CN101885152A - Automatically-aligned numerical control cutting method for pre-printed image plate - Google Patents
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Abstract
The invention discloses an automatically-aligned numerical control cutting method for a pre-printed image plate, which comprises the following steps of: A, extracting the profile of an image to be printed, and generating an initial numerical control machining code according to the extracted image; B, adding more than two identical identifying images at the blank of the periphery of the image to be printed; C, printing the image to be printed with the identifying images on the plate; D, clamping the pre-printed image plate obtained by the step C on a workbench of a numerical control cutting machine, and identifying the positions of the identifying images on a machine tool through a camera fixed on a main shaft of the numerical control cutting machine so as to establish the relation of conversion of coordinates between an image coordinate system and a cutting machine coordinate system; and E, editing the initial numerical control machining code obtained by the step A according to the relation of the conversion of coordinates obtained by the step D to obtain a directly-positioned numerical control machining code, so that the numerical control cutting machine cuts according to the obtained numerical control machining code. The automatically-aligned numerical control cutting method has the advantages of low hardware cost, simple and convenient operation and high alignment accuracy.
Description
Technical Field
The invention relates to a numerical control cutting method, in particular to an automatic alignment numerical control cutting method.
Background
The pre-printed image plate numerical control cutting is to print an image on a plane plate in advance, and then cut the plate along the edge of the image contour on a machine tool to obtain a product with the contour consistent with the contour of the printed image. The technology is practical and intuitive, and the processed product has the characteristics of attractive appearance, strong stereoscopic impression and the like, and has requirements and applications in various fields, such as ornaments, product outer packages, advertising industry and the like. In general, the cutting of a plate is usually performed by writing a numerical control program code of a pattern or a shape to be cut, fixing a plate blank on a machine tool and roughly determining a processing zero point of a part. Unlike this general sheet cutting and numerical control machining, the sheet cutting technique of preprinted images requires precise determination of the positional relationship between the image and the tool, i.e., coordinate alignment, prior to machining to ensure that the numerical control machining program controls the tool to follow the contour of the image.
At present, common numerical control cutting machines are generally used at home and abroad to process the pre-printed image plate products, no specific alignment tool is provided, and a manual method is mainly adopted to perform coordinate alignment. One method is to perform alignment according to the shape of a plate blank, find out the position of the plate on a machine tool, and then determine the position of an image to be processed according to the theoretical position of the image on the plate instead of the actual printing position. But actually the size of panel blank can be inconsistent, also often has rotation or translation error during the installation, and the image also has great error in the position on different panels, therefore machining precision is low, and the rejection rate is high.
The other method is to manually align the position of an actual image, the method usually prints some mark points on the image to assist the alignment work, the mark points and the image are printed on the plate simultaneously, although the positions on different plates are different after printing, the relative positions of the mark points and the image are not changed, and the actual position of the image can be known by aligning the positions of the mark points. When the alignment is performed, the movement of the cutter needs to be manually controlled and whether the cutter is located at the center of the mark point is judged, so that time is consumed, and each plate needs to be aligned again, so that the efficiency is quite low. If the alignment result and the set position only have a translation error, some processing parameters can be modified in the numerical control system by modifying, but if the image coordinate system and the cutting machine coordinate system have rotation transformation, the position of the plate needs to be adjusted and clamped again, and the requirement of batch production cannot be met.
For example, an edge-walking cutting method of laser cutting equipment is disclosed in a chinese patent application document (application number is 200810063771.X, published as 2009, 2, 11), and firstly, an image on a material to be cut is acquired by a camera, and is corrected by using a correction file to generate a contour graph; then establishing a matching model by taking the contour graph as a reference, and then collecting the real-time cut pattern according to set parameters through a camera; vectorizing the acquired image to generate a graph; comparing the graph with the matching model according to the set similarity, wherein the image which meets the set similarity is the successfully matched image, and generating cutting data for the successfully matched image according to the outline graph of the actually shot image; and finally, sending the cutting data to laser cutting equipment for cutting. The method can be self-adaptive to the difference of the cut images within a certain similarity range, but the processing precision of the method is not high due to the lower precision of the existing contour recognition technology, and when the difference of the images is larger, the images cannot be automatically calibrated and aligned, so that the automatic cutting of the images on the material cannot be completed.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a numerical control cutting method capable of automatically aligning on the basis of the existing automatic cutting technology based on image contour recognition, so that the precision and the cutting efficiency during image contour cutting are improved.
