CN104484507B - A kind of spare parts remanufacture method based on reverse-engineering - Google Patents
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Abstract
This patent discloses a kind of spare parts remanufacture method based on reverse-engineering, comprising the following steps: 1) obtains the surface point cloud data model of waste and old components.2) the original CAD model of the waste and old components is obtained.3) the surface point cloud data model of step 1) is registrated with the original CAD model of step 2).4) according to the registration of step 3) as a result, obtaining the maximum lesion depths of the waste and old components.If 5) the maximum lesion depths that step 4) obtains are lower than threshold value, using the maximum lesion depths as the amount of feeding, the waste and old components are carried out subtracting formula reparation.If the maximum lesion depths that step 4) obtains are higher than threshold value, the waste and old components are carried out to add formula reparation.
Description
Technical field
The present invention relates to machinery to remanufacture field.
Background technique
With increasingly sharpening for shortage of resources and environmental problem, Rebuilding engineering is had received widespread attention.Remanufacturing can
It develops and utilizes the value contained in waste and old resource to greatest extent, alleviates the contradiction of shortage of resources and the wasting of resources,
A large amount of failure, harm of the scrap products to environment are reduced, is the optimised form and preferred approach of worn-out machine tools recycling,
It is the important means to economize on resources.
However, manually participation is more for the process presence that remanufactures of current waste and old components, experience dependence is strong, remediation efficiency
The problems such as low, poor reliability, repair process is irreversible.
Summary of the invention
Present invention aim to address during the remanufacturing of waste and old components, repair mode and parameter be difficult to standardize and
The problem of quantization.
To realize the present invention purpose and the technical solution adopted is that such, a kind of components based on reverse-engineering are made again
Make method, which comprises the following steps:
1) the surface point cloud data model of waste and old components is obtained.Obtain the mode of body surface point cloud data model very
It is more, according to measuring probe whether with measurement surface contact, contact type measurement and non-contact measurement two major classes can be divided into.Contact
It is three coordinate measuring machine (CMM) that formula, which measures commonly used equipment, and non-contact measurement commonly used equipment includes laser scanner, and structure light is swept
Retouch instrument, Industrial CT Machine etc..
2) the original CAD model of the waste and old components is obtained;
3) the surface point cloud data model of step 1) is registrated with the original CAD model of step 2);
4) according to the registration of step 3) as a result, obtaining the maximum lesion depths of the waste and old components;
If 5) the maximum lesion depths that step 4) obtains are lower than threshold value, using the maximum lesion depths as the amount of feeding, to institute
Waste and old components are stated to carry out subtracting formula reparation.Material is removed on origianl component matrix it is worth noting that subtracting formula reparation and referring to
Repair mode reprocesses components injured surface by the machinings such as vehicle, milling, mill mode, until surface is damaged
Wound completely removes.
If the maximum lesion depths that step 4) obtains are higher than threshold value, the waste and old components are carried out to add formula reparation.It is worth
Illustrate, formula reparation is added to refer to that the repair mode of the added material on waste and old components matrix, common plus formula renovation technique have
Laser cladding, thermal spraying, built-up welding etc., laser cladding process is because its applicable material system is extensive, cladding layer is strong in conjunction with matrix
The features such as degree is high, matrix thermal deformation is small and technical process is easy to automate, has been increasingly used in remanufacturing reparation
In.
This patent proposes the waste and old spare parts remanufacture process frame based on reverse-engineering, the frame from the angle of system
Two main lines are repaired comprising adding formula reparation and subtracting formula, are analyzing waste and old component surface point cloud data model and original CAD model
Between on the basis of difference, waste and old components are unfolded to repair.
