motion control card 3 directly links to each other with data handling machine 1.
Fig. 2, Fig. 3 have provided layout structure and the fundamental measurement principle of apparatus of the present invention in actual measurement.Wherein: 6-laser radar on-line tri-dimensional measuring device, 7-system level direction of scanning, the tested forging of 8-, 9-forging manipulator clamp, 20-system vertical sweep direction.Wherein particularly, shown in Fig. 3,4, laser radar on-line tri-dimensional measuring device machinery exert part comprise 10-servomotor, 11-shaft coupling, 12-laser radar back bracket, 13-two-dimensional laser radar, 14-rotary main shaft again, 15-is spacing and zero point sensor, 16-contain bearing bearing seat, 17-band brake apparatus, 18-L shape install base plate, the vertical mounting seat of 19-.
The annexation of laser radar on-line tri-dimensional measuring device physical construction as shown in Figure 3 and Figure 4, two-dimensional laser radar 13 is fixed on the rotary main shaft 14 by laser radar back bracket 12, rotary main shaft 14 is installed on the L shaped installation base plate 18 by the bearing seat 16 that contains bearing, servomotor 10 is installed on the L shaped installation base plate 18, and be connected with rotary main shaft 14 by shaft coupling 11, spacing and zero point sensor 15 and band brake apparatus 17 all with rotary main shaft 14 concentric installations.L shaped installation base plate 18 is fixed on the vertical mounting seat 19.
Described two-dimensional laser radar 13, its plane of scanning motion is vertical with the Plane of rotation of rotary main shaft 14.Two-dimensional laser radar 13 is in 0 to 180 degree scope, every a unit rotation (unit rotation comprises three kinds of resolution of 0.25/0.5/1 degree), scanning obtains one group of workpiece 8 surface point cloud range data laser radar internal vertical level angle data, finishes the scanning in the vertical plane.Two-dimensional laser radar 13 itself is whenever finished the scanning in the vertical plane, and servomotor 10 drives laser radar 13, along the rotation of making a unit rotation (minimum 0.1 degree, concrete numerical value is provided with decision by system's initial parameter) in the surface level.The two-dimensional laser radar drives the rotation 7 of laser radar in horizontal plane in the scanning 20 of vertical direction in conjunction with servomotor, realizes the 3-D scanning of two-dimensional laser radar.
Described laser radar on-line tri-dimensional measuring device, in surveying work, the some cloud range data of the measuring workpieces that collects by two dimensional laser scanning radar 13 and this moment corresponding laser radar internal vertical level angle data; Simultaneity factor itself obtains the level angle data of servomotor in the same mechanical hook-up constantly.By communication cable 4 with above-mentioned data transmission to data collecting card 2 and be ultimately delivered to data handling machine 1.1 pair of above-mentioned data that receive of data handling machine, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, the final forging shape information (can be polytypes such as ellipse, circle, rectangle) that obtains, and then calculate the real surface pattern and the dimensional parameters of large forgings to be measured and form variations.
This embodiment is used to realize automatic, remote, the noncontact on-line measurement of large forgings under the large-sized forging manipulator operation operating mode.
Fig. 5 is the angle and distance synoptic diagram between test macro and the forging.As shown in the figure, under four scan condition of branch, the forging angle of each scanning is 90 degree, for a diameter is 6 meters forging, and test macro just can be realized at 1.24 meters of forging, suitably increase the distance of test macro from forging, reduce of the influence of forging high temperature on the one hand to testing tool equipment, on the one hand just can obtain all surfaces information of forging with assurance in addition so that the forging angle of each scanning greater than 90 degree, overlaps thereby make between the face of per twice scanning.
Present embodiment is as follows to the implementation method remote, the noncontact on-line measurement of large forgings:
(1) laser radar is installed on the base of laser radar on-line tri-dimensional measuring device, overhead about 3-3.5m, it is over against on-line measurement object space (as Fig. 2, Fig. 3) that the visual angle is installed, and laser radar is no more than 8m apart from forging manipulator clamp rotation center (promptly forging the Workpiece Rotating central axis); Concrete parameter is determined by system's initial alignment.