The idea of the invention is to add a plurality of positioning identification images to an image to be printed, extract the coordinates of specific points of the identification images in a cutting equipment coordinate system through a camera arranged on a cutting equipment main shaft, find the transformation relation between the image coordinate system and the cutting equipment coordinate system, correct a numerical control processing code generated by initial contour recognition, obtain the precisely positioned numerical control processing code, and thus realize the automatic alignment of the numerical control cutting of the pre-printed image. The method is specifically executed according to the following steps:
A. extracting the outline of an image to be printed and generating an initial numerical control machining code according to the extracted image outline;
there are many prior art alternatives to extracting the image contour in this step, such as: the method comprises a Canny edge detection method, a Sobel edge detection method, a binary method and the like, wherein the binary method is preferred in the invention, and the noise elimination processing is carried out on the image contour extracted by the binary method.
The adjacent contour points are adjacent or separated by one or two pixels on the pixel position, the actual printing distance between the adjacent contour points is determined by the image resolution and the printing size, the distance is usually small for a printing plate, if the image contour is directly used for generating an NC code, the step length is easily too small, the cutting speed of a machine tool fluctuates, the average speed is reduced, and the processing quality and the processing efficiency are influenced. Therefore, before the contour is delivered to a numerical control programming module to generate a numerical control code, curve fitting needs to be carried out on the image contour, and the curve fitting needs to be carried out to fit vector primitive objects such as straight lines, circular arcs, B splines and the like. The invention preferably selects a straight line fitting mode and provides a curvature-based piecewise fitting method.
The invention specifically extracts the contour of the printed image according to the following steps:
a1, carrying out binarization processing on the image to obtain a preliminary figure outline;
a2, removing noise in the preliminary figure outline obtained in the step A1;
a3, fitting the image contour into a vector primitive object by adopting a curvature-based piecewise fitting algorithm, which specifically comprises the following steps:
a301, estimating curvature by using the chord ratio, and comparing the curvature with a preset first threshold value; points with the curvature larger than a preset first threshold value are sharp points, so that a sharp point sequence in the figure outline is formed;
a302, taking two adjacent sharp points from the sharp point sequence as a first point and a last point of the contour segment to be generated;
a303, calculating the distance from other points between the first point and the last point to line segments formed by the first point and the last point, finding the point with the largest distance, and if the distance is smaller than an allowed error value given by a user, adding the contour segment between the first point and the last point into a contour segment sequence; if not, replacing the original end point with the farthest distance, and storing the original end point to the cusp sequence;
and A304, repeatedly executing the steps A302 and A303 until the cusp sequence is empty, and obtaining a complete contour segment sequence.
And after the processing process, editing the processing code of the numerical control cutting equipment according to the obtained image contour to obtain a primary numerical control processing code.
B. Adding more than 2 same identification images at the peripheral blank of the image to be printed;
in the step, the identification image can be added manually or through various image editing software, preferably software. The identification image can be selected at will according to actual conditions, such as a circle, a triangle, a square and the like.
C. Printing an image to be printed with a mark image on a plate;
D. c, clamping the pre-printed image plate obtained in the step C on a workbench of a numerical control cutting machine, and identifying the position of the identification image on the machine tool through a camera fixed on a main shaft of the numerical control cutting machine to establish a coordinate transformation relation between an image coordinate system and a cutting machine coordinate system;
the invention has no special requirements on the specific camera and the installation angle, and only needs to shoot the pre-printed image plate clamped on the machine tool; the camera is fixed on the main shaft of the numerical control cutting machine, so that the position coordinates of the identification image shot by the camera in the coordinate system of the cutting machine can be easily calculated, and the coordinate transformation relation between the image coordinate system and the coordinate system of the cutting machine can be obtained by combining the position coordinates of the identification image in the image coordinate system and utilizing the existing coordinate transformation method.