Detailed description of the invention
Fig. 1 is the waste and old spare parts remanufacture process frame based on reverse-engineering;
Fig. 2 is waste and old component surface point cloud data model acquisition step;
Fig. 3 is waste and old component surface point cloud data model collection result;
Fig. 4 is waste and old component surface point cloud data model preprocessing;
Fig. 5 is the damage boundary demarcation of waste and old component surface point cloud data model;
Fig. 6 is the reconstruct of the original CAD model of waste and old components;
Fig. 7 is the extraction of waste and old components deleted areas model;
Fig. 8 is registrated schematic diagram with original CAD model for surface point cloud data model;
Fig. 9 is to improve ICP registration Algorithm process;
Figure 10 is waste and old component surface lesion depths schematic diagram;
Figure 11 is waste mold surface point cloud data collection steps;
Figure 12 is that waste mold subtracts formula reparation process;
Figure 13 is traditional IC P and Revised ICP algorithm registration result compares;
Specific embodiment
Present invention will be further explained below with reference to the attached drawings and examples, but should not be construed the above-mentioned theme of the present invention
Range is only limitted to following embodiments.Without departing from the idea case in the present invention described above, known according to ordinary skill
Knowledge and customary means, make various replacements and change, should all include within the scope of the present invention.
Embodiment 1:
A kind of spare parts remanufacture method based on reverse-engineering, comprising the following steps:
1) the surface point cloud data model of waste and old components is obtained.Referring to fig. 2, in figure, using ATOS optical three-dimensional scanning
Instrument carries out data acquisition to waste and old components, and the equipment mobility is strong, and acquisition speed is fast, can obtain all kinds of components tables
Face point cloud data.In embodiment, the surface for being tested waste and old components is sprayed into white developer before acquisition, with reinforcing effect.It adopts
The result of collection such as Fig. 3.
In embodiment, it is preferable that pre-processed (filtering, elimination noise, data essence to collection result shown in Fig. 3
Letter etc.), waste and old component surface point cloud data model as shown in Figure 4 is obtained, it can be as the processing of subsequent step
Object.
2) the original CAD model (unworn) of the waste and old components is obtained.In the present embodiment, the waste and old components
Original CAD model can directly acquire, i.e., manufacturer or designer save the original CAD model.In original CAD mould
In the case that type is lost, referring to the method for the original CAD model of acquisition disclosed in embodiment 2.
3) referring to Fig. 7, the surface point cloud data model of step 1) is registrated with the original CAD model of step 2).That is, by two
A Unified Model can compare the difference of two models in (being placed on) same coordinate system, know the surface point cloud number
According to the lack part of model and the maximum lesion depths of waste and old components.
4) according to the registration of step 3) as a result, obtaining the maximum lesion depths of the waste and old components.In embodiment, institute
The component that waste and old components are abrasions is stated, there are several place's abration positions.Figure 10 shows the component wherein abration position at one,
Middle dotted line represents the original contour of components, and circle points indicate that the point on original contour, solid line indicate the profile after part injury,
Spider indicates the point on damage profile, wearing depth H.In the component, the abrasion of abration position at most deep one is worn
Depth is the maximum lesion depths being mentioned below.
If 5) the maximum lesion depths that step 4) obtains are lower than threshold value (less than the 5% of overall dimensions), with the maximum damage
Hurting depth is the amount of feeding, carries out subtracting formula reparation to the waste and old components.I.e. using waste and old components as blank, with it is given into
Machining is carried out to it to amount.
If the maximum lesion depths that step 4) obtains are higher than threshold value (greater than the 5% of overall dimensions), to described waste and old zero
Part carries out plus formula reparation.I.e. by the method in abration position added material, to repair the waste and old components.
Embodiment 2
In the repair process of waste and old components, it can be potentially encountered the case where original cad file of components is lost, need at this time
Its original CAD model is reconstructed according to the residual, information in collected surface point cloud data.It is different from traditional reverse modeling, in weight
When the original CAD model of the waste and old components of structure, due to including the damage field of components, this part in collected point cloud data
Point cloud data and the point cloud in other intact regions are discontinuous, cannot reflect the initial surface pattern of components, therefore in Reverse reconstruction
When point cloud data using damage field should be avoided.
The key step of the present embodiment is with embodiment 1, only, needs through following steps obtaining step 2) described in it is original
CAD model.
In embodiment, by calculating the Gaussian curvature of each point in point cloud data, the mutation of point cloud data mean curvature is extracted
Point puts one approximate damage field boundary line of construction according to these, and checks that the feature outlines reconstructed in reverse modeling are
It is no to pass through damage field, it is ensured that modeling accuracy.Its key step are as follows:
1) Point cloud curvature is estimated
Point cloud curvature estimation method it is very much, common method such as: paraboloid fitting process, 3DShepard Surface Fitting,
Gauss-Bonnet method etc., since paraboloid fitting process is more accurate compared with other methods to the processing of Noise point cloud data, therefore
Estimate the curvature at a cloud grid vertex using paraboloid fitting process, this method approached with the analytic surface of a second order to
Point in fixed point and its neighborhood, the surface of second order expression formula for fitting is by shown in formula (1).
