CN107816980B - Steel roller system position detection device and method - Google Patents

Steel roller system position detection device and method Download PDF

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CN107816980B
CN107816980B CN201710933419.6A CN201710933419A CN107816980B CN 107816980 B CN107816980 B CN 107816980B CN 201710933419 A CN201710933419 A CN 201710933419A CN 107816980 B CN107816980 B CN 107816980B
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CN107816980A (en
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魏海坤
王兆嘉
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Southeast University
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    • G01MEASURING; TESTING
    • G01CMEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
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Abstract

The invention discloses a steel roller system position detection device and a steel roller system position detection method. The invention has the advantages that the whole set of measuring device can realize the simultaneous detection of multiple parameter indexes of a single roller and a roller system, and the self-adaptive threshold value adjusting algorithm is adopted, so that the accuracy and the fitting speed of the traditional space circle fitting algorithm are improved, the device can be used for guiding the calibration of the roller system, and the productivity, the quality and the benefit of products are greatly improved.

Description

Steel roller system position detection device and method
Technical Field
The invention relates to a measuring device and a measuring method, in particular to a device and a method for detecting the position of a steel roll system.
Background
Due to long-term high-speed operation of the steel roll system, the spatial position relations such as verticality, levelness and the like of the steel roll system can be gradually changed, so that the problems of wrinkling, deviation, edge overflow, poor product plate shape and the like of a steel coil can be caused, and the productivity, the quality and the benefit can be directly influenced. Therefore, it is required to perform spatial position measurement on the roller train to obtain the offset such as levelness and verticality, so as to perform position adjustment on the roller shaft. The traditional steel ruler level gauge measuring method is often used in actual measurement, but the traditional steel ruler level gauge measuring method gradually exits from a historical stage due to limited precision and limited use environment; the method based on laser measurement is to form a 90-degree included angle between a reference laser and a detection target light source through an optical element to detect the mutual parallelism, but the method is not widely used due to low price, incapability of obtaining accurate deviation data, single function and the like; the motion detection method based on the gyroscope is precise in measurement, but the motion detection method is expensive in manufacturing cost and high in cost.
The total station has the characteristics of high speed, good flexibility, high automation degree and the like, and is widely applied to measurement of physical quantities such as horizontal angles, vertical angles, distances (slant distances and horizontal distances), height differences and the like. For a long time, technicians summarize the roller system evaluation standard taking levelness and verticality as main reference indexes, but the design of a measuring device and a data processing algorithm of a roller system position detection system is still incomplete.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to provide a steel roller system position detection device which can simultaneously detect multiple parameter indexes of a single roller and a roller system; the invention also aims to provide a detection method based on the steel roll system position detection device.
The technical scheme is as follows: the utility model provides a steel roller is position detection device, the device includes total powerstation, reference landmark and sighting rod, the sighting rod includes sighting rod arm, prism, slider and vacuum chuck, the total powerstation erects in one side of reference landmark and the roller that awaits measuring, prism fixed connection is at the sighting rod top, and sighting rod arm reciprocates along the slider, fixes a position through the locating pin, and slider fixed connection is on vacuum chuck.
In order to enhance the positioning effect, the sliding block and the marker post arm are preferably positioned by screws, the marker post arm is provided with a plurality of screw holes, the sliding block is provided with a first screw hole, the size of the first screw hole is consistent with that of the screw hole of the marker post arm, and the marker post arm and the sliding block are connected through the first screw; the edge of the outer side of the sliding block is provided with a second screw hole which is connected with the vacuum chuck through a second screw.
The marker arm is made of metal materials, preferably aluminum materials, the adjustable range is 0.5-2.0 m, and the method is suitable for measuring rollers with different specifications and sizes.
The prism is a plane prism, a 360-degree prism or a spherical prism, preferably a spherical prism, after high-precision processing and process control, the coincidence degree of the center of the prism and the center of a sphere is less than 0.1mm, the tolerance of the outer diameter is less than 0.1mm, namely the non-coincidence of the reflection center and the center of the sphere is less than 0.2 mm.