E. And D, editing the initial numerical control machining code obtained in the step A according to the coordinate transformation relation obtained in the step D to obtain a directly positioned numerical control machining code, and cutting by a numerical control cutting machine according to the obtained numerical control machining code.
And D, recalculating coordinates of the image contour in the initial numerical control machining code in a cutting machine coordinate system through the coordinate transformation relation obtained in the step D to obtain new coordinates, replacing the original coordinates with the newly obtained coordinates to obtain the directly positioned numerical control machining code, and cutting by the numerical control cutting machine according to the obtained numerical control machining code.
Compared with the prior art, the invention has the advantages of low hardware cost, simple and convenient operation and high alignment precision, thereby realizing high-efficiency and high-precision cutting processing of the pre-printed image plate.
Drawings
FIG. 1 is a schematic flow diagram of the present invention;
fig. 2 is a schematic illustration of a logo image employed in an embodiment.
Detailed Description
The technical scheme of the invention is explained in detail in the following with the accompanying drawings:
as shown in the attached figure 1, the invention realizes the alignment of the numerical control cutting of the pre-printed image plate by the following steps:
A. extracting the outline of an image to be printed and generating an initial numerical control machining code according to the extracted image outline; the method comprises the following steps:
a1, carrying out binarization processing on the image to obtain a preliminary figure outline;
in the embodiment, the image binarization processing is carried out by using a maximum inter-class variance method according to the gray level of the image, and an Otsu method is adopted to select a binarization threshold value;
the maximum inter-class variance method and the Otsu method in this step are prior arts in the field of Image Processing, and can be specifically referred to in the literature (KAPUR J., SAHOP., WONGA.A. new method for grade-level Image retaining using the entry of the history. computer Vision and Image Processing, 1985, 29: 210-239.)
A2, removing noise in the preliminary figure outline obtained in the step A1;
the method adopts a template method to remove noise, is simple and convenient, can well retain the edge information of the original image, and effectively improves the effect of subsequent edge detection;
the template method in this step is prior art and is described in detail in the literature (Jia Yonghong. digital image processing. Wuhan university Press. 2003.9)
A3, fitting the image contour into a vector primitive object by adopting a curvature-based piecewise fitting algorithm, which specifically comprises the following steps:
a301, estimating curvature by using the chord ratio, and comparing the curvature with a preset first threshold value; points with the curvature larger than a preset first threshold value are sharp points, so that a sharp point sequence in the figure outline is formed;
setting m pixel points on the contour line, and setting p pixel pointi(i ═ 1, 2, … m) and finding the adjacent point p of the adjacent k (k is an integer greater than 0, and preferably 2 in the present embodiment) pixelsi-k(xi-k，yi-k) And pi-k(xi+k，yi+k) The equation of the straight line connecting the two neighbors is:
Ax+By+C＝0 (1)
wherein,
A＝yi-k-yi+k
B＝xi+k-xi-k (2)
C＝yi+kxi-k-yi-kxi+k
note the book
Is a point pi-sTo point pi+sChord length between, point piThe distance to the chord is:
then p isiCurvature C at a pointikCan be expressed as
Cik＝dik/Lik (4)
According to the curvature of each pixel point on the contour line obtained by the calculation, comparing the curvature of each point with a preset first threshold value, and selecting the point with the curvature larger than the first threshold value as a sharp point;
the first threshold in this step may be selected according to actual conditions, and is preferably 0.25 in this embodiment;
a302, taking two adjacent sharp points from the sharp point sequence as a first point and a last point of the contour segment to be generated;
a303, calculating the distance from other points between the first point and the last point to line segments formed by the first point and the last point, finding the point with the largest distance, and if the distance is smaller than an allowed error value given by a user, adding the contour segment between the first point and the last point into a contour segment sequence; if not, replacing the original end point with the farthest distance, and storing the original end point to the cusp sequence;
taking the contour segment between two adjacent sharp points as an example, let TstartDenotes the first point of the current fitting segment, TendReferring to the end point of the current fit segment, the user-specified normal allowable error is ε, and the user-specified allowable maximum fit length is Lε；
(1) First connect Tstart、TendAnd obtaining a linear equation l passing through two points. Traverse TstartTo TendAmong all the contour points, find the point P farthest from the straight line lmaxIf P ismaxIf the distance to the straight line l is greater than epsilon, T is setendPut back the cusp sequence, PmaxBecome a new Tend；
(2) At Tstart、TendRepeating the operation (1) on the contour points until the point PmaxThe distance to the straight line l is equal to or less than epsilon. At this time, if the line segment TstartTendIs less than or equal to LεWill TendAdding a contour segment sequence; if the line segment TstartTendIs greater than LεThen, the line segment is divided equally, and each division point and T are divided equallyendAdding a sequence of contour segments.