Z=f (x, y)=a0+a1x+a2y+a3xy+a4x2+a5y2 (1)
To a certain data point p in point cloud datai, take the k- neighborhood of the point to form partial points cloud, in the partial points cloud
All point (xj, yj, zj), least square fitting is done by formula (2), that is, is solved:
After acquiring surface equation coefficient, surface equation (1) is rewritten as parametric equation form, as shown in formula (3).
R (x, y) is found out respectively to x, y, xx, and the partial differential of yy, xy are denoted as rx, ry, rxx, ryy, rxy, the per unit system of curved surface
Vector isThen first fundamental form of surface parameter E=rx·rx, F=rx·ry, G=ry·ry, the of curved surface
Two basic formal parameter L=rxxN, M=rxyN, N=ryy·n.Substitute into the calculation formula (4) of curved surface Gaussian curvature
Find out the Gaussian curvature at each point.
2) damage field boundary is divided
The each point Gaussian curvature value K being calculated according to upper stepi, pass through the threshold k of settinge, that is, work as Ki> KeWhen, then sentence
The point break as curvature mutation point, damage field boundary line is finally fitted by curvature mutation point, point cloud data is divided into damage
Region and intact region, as shown in figure 5, and will be in the point cloud data deposit set N in damage field boundary.
3) original CAD model is reconstructed
The reconstruct of the original CAD model of waste and old components, such as Fig. 6 are realized by the modeling approach of " point-line-face-body "
It is shown, one group of cross section contour is constructed on point cloud model first, whether is had in set N on each cross section contour by examining
The cross section contour of passing point cloud damage field is found out and deleted to point, finally obtains the feature outlines in the intact region of cloud.It is special
The operations such as sign contour line is stretched, scan, covering and cutting obtain the surface model of components, finally thicken to surface model
Or hypostazation obtains original CAD model.
Embodiment 3
The present embodiment key step is with embodiment 1, further, a kind of open improvement registration side for being suitable for step 3)
Method.
It is worth noting that the surface point cloud data model of waste and old components is to obtain maximum with being registrated for original CAD model
The key of lesion depths, the registration between two models are usually required by being registrated in advance and essence two steps of registration, and pre- registration is by two
A model is substantially adjusted to correct position, provides good initial value for accuracy registration, improves the efficiency of accuracy registration, be registrated in advance
Method mainly has Principal Component Analysis, principal axes algorithm, three point alignment methods etc..Accuracy registration is on the basis of pre- registration into one
The position of step two models of correction, keeps difference between the two minimum.With iteration closest approach (Iterative in accuracy registration algorithm
Clostest Point, ICP) algorithm is the most mature, and the essence of the algorithm is the Optimum Matching method based on least square method, is calculated
Method repeats the iterative process of " finding corresponding points --- optimal rigid body translation between corresponding points ", until meeting the convergence criterion set,
Its transformation relation formula and convergence criterion, such as formula (5), formula (6) is shown.
Qj=RPi+T (5)
ε=Σ | | qj-(Rpi+T)||2→min (6)
Wherein PiAnd QiFor 2 model data point sets, R is rotational transformation matrix, and T is translation transformation matrix, piFor model Pi
In point, qiFor model QiIn point, when ε minimum meets convergence criterion.
But in remanufacturing practical application, since there are local damage, surface point cloud data models for waste and old component surface
There is certain difference compared with original CAD model, best fit, institute on model are implemented to two models according to traditional ICP algorithm
Some points will all participate in being registrated operation, then the error of damage field can be homogenized, thus cannot get accurate maximum depth value.
Now illustrate the problem by Fig. 8, Fig. 8 (a) is certain waste and old original CAD model of components (thick dashed line) and surface point cloud data mould
Situation before type (heavy line) registration, learns, components damage concentration is in upper end (circled regions according to the duty status of the components
In domain), other positions are not then damaged or damage minimum;Fig. 8 (b) is using traditional ICP algorithm registration as a result, due to damage
The region that the error distribution in region has given damage small, so that not damaging or damage minimum region error occurs originally;Fig. 8
It (c) is then ideal registration effect.
