CN103776378A - Non-contact type flexible on-line dimension measurement system - Google Patents
Non-contact type flexible on-line dimension measurement system Download PDFInfo
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- CN103776378A CN103776378A CN201410067991.5A CN201410067991A CN103776378A CN 103776378 A CN103776378 A CN 103776378A CN 201410067991 A CN201410067991 A CN 201410067991A CN 103776378 A CN103776378 A CN 103776378A
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Abstract
Disclosed is a non-contact type flexible on-line dimension measurement system. A laser displacement sensor, an industrial camera and a power supply are fixed at the tail end of an industrial robot, and the robot saves measuring positions of workpieces to a robot moving track program through a teaching programming in advance. After the workpieces are placed on a measuring bracket and fixedly clamped, the robot drives the displacement sensor, the industrial camera and the power supply to operate to each measurement point on the workpieces for measurement according to pre-programmed programs; when the robot operates to each measurement point, the robot sends a measurement permission instruction to a measurement sensing system, a control system of the measurement sensing system performs measurement and real-timely sends measurement results to a measurement data saving and querying data base, subsequently, the control system of the measurement sensing system informs the robot of operation to the next measurement point, and the whole system repeatedly performs the above circulation to accomplish measurement work of one workpiece at all measurement points. By means of the non-contact type flexible on-line dimension measurement system, efficiency of measurement of automobile parts is improved, measurement samples are multiple, and measurement results are accurate.
Description
Technical field:
The present invention relates to physical field, relate in particular to measuring technique, particularly parts product is carried out the automatic measurement technology of size monitoring in auto parts and components production run, concrete is the online Size Measuring System of a kind of contactless flexibility.
Background technology:
The Geometrical Tolerance Principle (GD & T) that need to provide according to client in the production run of auto parts and components detects auto parts and components.Detection method of the prior art is first to make one to measure cubing, and after tested part is put up and had good positioning, parts or the unique point of utilizing in cubing Precision Machining in advance the good object of reference such as simulated block or clamp of Accurate Calibration to pay close attention to part are measured.A but this special measurement cubing dedicated test for certain particular component, can not be used for the measurement of other part, and the simulated block in cubing or clamp need Precision Machining, accurate assembling, precision calibration, so when requiring to detect number of spare parts when more, the cost of manufacture of overall cubing can be very high.And because special measurement cubing is all by manual operation, heavy parts or measuring point are required to more part, the workload of survey crew is very large, survey instrument is simple and precision is lower, measuring late time data needs manual entry computer to analyze, and manual entry has maloperation, impact analysis result.Because above problem causes the process efficiency of dimensional measurement, monitoring of whole part very low, in size monitor procedure, measure number of samples little, data results is difficult to embody part production run ability in a short time, be there is to time delay in on-the-spot warning, can not reflect in real time and produce line problem, can cause defective products to flow out.
Summary of the invention:
Technical matters to be solved by this invention is to provide the online Size Measuring System of a kind of contactless flexibility, and method efficiency that the described online Size Measuring System of this contactless flexibility will solve available technology adopting cubing manual measurement auto parts and components is low, hits is few, the technical matters of testing result time delay.
The online Size Measuring System of this contactless flexibility of the present invention, comprise combined type survey sensor and industrial robot, described industrial robot includes a mechanical arm, wherein, described combined type survey sensor is fixedly connected on the mechanical arm of described industrial robot, combined type survey sensor comprises an one dimension laser displacement sensor and an industrial camera, described one dimension laser displacement sensor is fixedly connected with industrial camera, one dimension laser displacement sensor includes signal wire, industrial camera includes output line, the signal wire of one dimension laser displacement sensor and the output line of industrial camera are all connected to a computing machine, industrial robot is connected with a robot controller, described robot controller is connected with described computing machine with data line by signal, in computing machine, be provided with machine vision processing module, utilize one dimension laser displacement sensor to measure the physical location profile tolerance on tested part, utilize industrial camera to gather the hole on tested part, or edge, or the image at hollow out position, the described machine vision processing module of recycling calculates the hole on tested part, or edge, or the locus at hollow out position, by the hole on the physical location profile tolerance of the tested part measuring and tested part, or edge, or the digital-to-analogue theoretical position of the locus at hollow out position and part compares, obtaining its deviate is measurement result.