And A304, repeatedly executing the steps A302 and A303 until the cusp sequence is empty, and obtaining a complete contour segment sequence.
B. Adding more than 2 same identification images at the peripheral blank of the image to be printed;
the identification image selected in the embodiment is circular as shown in the attached drawing 2, the outer ring is black, the inner part is white, and the size of the circular ring is designed to be 10mm in diameter of the outer circle and 6mm or 8mm in diameter of the inner circle in order to save materials and guarantee precision.
C. Printing an image to be printed with a mark image on a plate;
D. c, clamping the pre-printed image plate obtained in the step C on a workbench of a numerical control cutting machine, and identifying the position of the identification image on the machine tool through a camera fixed on a main shaft of the numerical control cutting machine to establish a coordinate transformation relation between an image coordinate system and a cutting machine coordinate system;
in order to simplify subsequent data processing, the present embodiment uses a digital camera and is mounted on the spindle of the numerical control cutting machine in a direction such that the optical axis of the camera is perpendicular to the table top of the machine.
The steps can be divided into the following steps:
d1, clamping the pre-printed image plate obtained in the step C on a workbench of a numerical control cutting machine tool;
d2, operating the numerical control cutting machine to make one of the identification images appear in a viewfinder of a camera arranged on a main shaft of the numerical control cutting machine and shoot;
d3, processing the shot image, extracting the coordinates of the fixed point in the identification image in the shot image, and calculating the coordinates of the fixed point in the identification image in the cutting machine coordinate system by combining the coordinates of the video camera in the cutting machine coordinate system and applying a single-camera projection model;
for convenience, the embodiment selects the circle center of the circular ring as a fixed point of the identification image; the specific calculation method comprises the following steps:
d301, extracting the coordinates of the circle center of the circular identification image in the coordinate system of the shot image:
firstly, the Canny edge detection operator is used for extracting the edge contour of the image, but the Canny edge detection operator can only obtain the edge contour with integral pixel precision, so the edge positioning precision is not high. The invention further adopts a method of combining image gray gradient and gray moment to extract the boundary sub-pixel outline, and then carries out ellipse fitting on the sub-pixel boundary, wherein the center of the fitted ellipse is the coordinate of the circle center of the circular identification image in the coordinate system of the shot image;
the methods involved in this step are all prior art, and the details are given in (Zhang Hui. binocular stereo measurement key technology based on random illumination and its system research [ doctor academic thesis ]. Nanjing aerospace university 2008.10)
D302, calculating the coordinates of the circle center in the machine tool according to the single-camera projection model:
let OoXoYoZoIs a camera coordinate system, origin OoIs the optical center of the camera lens, ZoThe axis being the optical axis of the camera, XoAxis, YoThe axes are parallel to the u-axis (horizontal pixel direction) and the v-axis (vertical pixel direction) of the image plane. ocAs an image plane ocThe origin of uv coordinate system being the optical axis and the image planeAnd (4) an intersection point. And OXYZ is a cutting machine coordinate system. Because of the optical axis Z of the cameracPerpendicular to the machine coordinate plane, i.e. ocThe uv coordinate system is parallel to the cutter coordinate system. H is the distance between two coordinate system planes, d is a point d (u) on the image planed，vd) D is the point of projection of the point D on the cutting machine coordinate system, and the coordinate of D on the cutting machine coordinate system is D (X)D，YD) C is the optical axis ZcThe intersection point with the cutting machine coordinate system and the coordinate thereof is C (X)C，YC). According to the similar triangle principle, there are:
XD-XC＝ud/kH，YD-YC＝vd/kH (5)
wherein k isHIt can be easily seen that k is the projection scale factor when the distance between the camera image plane and the cutting machine coordinate system plane is H, and as long as H is fixedHIt is not changed. Thus the system calibrates in advance the distance of the image plane from the machine plane H0Of the hour
When the camera is at the image plane and is away from the machine tool plane H0When the height is high, the image of the mark point is photographed, and the center of the circle of the mark point is obtained through image processing
The machine tool coordinate of the camera is formed by the intersection point of the optical axis of the camera and the plane of the machine tool
Indicating that the center of a circle of the mark point is positioned at the coordinate of the cutting machine coordinate system
Comprises the following steps:
according to the formula (6), the coordinates of the circle center of each identification image under the coordinate system of the cutting machine can be determined.