The method for detecting the position of the steel roll system comprises the following steps:
(1) starting a total station, adjusting the marker arm to a proper length, fixing the marker arm on the end surface of the roller shaft to be measured through a vacuum chuck, and measuring the three-dimensional coordinate of the center of the prism by using the total station;
(2) rotating the roller to drive the marker post to rotate, so that the marker post stops at any position, and measuring the three-dimensional coordinate of the center of the prism by the total station again;
(3) repeating the process to continuously obtain 8-10 groups of data to finish single-roller measurement;
(4) transmitting the total station data to a PC (personal computer) through a serial port, and calculating the position deviation index of the roller system by using the PC, wherein the calculation method comprises the following steps:
(41) preprocessing the scattered data points acquired from a single roll shaft, fitting a space circle, and explaining the fitting accuracy of the circle by using the distance relation between the fitting circle and actual measuring points to reflect the standard degree of the measured end face of the single roll; the distance relation comprises two indexes of average deviation and standard deviation, and the distance average deviation calculation formula is as follows:
Figure BDA0001429297720000021
wherein d isiThe Euclidean distance from the ith point to the fitting plane is calculated by the following formula:
Figure BDA0001429297720000022
(42) preprocessing scattered points of data acquired from a single roll shaft, performing multi-point plane fitting by using a Least Square (LS) or Singular Value Decomposition (SVD) method to obtain a fitting plane normal vector, calculating the verticality and the levelness of the roll system by using an end face normal vector of each roll in the roll system, reflecting the position point of the single roll shaft in the roll system by using the circle center of the fitting plane, and reflecting the spatial position deviation of the roll system by using the three indexes.
The perpendicularity index reflects the degree that when a roller shaft in the roller system is projected on a horizontal plane, the central axis of the roller shaft is projected and deviates from a vertical line of a reference landmark when looking down according to a overlooking visual angle, and the central axis is projected and deviates from the vertical line of the reference landmark by taking the central line vertical to equipment as +/-0, the left deviation is negative and the right deviation is positive; the device centerline is a line perpendicular to the reference landmark line. Firstly, finding a vector which is vertical to a landmark and is parallel to the ground, and solving an included angle theta between the vector and a normal vector of each roll shaft fitting plane, wherein perpendicularity is defined as an offset distance of the roll shaft normal vector under a unit length, the unit length is 1m, and a perpendicularity calculation formula is as follows:
Averticality=θ×L
L=1m
The levelness is viewed from a side view parallel to the ground level to the measured roll train. The operation side is +/-0, the transmission side is positive when higher than the operation side, and the lower side is negative; the operation side is one side of the mark post and the transmission side is one side of the other end face of the roll shaft. And calculating a vector included angle between a normal vector of the roll shaft fitting plane and the ground horizontal plane, and converting the vector included angle into an offset distance under the unit length to define the offset distance as levelness. Set the normal vector of the fitting surface of the roll shaft
Figure BDA0001429297720000031
Then the corresponding vector of the earth horizontal plane is taken as
Figure BDA0001429297720000032
Phi is a vector included angle between a normal vector of a fitting plane of the roll shaft and the horizontal plane of the ground,
Figure BDA0001429297720000033
the levelness calculation formula is as follows:
Alevelness degree=Φ×L
L=1m
(5) And continuously measuring a plurality of single rollers according to the steps, calculating the position deviation of the single rollers, the levelness and the verticality of the roller system to obtain a position deviation index, and manually finishing the calibration work of the roller system.
The data preprocessing and spatial circle fitting process in the step (41) is as follows: firstly, performing scattered point plane fitting, and establishing a new coordinate system on a fitted plane to ensure that an XOY plane under the new coordinate system is superposed with the given fitted plane; then sorting the scattered points according to the distance to the fitting plane, wherein the distance is the absolute value of the Z coordinate component of the scattered points in the new coordinate system, filtering noise points according to a noise filtering formula, reserving the points with small distances, repeating the steps if the noise filtering formula is not satisfied until all the reserved points meet the condition, and ending the circulation; and finally fitting the space circle. The noise filtering adopts a self-adaptive threshold value adjusting algorithm, and the calculation formula is as follows:
Figure BDA0001429297720000034
wherein, XdIs the distance of the scatter point to the fitted plane,
Figure BDA0001429297720000035
the distance average deviation is shown, s is the standard deviation of the distance from a scattered point to a plane, lambdas is a threshold value, and lambdas is a threshold value parameter and takes a non-negative number.