Further, in the investigative range of combined type survey sensor, be provided with a part support, described part support is connected with a detent mechanism, in described detent mechanism, include a driving mechanism, the control end of described driving mechanism is connected with a programmable logic controller (PLC), and described programmable logic controller (PLC) is connected with starting switch.
Further, described computing machine is connected with a database and webpage querying server, and described webpage querying server connects in one network.
Further, according to the measurement result data of the signal wire of one dimension laser displacement sensor and industrial camera, the position data of the measuring point on structure tested part in sensor three-dimensional system of coordinate, it is principle structure that described sensor three-dimensional system of coordinate is built by the right hand.
Further, utilize a three-coordinates measuring machine in advance the exemplar of tested part to be measured, bias vector using the three-dimensional coordinates measurement result of exemplar as the relative part theoretical value of this exemplar mould, the bias vector of this bias vector and tested part relative standard exemplar is carried out to vector calculus, obtain the bias vector of general tested part relative number theory of modules position, by the bias vector of general tested part relative number theory of modules position, through odd, coordinate transform is transformed in part coordinate system, obtain thus the X of deviation at part coordinate system, Y, component and direction in tri-directions of Z.
Further, described industrial machine people is 6 axle robots.
Further, on combined type survey sensor, be connected with light source.
Further, the output line of industrial camera is the gigabit Ethernet line for vision signal output.
The present invention and prior art are compared, and its effect is actively with obvious.Laser displacement sensor, industrial camera and light source are fixed on industrial machine robot end by the present invention, and robot is saved in the measuring position of workpiece in robot running orbit program by teach programming in advance.After workpiece is placed into measurement support and is fixedly clamped, operating personnel start programmable logic controller (PLC), programmable logic controller (PLC) is detecting that after all measuring conditions meet, issuing robot measures the signal allowing, and each measurement point that robot drives laser displacement sensor, industrial camera and light source to move on workpiece by the program of finishing is in advance measured.When robot often moves to a measuring point, send measurement can to measurement sensor-based system and allow instruction, measuring the control system of sensor-based system measures, and measurement result is sent in measurement data preservation, Query Database in real time, the control system of measuring afterwards sensor-based system reinforms robot and can run to next measuring point, whole system is repeatedly carried out with cocycle, completes the surveying work of all measuring points of workpiece.The efficiency that has improved measured automobiles parts, hits is many, and testing result accurately also can obtain in real time.
Accompanying drawing explanation:
Fig. 1 is the structural representation of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 2 is the structural representation of the combined sensor in the online Size Measuring System of contactless flexibility of the present invention.
Fig. 3 is the measuring system operational flow diagram in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 4 is measuring system control software in an embodiment of the online Size Measuring System of contactless flexibility of the present invention and the communication flow diagram of industrial robot.
Fig. 5 is the structure schematic diagram of the sensor three-dimensional system of coordinate in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 6 utilizes one dimension laser displacement sensor to measure the schematic diagram of the vector operation of surface profile in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 7 is the vector operation schematic diagram while utilizing the position degree of industrial camera measured hole in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 8 is the homogeneous coordinate transformation matrix form in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Fig. 9 is the homogeneous coordinate transformation schematic diagram in an embodiment of the online Size Measuring System of contactless flexibility of the present invention.