D4, operating the cutter to move the camera to other mark images in sequence, and executing the steps D3-D4; until the coordinates of the circle centers of all the identification images in the coordinate system of the cutting machine are determined;
d5, obtaining a linear transformation matrix between the coordinate system of the image to be printed and the coordinate system of the cutting machine according to the coordinates of the circle centers of all the identification images in the coordinate system of the image to be printed and the coordinates of the circle centers of all the identification images obtained in the step D4 in the coordinate system of the cutting machine;
in the embodiment, a linear transformation matrix is calculated initially, and then the linear transformation matrix is optimized by using SVD decomposition;
let OXYZ be the cutting machine coordinate system, oxy be the image coordinate system to be printed, two marked image fixing points p on the preprinted image1，p2The coordinate in the coordinate system of the image to be printed is p1(x1，y1)，p2(x2，y2) The included angle between the coordinate system of the image to be printed and the coordinate system of the cutting machine is
The coordinate of the origin o of the coordinate system of the image to be printed under the coordinate system of the cutting machine is o (t)1，t2). Thus p isj(j ═ 1, 2) coordinates p in the cutting machine coordinate systemj(Xj，Yj) Comprises the following steps:
Mca linear transformation matrix for transforming an arbitrary point in the image from the coordinate system of the image to be printed to the coordinate system of the cutting machine. From two points p in the image1，p2The simultaneous equation (7) can solve three position parameters
t1、t2Respectively as follows:
m calculated at this timecThe matrix is based on machine coordinates of the intersection of the optical axis of the camera and the machine table, and in practice the coordinate transformation should be based on the intersection of the tool axis and the machine table. Therefore, it is necessary to pair McCorrecting the offset relation between the tool axis and the camera axis, and setting TxFor the tool offset with respect to the X-axis of the camera, TyFor tool offset with respect to the Y-axis of the camera, a linear transformation matrix McThe correction result is:
the linear transformation matrix obtained by using the two identification images is used as the upper surface;
in order to further improve the alignment precision, the number of the identification images can be increased, and when the number of the set identification images exceeds 2, an optimal transformation matrix M is solved by using a method of solving least squares by SVD:
setting N (N is an integer greater than or equal to 2) identification images on the pre-printed image, wherein the coordinate of the selected fixed point in the identification images in the coordinate system of the image to be printed is pj＝(xj，yj，1)TJ is 1, 2, … N, and the coordinate in the cutting machine coordinate system is Pj＝(Xj，Yj，1)TThe formula (10) is established by using the least square method, and the sum sigma is solved by using the SVD matrix decomposition algorithm2The minimum M matrix is the optimal linear transformation matrix,
E. and D, editing the initial numerical control machining code obtained in the step A according to the coordinate transformation relation obtained in the step D to obtain a directly positioned numerical control machining code, and cutting by a numerical control cutting machine according to the obtained numerical control machining code.
The step D is to calculate the coordinates of all points of the image contour in the initial numerical control machining code again through the coordinate transformation relation obtained in the step D to obtain new coordinates in a cutting machine coordinate system, replace the original coordinates with the newly obtained coordinates to obtain the directly positioned numerical control machining code, and cut the numerical control machining code by the numerical control cutting machine according to the obtained numerical control machining code.