Preferably, the data preprocessing and spatial circle fitting process is as follows:
(1) firstly, performing plane fitting of a scatter point, and using a least square method (LS), wherein for the scatter point (x, y, z) acquired by a total station, a plane equation of the scatter point is as follows:
A′x+B′y+C′z+1=0
for a series of scatter points, the above equation is satisfied, so the writing matrix form is:
Figure BDA0001429297720000041
therefore, the parameters A ', B ', C ' can be obtained by the following formula:
Figure BDA0001429297720000042
the plane fitting is accomplished by this process.
(2) Transforming the given coordinate system to a new coordinate system to ensure that the new XOY plane is superposed with the given fitting plane, thus ensuring that the absolute value of the Z coordinate of each point in the transformed coordinate system is the distance from the point to the plane; firstly, establishing a new coordinate system, finding any two points on a fitting plane, wherein one point is used as an original point of the new coordinate system, the other point is used as a point on an X axis of the new coordinate system, and a vector direction formed by connecting the original point to the point on the X axis represents the positive direction of the X axis; fitting the normal vector direction of the plane as the positive direction of the Z axis in the new coordinate system; and determining a Y-axis direction vector by using the determined X-axis and Z-axis information, wherein a specific solving formula is as follows:
Figure BDA0001429297720000043
wherein OX is a new X axis, OZ is a new Z axis, and the obtained OY is a new Y axis; and then converting the coordinates of all points in the original coordinate system into the new coordinate system according to the relative positions.
(3) And sequencing the absolute values of the Z coordinate components of the scattered points in the new coordinate system, filtering noise points according to a noise filtering formula, and reserving the points with small distances.
(4) And fitting the spatial circle after the noise point filtering step is finished, wherein the process of fitting the circle is performed on a previous fitting plane, and the equation of the plane circle is as follows:
(x-xc)2+(y-yc)2=R
after unfolding, obtaining:
Figure BDA0001429297720000044
let A equal 2xc,B=2yc
Figure BDA0001429297720000045
The following can be obtained:
x2+y2-Ax-By+D=0
for all scatters satisfying the above equation, writing in a matrix form yields:
Figure BDA0001429297720000051
obtaining through matrix transformation:
Figure BDA0001429297720000052
dissolving to obtain A, B and D, substituting
Figure BDA0001429297720000053
The coordinates (a, b) of the center of the circle and the radius R of the circle can be obtained.
Has the advantages that: compared with the prior art, the invention has the following advantages: (1) the whole set of detection device is ingenious in design and convenient to assemble, is very stable after installation, can realize simultaneous detection of multiple parameter indexes of a single roller and a roller system, is simple and easy to obtain, can evaluate comprehensively, can objectively reflect the position of the roller system and meet the precision requirement, is suitable for field measurement under different conditions, and can well complete the work of measuring the spatial position of the roller system. (2) The steel roller system position detection device provided by the invention utilizes the total station and the PC to realize automatic measurement and calculation of the roller system position deviation, and has the advantages of high automation degree and high data processing speed; the marking rod adopted by the device utilizes the sliding block to move up and down to adjust the height, and is suitable for measuring rollers with different specifications and sizes. (3) The detachable vacuum chuck adopted by the device has the advantages of low cost, portability, simple operation and accurate measurement, the size and the shape of the detachable vacuum chuck can be selected according to actual conditions, and the generated suction force is variable; compared with the common magnet, the sucking disc can prevent rust and electromagnetic interference, prevent the phenomena of nonuniform magnetic force and unstable attraction caused by magnet damage, and is suitable for being attracted on the end surfaces of rollers made of different materials, not just steel alloy materials. (4) The detection method disclosed by the invention is simple and effective in design and high in data processing and calculation efficiency, can accelerate the noise point filtering speed by adopting the self-adaptive threshold value adjustment algorithm, overcomes the defects that the filtered points are close to the fitting plane and the points which should not be filtered or retained are abnormal values due to the fixed denoising ratio, avoids invalid repeated calculation and the influence of extreme values on the result, improves the accuracy and the fitting speed of the traditional space circle fitting algorithm, can be used for guiding the roll system calibration, and greatly improves the productivity, the quality and the benefit of products.