(2) after end is parked in large forgings, laser radar on-line tri-dimensional measuring device carries out single pass to large forgings; Follow by forging manipulator the uniform Equidirectional overturning of forging 3 times (rotating 90 degree) at every turn, revolution is moving once then to carry out single pass to forging respectively, the face of four scannings produces between any two overlaps, thereby obtains whole parameters of forging shape by these four times scanning;
(3) disposal route of laser radar on-line tri-dimensional measuring device when each surface of scanning is: the clamping location by forging manipulator is within the visual field of lidar measurement a side surface of forging.Laser radar is from one section of forging, earlier by the cross section of two dimensional laser scanning radar at vertical direction scanning forging; Servomotor carries out the deflection of horizontal direction then, then scans next cross section, realizes the scanning on forging surface in the laser radar visual angle in this way.In the horizontal direction, limit sweep limit by the deflection angle that limits motor; At vertical direction, whether point passes through on the forging surface is judged apart from thresholding.
(4) system scan obtains some cloud range data and the corresponding horizontal and vertical two corner data of measuring workpieces, computing machine receives above-mentioned data, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, finally obtain forging shape information (can be polytypes such as ellipse, circle, rectangle), and then calculate the real surface pattern and the dimensional parameters of large forgings to be measured, and form variations.
Described laser radar on-line tri-dimensional measuring device comprises that (with the two-dimensional laser radar is core to the three-dimensional laser radar test macro, cooperation by mechanical system, realized 3-D scanning), and corresponding measuring process and method, forging form parameter and form variations can be obtained.
When apparatus of the present invention and method can be used for the large forgings of forging operation machine operation, the on-line measurement of large forgings.The horizontal survey angular range is 0-180 degree, and angular resolution is divided into 0.25 °, 0.5 °, 1 ° third gear.The vertical angle measurement range is 0-120 degree, and angular resolution is up to 0.1 °.The measurement full accuracy of measuring distance scope when 8.191m is 1mm.The measurement full accuracy of measuring distance range expansion during to 81.91m is 10mm.Measure a diameter 6m, length is that the needed time of the large forgings of 12m is relevant with precision, and when elected location survey accuracy of measurement was 1mm, the required time was about 1 minute, and the form accuracy error is no more than 2%; When elected location survey accuracy of measurement was 10mm, the required time, the form accuracy error was no more than 5% less than 1 minute.By adopting laser radar scanning, realized the quick measurement of large forgings shape, measuring accuracy, reliability also are improved simultaneously, and measurement range has also obtained expansion.
The suitable measuring object of above-mentioned laser radar on-line tri-dimensional measuring device not only comprises the large forgings of high temperature under hot, also is suitable for large forgings even structural member under the various normal temperature cold conditions.
Claims (7)
1, a kind of laser radar on-line tri-dimensional measuring device of large forgings, comprise the two-dimensional laser radar, servomotor, shaft joint, rotary main shaft, spacing and zero point sensor, the bearing seat that contains bearing, band brake apparatus, the laser radar back bracket, L shaped installation base plate, vertical mounting seat, motion control card, data collecting card, data handling machine, it is characterized in that: the two-dimensional laser radar is connected to data collecting card by communication cable, data collecting card directly links to each other with data handling machine, servomotor is connected to motion control card by the motion control cable, motion control card directly links to each other with data handling machine, the two-dimensional laser radar is fixed on the rotary main shaft by the laser radar back bracket, rotary main shaft is installed on the L shaped installation base plate by the bearing seat that contains bearing, servomotor is installed on the L shaped installation base plate, and be connected with rotary main shaft by shaft joint, spacing and zero point sensor and band brake apparatus are installed in the rotary main shaft end, L shaped installation base plate is fixed on the vertical mounting seat, drive two-dimensional laser radar rotation horizontal plane in the scanning of vertical direction in conjunction with servomotor by the two-dimensional laser radar, realize the 3-D scanning of two-dimensional laser radar.