The correlation calculation in this embodiment can be automatically implemented by the computer system.
Claims (6)
1. An automatic alignment pre-printed image plate numerical control cutting method is characterized in that: the method comprises the following steps:
A. extracting the outline of an image to be printed and generating an initial numerical control machining code according to the extracted image;
B. adding more than 2 same identification images at the peripheral blank of the image to be printed;
C. printing an image to be printed with a mark image on a plate;
D. c, clamping the pre-printed image plate obtained in the step C on a workbench of a numerical control cutting machine, and identifying the position of the identification image on the machine tool through a camera fixed on a main shaft of the numerical control cutting machine to establish a coordinate transformation relation between an image coordinate system and a cutting machine coordinate system;
E. and D, editing the initial numerical control machining code obtained in the step A according to the coordinate transformation relation obtained in the step D to obtain a directly positioned numerical control machining code, and cutting by a numerical control cutting machine according to the obtained numerical control machining code.
2. The automatically-aligned digitally controlled cutting method for pre-printed image sheets as claimed in claim 1, wherein: a piecewise fitting vectorization algorithm based on curvature is adopted for extracting the contour of the image to be printed in the step A, and the method specifically comprises the following steps:
a1, carrying out binarization processing on the image to obtain a preliminary figure outline;
a2, removing noise in the preliminary figure outline obtained in the step A1;
a3, fitting the image contour into a vector primitive object by adopting a curvature-based piecewise fitting algorithm, which specifically comprises the following steps:
a301, estimating curvature by using the chord ratio, and comparing the curvature with a preset first threshold value; selecting points with curvatures larger than a preset first threshold value as sharp points to form a sharp point sequence in the graph outline;
a302, taking two adjacent sharp points from the sharp point sequence as a first point and a last point of the contour segment to be generated;
a303, calculating the distance from other points between the first point and the last point to line segments formed by the first point and the last point, finding the point with the largest distance, and if the distance is smaller than an allowed error value given by a user, adding the contour segment between the first point and the last point into a contour segment sequence; if not, replacing the original end point with the maximum distance, and storing the original end point into the cusp sequence;
and A304, repeatedly executing the steps A302 and A303 until the cusp sequence is empty, and obtaining a complete contour segment sequence.
3. The automatically-aligned digitally controlled cutting method for pre-printed image sheets as claimed in claim 2, wherein: the first threshold value is 0.25.
4. The automatically-aligned digitally controlled cutting method for pre-printed image sheets as claimed in claim 1, wherein: the step D comprises the following sub-steps:
d1, clamping the pre-printed image plate obtained in the step C on a workbench of a numerical control cutting machine tool;
d2, operating the numerical control cutting machine to make one of the identification images appear in a viewfinder of a camera arranged on a main shaft of the numerical control cutting machine and shoot;
d3, processing the shot image, extracting the coordinates of the fixed point in the identification image in the shot image, and calculating the coordinates of the fixed point in the identification image in the cutting machine coordinate system by combining the coordinates of the video camera in the cutting machine coordinate system and applying a single-camera projection model;
d4, operating the cutter to move the camera to other mark images in sequence, and executing the steps D3-D4; determining the coordinates of all the marked image fixing points in the cutting machine coordinate system;
d5, obtaining a linear transformation matrix between the coordinate system of the image to be printed and the coordinate system of the cutting machine according to the coordinates of all the identification image fixing points in the coordinate system of the image to be printed and the coordinates of all the identification image fixing points obtained in the step D4 in the coordinate system of the cutting machine;
5. the automatically-aligned digitally controlled cutting method for pre-printed image sheets as claimed in claim 4, wherein: the identification image is a circular ring, and the inner circle and the outer circle are respectively white and black; the identification image fixed point refers to the circle center of the circular ring.
6. The automatically-aligned numerically controlled cutting method for pre-printed image plate according to claim 5, wherein: the diameter of the excircle of the ring is 10mm, and the diameter of the inner circle is 6mm or 8 mm.
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