Drawings
FIG. 1 is a schematic view of a detection apparatus of the present invention;
FIG. 2 is an enlarged view of portion A of FIG. 1;
FIG. 3 is a front view of the post structure of the present invention;
FIG. 4 is a left side view of the post structure of the present invention;
FIG. 5 is an enlarged top view of the post structure of the present invention;
FIG. 6 is a flow chart of a data processing algorithm of the present invention.
Detailed Description
The technical scheme of the invention is further explained by combining the attached drawings.
As shown in fig. 1-5, the device for detecting the position of a steel roller system disclosed by the invention comprises a total station 1, a reference landmark 2 and a target, wherein the target comprises a target arm 3, a prism 4, a slide block 5 and a vacuum chuck 6, the total station 1 is erected on one side of the left reference landmark 2 and the right reference landmark 2 of the roller system, the specific measurement position is adjusted according to actual operation, the spherical prism 4 is fixedly connected above the target 3 and can be fixedly connected through a screw hole, the total station 1 is used for obtaining the central position coordinates of the prism 4 when the end face of a roller 7 to be detected rotates, and the center of the prism 4 can be aimed when the targets on all the single rollers 7 rotate. The marker post arm 3 is made of aluminum, the marker post arm 3 is provided with a plurality of screw holes, the size of the screw holes is consistent with that of the first screw hole 51 on the side surface of the sliding block 5, the marker post arm 3 and the sliding block 5 are connected through first screws, the marker post arm moves up and down along the sliding block, the length between the sliding block 5 and the prism 4 is adjusted, the adjustable range is 0.5-2.0 m, and the device is suitable for measuring rollers with different specifications and sizes; the outer edge of the sliding block 5 is provided with a second screw hole 52 which is connected with a vacuum chuck 6 by a second screw, and the vacuum chuck 6 is fixed on the end surface of the roller shaft 7 to be measured; the first screw hole 51 corresponds to a first screw, and the second screw hole 52 corresponds to a second screw. The vacuum chuck 6 generates different suction forces through the suction of vacuum equipment, and can be sucked on end faces made of different materials. When the device works, the vacuum sucker 6 is attached to the end face of the roller shaft 7 to be detected, negative air pressure is generated inside the device after the vacuum device sucks the device, and the end face of the roller shaft 7 is sucked; when not in work, air is injected.
The working principle of the steel roll system position detection device is as follows: after the whole device is assembled, the total station is started, the marker post is adjusted to a proper length, the vacuum sucker and the marker post are assembled, vacuum equipment is used for sucking, negative air pressure is generated in the sucker, the sucker is attracted to the end face of the roller, and the marker post is fixed. Measuring the three-dimensional coordinate of the prism center by using a total station; rotating the roller from the position to drive the mark post to rotate so as to stop at any position; the total station measures the three-dimensional coordinates of the prism center again; repeating the process to continuously obtain 8-10 groups of data to finish the measurement of a single roller; transmitting the total station data back to a PC (personal computer) through a serial port, continuously measuring a plurality of single rollers, and obtaining various parameter values reflecting the spatial position deviation of the roller system according to the data processing procedures of plane fitting, coordinate conversion, self-adaptive noise point filtering, spatial circle fitting, single roller position deviation calculation and roller system levelness and verticality calculation; and the operator manually finishes the roll system calibration work based on the operation. The fixed position of the marker post is guaranteed not to shake during the measurement, the marker post is prevented from being directly touched during the rotation of the single roller, the inaccurate measuring position of the total station or the relative position of the marker post and the single roller is prevented from being deviated, and the deviation is caused as a result. The measuring positions are uniformly distributed in the measurable area as much as possible, and the result validity is ensured.