Embodiment:
Embodiment 1:
As shown in Figure 1, the online Size Measuring System of contactless flexibility of the present invention, comprise combined type survey sensor and industrial robot 4, described industrial robot 4 includes a mechanical arm, wherein, described combined type survey sensor is fixedly connected on the mechanical arm of described industrial robot 4, combined type survey sensor comprises an one dimension laser displacement sensor 1 and an industrial camera 2, described one dimension laser displacement sensor 1 is fixedly connected with industrial camera 2, on combined type survey sensor, be connected with light source 3, one dimension laser displacement sensor 1 includes signal wire, industrial camera 2 includes vision signal output line, the vision signal output line of the signal wire of one dimension laser displacement sensor 1 and industrial camera 2 is all connected to a computing machine 6, industrial robot 4 is connected with a robot controller 5, described robot controller 5 is connected with described computing machine 6 with data line by signal, in computing machine 6, be provided with machine vision processing module, utilize one dimension laser displacement sensor 1 to measure the physical location profile tolerance on tested part 11, utilize industrial camera 2 to gather the hole on tested part 11, or edge, or the image at hollow out position, the described machine vision processing module of recycling calculates the hole on tested part 11, or edge, or the locus at hollow out position, by the hole on the physical location profile tolerance of the tested part measuring 11 and tested part 11, or edge, or the digital-to-analogue theoretical position of the locus at hollow out position and part compares, obtaining its deviate is measurement result.
Further, in the investigative range of combined type survey sensor, be provided with a part support 10, described part support 10 is connected with a detent mechanism, in described detent mechanism, include a driving mechanism, the control end of described driving mechanism is connected with a programmable logic controller (PLC) 9, and described programmable logic controller (PLC) 9 is connected with starting switch 8.
Further, described computing machine 6 is connected with a database and webpage querying server 7, and described webpage querying server connects 7 in one network.
Further, according to the measurement result data of the signal wire of one dimension laser displacement sensor 1 and industrial camera 2, the position data of measuring point on structure tested part 11 in sensor three-dimensional system of coordinate, it is principle structure that described sensor three-dimensional system of coordinate is built by the right hand.
Further, utilize a three-coordinates measuring machine in advance the exemplar of tested part 11 to be measured, bias vector using the three-dimensional coordinates measurement result of exemplar as the relative part theoretical value of this exemplar mould, the bias vector of this bias vector and tested part 11 relative standard's exemplars is carried out to vector calculus, obtain the bias vector of general tested part 11 relative number theory of modules positions, by the bias vector of general tested part 11 relative number theory of modules positions, through odd, coordinate transform is transformed in part coordinate system, obtain thus the X of deviation at part coordinate system, Y, component and direction in tri-directions of Z.
Further, described industrial robot 4 is 6 axle robots.
As shown in Figure 2, in industrial camera 2, include camera lens 21, light source 3 surrounding lens 21 arrange, industrial camera 2 and one dimension laser displacement sensor 1 are all connected on a support 12, on tested part 11, there is hole characteristic 111, hole characteristic 111 is arranged in the visual field of camera lens 21, and the laser rays 101 that one dimension laser displacement sensor 1 sends drops on the measuring point 112 of tested part 11.
Concrete, as shown in Figure 3 and Figure 4, in an embodiment of the present invention, combined type survey sensor is fixed on the end of the mechanical arm of industrial robot 2, tested part 11 is placed on and is measured on support 10, by peripheral start button to programmable logic controller (PLC) 9 enabling signals, by programmable logic controller (PLC) 9, the numbering of measuring support 10 correspondences is sent to the measuring system control software (AutoCF) in computing machine 6 again, then move the robot program that this part is corresponding and start part to measure by measuring system control software startup industrial robot 2.Industrial robot 2 is in measuring process, can first run to behind the measuring position of some measuring points slack, and the signal that sends " allowing to measure ", " measuring point numbering " is to controlling software, control software and obtain understanding the measurement configuration information (comprising the measured value of use laser measurement or video camera measurement, standard component etc.) of this measuring point of Automatically invoked after " measuring point numbering " information, and according to measurement configuration information content, this measuring point is measured.Complete after the measurement of a measuring point, measurement result information can write in remote server data storehouse by the mode of Ethernet at once.Measurement control software can be given the signal of 2 one of industrial robots " measuring point is measured and finished " afterwards, and industrial robot 2 obtains can running to next measuring point after this signal, then repeats circulation recited above.After finally completing the measurement of all measuring points of part, when getting back to original position, industrial robot 2 can send to measurement control software the signal of " parts measurement finishes ", measurement control software exits internal measurement circulation, and does some post-processed work (as statistics the write into Databasce etc. of accessory size qualification rate).