2, the laser radar on-line tri-dimensional measuring device of large forgings according to claim 1 is characterized in that, described two-dimensional laser radar, and its plane of scanning motion is vertical with the Plane of rotation of rotary main shaft.
3, the laser radar on-line tri-dimensional measuring device of large forgings according to claim 1 and 2, it is characterized in that, the data that described two-dimensional laser radar collects are transferred to data collecting card in the computing machine by communication cable, the two-dimensional laser radar collects the some cloud range data of measuring workpieces, by communication cable above-mentioned data and at this moment corresponding two-dimensional laser radar internal vertical corner data and servomotor together is sent to data handling machine in same level angle data constantly.
4, the laser radar on-line tri-dimensional measuring device of large forgings according to claim 3, it is characterized in that, described data handling machine receives the data that data collecting card transmits, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, finally obtain the forging shape information, and then calculate real surface pattern and the dimensional parameters and the form variations of large forgings to be measured.
5, the laser radar on-line tri-dimensional measuring device of large forgings according to claim 1 is characterized in that, described motion control card links to each other with the driver module of servomotor by the motion control cable.
6, the On-line Measuring Method of the laser radar on-line tri-dimensional measuring device of large forgings according to claim 1, it is characterized in that, at first with the two-dimensional laser radar fix in forging axis place horizontal plane, the two-dimensional laser radar scans four surfaces of forging respectively then, the two-dimensional laser radar with the plane interscan of forging axis normal, servomotor drives the rotation of two-dimensional laser radar in horizontal plane, thereby realized the 3-D scanning of forging, obtain forging shape and parameter thereof by data processing at last, and obtain the form variations of forging, specifically comprise the steps:
(1) the two-dimensional laser radar is installed on the base of laser radar on-line tri-dimensional measuring device of large forgings, the installation visual angle of the laser radar on-line tri-dimensional measuring device of large forgings is over against the on-line measurement object space;
(2) after end is parked in large forgings, laser radar on-line tri-dimensional measuring device by large forgings carries out single pass to large forgings, then by forging manipulator with the uniform Equidirectional overturning of forging 3 times, each 90 degree that rotate, revolution is moving once to carry out single pass to forging respectively, the face of four scannings produces between any two overlaps, thereby obtains whole parameters of forging shape by these four times scanning;
When (3) laser radar on-line tri-dimensional measuring device by large forgings scans each surface, clamping location by forging manipulator, one side surface of forging is within the visual field of lidar measurement, the two-dimensional laser radar is from an end of forging, scan a cross section of forging earlier at vertical direction, servomotor carries out the deflection of horizontal direction then, then scans next cross section, realizes the scanning on forging surface in the laser radar visual angle in this way;
(4) scanning of the laser radar on-line tri-dimensional measuring device of large forgings obtains some cloud range data and the corresponding horizontal and vertical two corner data of measuring workpieces, computing machine receives above-mentioned data, carry out polar coordinates and rectangular coordinate data-switching, revert back to the rectangular coordinate of analyzing spot cloud, and then the reconstruction of three-dimensional surface and entity, finally obtain the forging shape information, and then calculate real surface pattern and the dimensional parameters and the form variations of large forgings to be measured.
7, the On-line Measuring Method of the laser radar on-line tri-dimensional measuring device of large forgings according to claim 6 is characterized in that, described step (3) in the horizontal direction, limits sweep limit by the deflection angle that limits servomotor.
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| CNB2007101718781A CN100510614C (en) | 2007-12-06 | 2007-12-06 | Large-scale forging laser radar on-line tri-dimensional measuring device and method |
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| CNB2007101718781A CN100510614C (en) | 2007-12-06 | 2007-12-06 | Large-scale forging laser radar on-line tri-dimensional measuring device and method |
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| CN115453546B (en) * | 2022-08-25 | 2024-05-07 | 燕山大学 | Contact type measuring device and measuring method for online measurement of large-scale forge piece |
| CN115365891B (en) * | 2022-09-22 | 2024-05-28 | 山东大学 | Online measurement-error correction device and method for inner shape surface of special-shaped shell |
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| CN101187548A (en) | 2008-05-28 |
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