The resolving ideas of the present embodiment is thus: increasing the screening to two model corresponding points in traditional IC P method for registering
Process, by check corresponding points distance and direction vector angle whether in the range of setting, come judge corresponding points whether be
The point of damage field if being judged as the point of damage field, rejecting this group of corresponding points and regenerating corresponding points collection, then is matched
Quasi- operation, improved registration Algorithm flow chart are as shown in Figure 9.
Its key step are as follows:
1) pre- registration: using the method for three point alignments, using original CAD model point set Q as reference data, to surface point cloud number
Pre- registration initial transformation is carried out according to model point set P, the surface point cloud data model point after original CAD model point set Q and in advance registration
Collect P0It may be expressed as:
P0={ pi0|pi0∈R3, i=1,2 ... n }, Q0={ qj0|qj0∈R3, j=1,2 ... m }.
2) corresponding points are found: to surface point cloud data model point set PkIn any point pik, find pikTo archetype
The nearest point of distance in point set Q, remember archetype point set Q in pikIt is q apart from nearest pointik, form corresponding point set Qk=
{qik|qik∈R3, i=1,2 ... n }, distance calculation formula dik=| | pik-qik| | → min, k are the number of iterations.
3) transformation matrix is solved: the correspondence point set P obtained to searchingkWith Qk, Σ is calculated using analytic method is optimized | |
Rkpik+Tk-qik||2→ min acquires rotational transformation matrix R when kth time iterationkWith translation transformation matrix Tk。
4) relative position more between new model: the transformation matrix obtained in step 3, to surface point cloud data model point set P
Rotation and translation transformation are carried out, the new position of surface point cloud data model, i.e. P are obtainedk+1=RkPk+Tk。
5) check corresponding points distance and orientation consistency: whether distance is less than the threshold value d of setting between inspection corresponding pointse, i.e.,
di k< de, and the direction vector of each group corresponding points is calculated, check whether its angle theta is less than the threshold θ of settinge, i.e. θ < θe。
6) damage field corresponding points are rejected: if distance d between corresponding pointsik> deOr θik> θe, then judge corresponding points for damage
Damage field point is rejected and generates new surface point cloud data model point set P ' and original CAD model point set Q ' by region point.
7) iteration ends determine: average distance is less than given threshold value between corresponding points, i.e.,Its
InThen iteration ends.
Embodiment 4
The present embodiment applies method described in embodiment 1,2 or 3, carries out repair place to the hang-wheel on Gear Hobber frame of abrasion
Reason.
Hang-wheel on Gear Hobber frame is one of key components and parts of gear-hobbing machine, for installing differential gearing, realizes that straight-tooth processing passes
The switching of dynamic chain and helical teeth processing transmission interchain.After change gear plate abrasion, the engagement between differential hanging gear will be directly affected, it is final to influence
Helical gear machining accuracy.Fig. 2 (a) is the change gear plate dismantled from certain waste and old gear-hobbing machine, the arc groove region of change gear plate
There is noticeable wear, other positions in order, now implement it to remanufacture reparation.
After change gear plate component disassembly, cleaning, white developer is sprayed to enhance scanning effect on its surface, utilizes ATOS
Optical three-dimensional scanning instrument collection surface point cloud data, collection process are as shown in Figure 2.
Since the original CAD model of change gear plate has been lost, need according to scanning its original CAD model of Surface Reconstruction from Data Cloud,
Restructuring procedure is shown in Fig. 5 and Fig. 6.It is learnt according to registration result analysis, change gear plate damage field is concentrated and abrasion is deeper, is greater than whole
The 5% of size, thus select plus formula recovery scenario, add formula repair process as shown in Fig. 7 (lowermost part), change gear plate is original
CAD model is registrated with surface point cloud data model by method for registering described in embodiment 3, then real to two models after registration
Boolean operation is applied, the model of defect is obtained.Finally, being sliced to defect model, generates defect model and cut
Facial contour data, simulated laser deposition path.
Embodiment 5
The present embodiment applies method described in embodiment 1,2 or 3, carries out repair process to the hammering mold of abrasion.