One dimension laser displacement sensor 1 is mainly that the profile tolerance of physical location is measured, and industrial camera 2 has been mainly the measurement to the feature such as hole, limit.Two kinds of survey sensors are used in combination the measurement that can complete most of auto parts and components form and position tolerance aspect.The present embodiment is in the time measuring by two kinds of sensors, and two kinds of data are not computation simultaneously, but for different measuring points, and select different sensors to measure.But measurement result data can be configured to the data of sensor three-dimensional system of coordinate, it is principle structure that sensor three-dimensional system of coordinate is built by the right hand, as shown in Figure 5.The measurement result of each measuring point is calculated in sensor three-dimensional system of coordinate, that is, laser measurement result can be expressed as: { 0,0, z }, camera review measurement result can be expressed as: { x, y, 0 }.More than the three-dimensional data of structure obtains final results needed by coordinate transform and vector calculus.
The Processing Algorithm of the measurement data to laser sensor feedback is one of important innovations content of the present embodiment.As shown in Figure 6, by coordinate transform, each bias vector is transformed to the inner laggard row vector computing of same coordinate system (part three-dimensional system of coordinate or sensor three-dimensional system of coordinate), thereby obtain: the bias vector rx of the relative digital-to-analogue point of measurement point, that is, and rx=rs+rm.Wherein, rs can measure master body by three-dimensional coordinates measurement equipment, and rm measures, final in part coordinate system three components of rx vector, be the X of deviation result, Y, the offset component in tri-directions of Z.When measurement, require laser rays to overlap as far as possible with the normal direction of digital-to-analogue point.
The Processing Algorithm of the deviation data that camera review is measured is also one of important innovations content of the present embodiment.First need the image obtaining by video camera to carry out a series of image processing step the final geometric element that obtains measured point, thereby on two-dimensional directional, judge position deviation amount.The feature object that video camera is measured is mainly the measurement point that part edge, regular symmetric hole, asymmetric hole, polygonal hole, nut bore etc. have edge feature.Image is processed and is mainly comprised following step:
1) Gaussian image filtering-first to by camera acquisition to image on region-of-interest (ROI) is set, all images of later stage are processed computing and are all carried out in this region, can greatly reduce like this data volume and the operand of image processing, improve measuring speed.Filter in ROI region, undesired signal, the assorted point of image are disposed, retain the larger picture edge characteristic of contrast;
2) in the image of Canny Image Edge-Detection-after after filtering, carry out the computing of Canny rim detection, the final bianry image that has marginal information that obtains, edge pixel value is 255, the pixel value of other background is 0;
3) in the image that profile extracts-exports in rim detection, obtain all profiles, marginal information is converted to profile information;
4) matching of geometric configuration-in the present embodiment, be mainly ellipse fitting; by least square method, profile is carried out to ellipse fitting; obtain the oval information of corresponding each profile; comprise oval center, major axis, minor axis, angle of inclination etc.; and screen by major axis minor axis comparison ellipse; retain the oval information that approaches target shape; the position of the final geometric center that obtains impact point; thereby obtain the departure of center, experiment confirms that the effect of fitted ellipse is more reliable than the effect of fitting circle, much stable;
The Processing Algorithm of the deviation data that camera review is measured is also one of important innovations content of native system.As shown in Figure 7, by coordinate transform, each bias vector is transformed to the inner laggard row vector computing of same coordinate system (part three-dimensional system of coordinate or sensor three-dimensional system of coordinate), thereby obtain: the bias vector rx of the relative digital-to-analogue point of measurement point, that is, and rx=rs+rm.Wherein, rs can measure master body by three-dimensional coordinates measurement equipment, and rm measures by native system, final in part coordinate system three components of rx vector, be the X of deviation result, Y, the offset component in tri-directions of Z.Consistent with laser measurement algorithm above, but the CCD plane that requires video camera as far as possible with measured hole place plane parallel.