The three-dimensional coordinates of the roll system scattering points acquired by the total station are transmitted to the PC through the serial port, and then data processing is performed by the PC, as shown in fig. 6, according to the process, the method mainly comprises the following steps:
1. performing plane fitting on the plurality of measuring points by using a least square fitting (LS) or Singular Value Decomposition (SVD) method to obtain a plane equation;
2. transforming the given coordinate system to a new coordinate system, wherein an XOY plane of the new coordinate system is superposed with the given plane, so that the absolute value of the Z coordinate of each point in the transformed coordinate system is the distance from the point to the plane;
3. selecting a proper threshold parameter lambda according to actual requirements, filtering and screening the obtained points according to a self-adaptive threshold adjustment algorithm, and selecting the points which meet the requirements and can reflect the indexes of the roller system for reservation, so that the influence of extreme values on the measurement result is avoided, and the error is reduced;
4. performing space circle fitting on the retained data, calculating the distance between an actual point and a fitting circle, and describing the fitting accuracy of the circle through two indexes of distance average deviation and standard deviation so as to reflect the standard degree of the measured end face of a single roller;
5. a reference coordinate system is obtained for the whole roll system, the perpendicularity and the levelness of the roll system are calculated by using the normal vector of the end surface of each roll in the roll system, and the spatial position deviation of the roll system is reflected by combining the circle center of the roll and the three indexes to guide the calibration of the roll system, so that the productivity, the quality and the benefit are improved.
The total station is of a Leica Nova TS60 type, the highest angle measurement precision is 0.5 second, the highest distance measurement precision is 0.6mm +1 ppm/typical 2.4 second, and the total station is provided with a rotary motor, can automatically focus and aim at when a prism is equipped, and has high automation degree. The PC and the USB interface adopt RS232 serial port communication, and single end sends data. The GSI output format is: [ scatter number, north coordinates, east coordinates, elevation coordinates, measurement date, measurement time, carriage return/linefeed ], for example: [2004,4997.635,6010.784,393.173,09/10/2001,16:34:12.2]. The east coordinate is converted into an X coordinate in a data algorithm, the north coordinate is converted into a Y coordinate, and the elevation coordinate is converted into a Z coordinate. The PC machine is loaded with a Windows7 operating system and provides a network cable and a USB interface.
The invention can realize the position detection of the steel roller system, and after various parameter indexes are obtained through calculation, the steel roller system is used for guiding the calibration of the roller system. Before each starting program is detected, the Windows application program on the PC is started, then the total station is started, and the RS232 is used for connecting the PC and the total station. After the spherical prism is arranged at the screw hole of the sighting rod, the sucker at the lower part of the sighting rod is attached to the end surface of the roller shaft, one worker rotates the roller and is responsible for measuring data at the total station, and the other worker processes the data at the PC by utilizing an application program to obtain a calculation index and a calibration guidance suggestion.

Claims (5)

1. A method for detecting the position of a steel roll system is characterized by comprising the following steps:
(1) starting a total station, adjusting the marker arm to a proper length, fixing the marker arm on the end surface of the roll shaft to be measured through a vacuum chuck, and measuring the three-dimensional coordinate of the center of the prism by the total station;
(2) rotating the roller to drive the marker post to rotate, so that the marker post stops at any position, and measuring the three-dimensional coordinate of the center of the prism by the total station again;
(3) repeating the process of the step (2), continuously measuring 8-10 groups of data, and completing single-roller measurement;
(4) transmitting the data of the total station to a PC (personal computer) and calculating the position deviation index of the roller system;
(5) and continuously measuring a plurality of single rollers according to the steps, calculating the position deviation of the single rollers, the levelness and the verticality of the roller system to obtain a position deviation index, and manually finishing the calibration work of the roller system.