In use, mold cavity bears huge shock loading to hammering mold, and type chamber locally generates plastic deformation,
Meanwhile blank metal and mold cavity surface generate severe friction, mold cavity surface will appear abrasion and even peel off.To failure hammering mold
It carries out remanufacturing reparation, is able to extend die life, reduce production cost.Figure 11 (a) show the steam turbine leaf scrapped
Piece hammering mold, now carries out it and remanufactures reparation.
The collection process of die surface point cloud data is as shown in figure 11, because mould upper surface is main working face, thus it is only right
Mould upper surface carries out data acquisition, improves remediation efficiency.
Since mold damage field is big, abrasion is shallower, and less than the 5% of overall dimensions, and machining allowance is sufficient, therefore selection subtracts
Mould upper surface is milled shape according to original design shape by formula recovery scenario again.Subtract the as shown in figure 12 of formula repair process, by mould
Have original CAD model and be registrated with surface point cloud data model by the method for registering that embodiment 3 describes, Figure 13 is according to tradition
ICP algorithm is registrated the Comparative result being registrated with Revised ICP algorithm, by same point on measurement analysis point cloud model, respectively at this
Abrasion loss under two kinds of method for registering, as shown in table 1.
The measurement of 1 failure site abrasion loss of table
Table 1 the result shows that, using traditional ICP algorithm with punctual, the abrasion loss of plane domain in 0.49~0.82mm,
Using Revised ICP algorithm on time, the abrasion loss of plane domain is 0.02mm or so, and the mold plane region there's almost no
Abrasion, therefore it is more accurate to improve ICP registration result.The distance between two model corresponding points is measured after registration, is obtained between corresponding points most
Big distance is 4.53mm, i.e. the greatest wear depth H of mold is 4.53mm, then subtracts formula Repair gene surplus and take 4.53mm.
Finally, by original CAD model and subtracting formula Repair gene margin value, machining tool path is generated.
Claims (1)
1. a kind of spare parts remanufacture method based on reverse-engineering, which comprises the following steps:
1) the surface point cloud data model of waste and old components is obtained;
Estimate that the curvature at a cloud grid vertex, this method are forced with the analytic surface of a second order using paraboloid fitting process
Point in nearly set point and its neighborhood, the surface of second order expression formula for fitting is by shown in formula (1):
Z=f (x, y)=a0+a1x+a2y+a3xy+a4x2+a5y2 (1)
In formula, a0、a1、a2、a3、a4And a5It is the obtained surface equation i.e. formula 1 to 3 after least square method is fitted respectively
Coefficient;
To a certain data point p in point cloud datai, take the k- neighborhood of the point to form partial points cloud, to all in the partial points cloud
Point (xj, yj, zj), least square fitting is done by formula (2), that is, is solved:
After acquiring surface equation coefficient, surface equation (1) is rewritten as parametric equation form, as shown in formula (3):
In formula, r (x, y) is the parametric equation of surface equation;
R (x, y) is found out respectively to x, y, xx, and the partial differential of yy, xy are denoted as rx, ry, rxx, ryy, rxy, the unit normal vector of curved surface
ForThen first fundamental form of surface parameter E=rx·rx, F=rx·ry, G=ry·ry, the second of curved surface is substantially
Formal parameter L=rxxN, M=rxyN, N=ryy·n;
The calculation formula (4) for substituting into curved surface Gaussian curvature, can find out the Gaussian curvature at each point:
By calculating the Gaussian curvature of each point in point cloud data, the point of point cloud data mean curvature mutation is extracted;By curvature mutation
Point fits damage field boundary line, and point cloud data is divided into damage field and intact region;
2) the original CAD model of the waste and old components is obtained;The point cloud number using damage field should be avoided in Reverse reconstruction
According to;
3) the surface point cloud data model of step 1) is registrated with the original CAD model of step 2);
4) according to the registration of step 3) as a result, obtaining the maximum lesion depths of the waste and old components;
If 5) the maximum lesion depths that step 4) obtains are lower than threshold value, using the maximum lesion depths as the amount of feeding, to described useless
Old components carry out subtracting formula reparation;
If the maximum lesion depths that step 4) obtains are higher than threshold value, the waste and old components are carried out to add formula reparation.
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