The coordinate space mapping algorithm of bias vector is one of important innovations content of the present embodiment.Generally because the absolute fix error ratio of industrial industrial robot 2 is larger, far below its repetitive positioning accuracy, and owing to not using absolute coordinate in computation process, and use the vector of relative deviation to calculate.Vector calculus can integral translation in coordinate system, so in the calculating process of coordinate transform, only consider Rotating Transition of Coordinate, and do not calculate translation transformation, thereby avoided the large problem of industrial robot 2 absolute fix error.The homogeneous coordinate transformation matrix of structure is as shown in the T in Fig. 8, and wherein the translation vector part of the 4th row is 0.As shown in Figure 9, in measurement data result treatment calculating process, measurement result under sensor coordinate system (in figure { S}) need to be transformed into the last joint coordinate system of industrial robot 2 (in figure { E}), further be transformed into again industrial robot 2 basis coordinates systems (in figure { R}), be finally transformed into part coordinate system (in figure { P}).
Coordinate transformation process in the present embodiment is the rotational transform of coordinate system attitude in fact just because computing to as if bias vector, vector can translation in coordinate system in the time of computing, and does not need to consider the starting point of vector and the absolute coordinate of terminal.So in the time that the relative rotational transform of each coordinate system of demarcation is related to, as long as determine rotation angle value.
Claims (8)
1. the online Size Measuring System of contactless flexibility, comprise combined type survey sensor and industrial robot, described industrial robot includes a mechanical arm, it is characterized in that: described combined type survey sensor is fixedly connected on the mechanical arm of described industrial robot, combined type survey sensor comprises an one dimension laser displacement sensor and an industrial camera, described one dimension laser displacement sensor is fixedly connected with industrial camera, one dimension laser displacement sensor includes signal wire, industrial camera includes output line, the signal wire of one dimension laser displacement sensor and the output line of industrial camera are all connected to a computing machine, industrial robot is connected with a robot controller, described robot controller is connected with described computing machine with data line by signal, in computing machine, be provided with machine vision processing module, utilize one dimension laser displacement sensor to measure the physical location profile tolerance on tested part, utilize industrial camera to gather the hole on tested part, or edge, or the image at hollow out position, the described machine vision processing module of recycling calculates the hole on tested part, or edge, or the locus at hollow out position, by the hole on the physical location profile tolerance of the tested part measuring and tested part, or edge, or the digital-to-analogue theoretical position of the locus at hollow out position and part compares, obtaining its deviate is measurement result.
2. the online Size Measuring System of contactless flexibility as claimed in claim 1, it is characterized in that: in the investigative range of combined type survey sensor, be provided with a part support, described part support is connected with a detent mechanism, in described detent mechanism, include a driving mechanism, the control end of described driving mechanism is connected with a programmable logic controller (PLC), and described programmable logic controller (PLC) is connected with starting switch.
3. the online Size Measuring System of contactless flexibility as claimed in claim 1, is characterized in that: described computing machine is connected with a database and webpage querying server, and described webpage querying server connects in one network.
4. the online Size Measuring System of contactless flexibility as claimed in claim 1, it is characterized in that: according to the measurement result data of the signal wire of one dimension laser displacement sensor and industrial camera, the position data of measuring point on structure tested part in sensor three-dimensional system of coordinate, it is principle structure that described sensor three-dimensional system of coordinate is built by the right hand.
5. the online Size Measuring System of contactless flexibility as claimed in claim 4, it is characterized in that: utilize a three-coordinates measuring machine in advance the exemplar of tested part to be measured, bias vector using the three-dimensional coordinates measurement result of exemplar as the relative part theoretical value of this exemplar mould, the bias vector of this bias vector and tested part relative standard exemplar is carried out to vector calculus, obtain the bias vector of general tested part relative number theory of modules position, by the bias vector of general tested part relative number theory of modules position, through odd, coordinate transform is transformed in part coordinate system, obtain thus the X of deviation at part coordinate system, Y, component and direction in tri-directions of Z.
6. the online Size Measuring System of contactless flexibility as claimed in claim 1, is characterized in that: described industrial machine people is 6 axle robots.
7. the online Size Measuring System of contactless flexibility as claimed in claim 1, is characterized in that: on combined type survey sensor, be connected with light source.
8. the online Size Measuring System of contactless flexibility as claimed in claim 1, is characterized in that: the output line of industrial camera is the gigabit Ethernet line for vision signal output.
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