2. The method for detecting the position of the steel roll system according to claim 1, wherein the method for calculating the roll system position deviation index in the step (4) is as follows:
(41) preprocessing the scattered points of the data acquired from a single roll shaft, fitting a space circle, and explaining the fitting accuracy of the circle by using the distance relationship between the fitting circle and actual measuring points, wherein the position relationship comprises two indexes of average deviation and standard deviation, and the distance average deviation calculation formula is as follows:
Figure FDA0002298295520000011
in the formula diThe Euclidean distance from the ith point to the fitting plane is calculated by the following formula:
Figure FDA0002298295520000012
(42) preprocessing scattered data points acquired from a single roll shaft, then performing multi-point plane fitting to obtain a fitting plane normal vector, calculating the verticality and the levelness of the roll system through the end face normal vector of each roll in the roll system, reflecting the position point of the single roll shaft in the roll system by using the circle center of the fitting plane, and reflecting the spatial position deviation of the roll system by using the three indexes; the perpendicularity is +/-0 by being perpendicular to the central line of the equipment, the left deviation is negative, and the right deviation is positive; and (3) calculating an included angle theta between the normal vector of the normal vector and each roll shaft fitting plane through a vector which is vertical to the landmark and is parallel to the ground, wherein the verticality is defined as the offset distance of the roll shaft normal vector under the standard length, the standard length is 1m, and the verticality calculation formula is as follows:
Averticality=θ×L
L=1m
The levelness is +/-0 on the operating side, and the transmission side is positive when higher than the operating side and negative when lower than the operating side; the operating side is the side where the marker post is attached, and the transmission side is the side of the other end face of the roll shaft; calculating a vector included angle between a normal vector of a roll shaft fitting plane and the ground horizontal plane, and converting the vector included angle into an offset distance under a standard length to define the offset distance as levelness; set the normal vector of the fitting surface of the roll shaft
Figure FDA0002298295520000021
Then the corresponding vector of the earth horizontal plane is taken as
Figure FDA0002298295520000022
Computing
Figure FDA0002298295520000023
The levelness calculation formula is as follows:
Alevelness degree=Φ×L
L=1m。
3. The method for detecting the position of a steel roll system according to claim 2, wherein the data preprocessing and the spatial circle fitting in the step (41) are as follows: firstly, performing scattered point plane fitting, and establishing a new coordinate system on a fitted plane to ensure that an XOY plane under the new coordinate system is superposed with the given fitted plane; then sorting the absolute values of the Z coordinate components of the scattered points in the new coordinate system, filtering noise points according to a noise filtering formula, reserving the points with small distances, repeating the steps until all the reserved points meet the conditions if the noise filtering formula is not met, and ending the circulation; and finally fitting the space circle.
4. The method for detecting the position of the steel roll system according to claim 3, wherein the noise filtering in the step (41) adopts an adaptive threshold adjustment algorithm, and the calculation formula is as follows:
Figure FDA0002298295520000024
wherein, XdIs the distance of the scatter point to the fitted plane,
Figure FDA0002298295520000025
in order to average the deviation of the distance,sis the standard deviation of the distance from the scattered point to the plane, λ s is the threshold, and λ is the threshold parameter.
5. The method for detecting the position of a steel roll system according to claim 3, characterized in that: the data preprocessing and space circle fitting process comprises the following steps:
(1) firstly, performing plane fitting of a scattered point, and performing a plane equation of the scattered point (x, y, z) acquired by the total station by using a least square method:
A′x+B′y+C′z+1=0
for a series of scatter points, the above equation is satisfied, so the writing matrix form is:
Figure FDA0002298295520000026
therefore, the parameters A ', B ', C ' can be obtained by the following formula:
Figure FDA0002298295520000031
completing plane fitting through the process;
(2) establishing a new coordinate system, finding any two points on a fitting plane, wherein one point is used as an original point of the new coordinate system, the other point is used as a point on an X axis of the new coordinate system, and a vector direction formed by connecting the original point to the point on the X axis represents the positive direction of the X axis; fitting the normal vector direction of the plane as the positive direction of the Z axis in the new coordinate system; and determining a Y-axis direction vector by using the determined X-axis and Z-axis information, wherein a specific solving formula is as follows:
Figure FDA0002298295520000032
wherein OX is a new X axis, OZ is a new Z axis, and the obtained OY is a new Y axis; then, converting the coordinates of all points in the original coordinate system into a new coordinate system according to the relative positions;
(3) sorting the absolute values of the Z coordinate components of the scattered points in the new coordinate system, filtering noise points according to a noise filtering formula, and reserving points with small distances;
(4) fitting a spatial circle, the process being performed on a previously fitted plane, the equation for the plane circle being:
(x-xc)2+(y-yc)2=R
after unfolding, obtaining:
Figure FDA0002298295520000033
let A equal 2xc,B=2yc
Figure FDA0002298295520000034
The following can be obtained:
x2+y2-Ax-By+D=0
for all scatters satisfying the above equation, writing in a matrix form yields:
Figure FDA0002298295520000035
obtaining through matrix transformation:
Figure FDA0002298295520000036
dissolving to obtain A, B and D, substituting
Figure FDA0002298295520000041
The coordinates (a, b) of the center of the circle and the radius R of the circle can be obtained.
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