CN108062072A - A kind of dual camera image collecting device and the flat-bottom milling cutter of image mosaic abrasion online test method - Google Patents
A kind of dual camera image collecting device and the flat-bottom milling cutter of image mosaic abrasion online test method Download PDFInfo
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- CN108062072A CN108062072A CN201711185500.7A CN201711185500A CN108062072A CN 108062072 A CN108062072 A CN 108062072A CN 201711185500 A CN201711185500 A CN 201711185500A CN 108062072 A CN108062072 A CN 108062072A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
- G05B19/4065—Monitoring tool breakage, life or condition
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
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Abstract
A kind of dual camera image collecting device and the flat-bottom milling cutter of image mosaic abrasion online test method, the present invention relates to the online tool wear monitoring fields based on machine vision.The present invention is in order to solve the problems, such as in conventional images splicing that the matching of light modified-image is difficult, conventional offline measurement secondary clamping can cause error and machining accuracy and efficiency low.The L-shaped mounting bracket of apparatus of the present invention includes bottom plate and adjusting rod, and adjusting rod is vertically installed in one end of bottom plate, is threaded on adjusting rod；Camera fixed case is set on bottom plate, and CCD camera is arranged in camera fixed case, and a side of camera fixed case is LED lighting board, and LED lighting board sets a hole corresponding with CCD camera camera；Adjusting knob is set on installing plate, and adjusting rod is furnished with slideway, and installing plate is embedded in slideway, and adjusting knob is used cooperatively by screw thread and adjusting rod, realizes the relative movement of installing plate and slideway.The present invention is used for online tool wear monitoring field.
Description
Technical field
The present invention relates to the online tool wear monitoring fields based on machine vision, and in particular to dual camera Image Acquisition
Device and the flat-bottom milling cutter of image mosaic abrasion online test method.
Background technology
With modern manufacturing industry and the high speed development of industrial automation, numerically-controlled machine tool and machining center have obtained extensively should
With as the direct executor of working angles, the abrasion of cutter can reduce the precision in process, and drop processing efficiency
It is low, therefore the monitoring of cutting tool state just becomes more and more important, its unmanned and automation development in process is promoted
Aspect plays the role of very important.Cutting tool wear and damage is inevitable during the cutting process, it can give automation
Processing brings many undesirable influences, influences the surface quality of workpiece, causes the damage of lathe or even can threaten the life of operator
Life safety, causes incalculable damage.
The method monitored at present for tool wear (damage) in process mainly has indirect monitoring and directly prison
Survey two methods.Indirect monitoring method has a certain of stronger inner link by measuring in working angles with tool wear or breakage
Kind or several parameters measure certain physical phenomenon, are changed according to it and monitor tool wear by certain calibration relation
Or damaged state.Such as：Monitor the variation suddenly of workpieces processing quality (surface roughness, surface figure accuracy etc.)；Lathe is neglected
So vibration；Abnormal sound during cutting；The variation suddenly of temperature during cutting；The variation suddenly of cutting force；Spindle power is suddenly
It increaseds or decreases, can indirectly react the abrasion of cutter and damaged state.Currently used method has based on sound emission
The monitoring method of signal, the monitoring method based on Cutting Force Signal, the monitoring method based on workpiece size, based on cutting temperature
Monitoring method etc..Direct method is to be evaluated by certain monitoring method directly from cutter abrasion in itself or damaged state, such as
Whether cutter changes in shape and weight, and wear or break judging cutter according to specific measurement technology and method
Damage.Common method has optical scanning method, computer vision method, contact detection sensor method etc..
Existing indirect method is monitored the tool wear in processing, is substantially by obtaining the machinery in process
Signal is detected cutting tool state.The evaluation criterion of these methods can be with the size of workpieces processing, process velocity, feeding
The factors such as amount, the material of workpiece and cutter model and change, it is necessary to constantly some parameters of update the system and relevant setting.
And for tool wear threshold value selection and setting it is extremely difficult, can all change in actual processing, to process ring
Border requirement is stringent, so as to affect the application of actual processing.And it can only judge whether cutter wears (qualitative), and cannot obtain
Obtain the information such as specific tool in cutting sword form parameter and geometric accuracy.And conversion due to signal and calculating are when needing to expend
Between, Efficiency and accuracy is not high.Therefore, the best approach for accurately obtaining the form parameter of tool in cutting sword is still direct method,
At present, there are many cutter pre-regulating based on the direct method of measurement/measuring instrument productions for the manufacture developed country such as Britain, the U.S., Germany, Japan
Product, but there are still the problem of the following aspects at present：Most of measuring methods and product are limited by measuring principle, only
Self-contained unit can be made, online/On-machine Test can not be realized, off-line measurement, therefore knife can only be carried out stage by stage in process
Tool can not obtain the shape information of cutting edge in time, lead to not the abrasion condition of monitoring cutter in time；It is repeatedly offline simultaneously to survey
Secondary clamping error is measured or caused, machining accuracy and processing efficiency is caused to reduce；The existing cutter based on image technique is direct
Measuring method and product, to guarantee to realize the accurate measurement for small size cutter, using the optics of big multiplying power small field of view
Camera lens, image can not accurately obtain the shape information of tool in cutting sword beyond visual field during large scale cutting tools measurement, can only replace
The small big visual field camera lens of multiplying power, this can cause measurement accuracy to decline, and the times such as equipment mounting and adjusting increase, detection efficiency
It reduces.
The content of the invention
The purpose of the present invention is to solve light modified-image matching difficulty, conventional offlines in conventional images splicing
The problem of measurement secondary clamping can cause error and machining accuracy and low efficiency, and propose a kind of dual camera image collector
It puts and the flat-bottom milling cutter of image mosaic wears online test method.
A kind of dual camera image collecting device includes：L-shaped mounting bracket, camera fixed case, LED lighting board, CCD camera,
Camera steering knob, transmission line, adjusting knob and installing plate；
L-shaped mounting bracket includes bottom plate and adjusting rod, and adjusting rod is vertically installed in one end of bottom plate, spiral shell is set on adjusting rod
Line；
Camera fixed case is set on bottom plate, and CCD camera is arranged in camera fixed case, and a side of camera fixed case is
LED lighting board, 2 holes corresponding with CCD camera camera position are set in LED lighting board, and CCD camera passes through camera and turns to rotation
Button realizes the rotation of camera, and the image that CCD camera is shot is by transmission line to computer；
Adjusting knob is set on a mounting board, and adjusting rod is furnished with slideway, and installing plate is embedded in slideway, and adjusting knob passes through spiral shell
Line is used cooperatively with adjusting rod, realizes the relative movement of installing plate and slideway；Make installing plate along adjusting by rotating adjusting knob
Bar moves up and down.
The flat-bottom milling cutter abrasion online test method of image mosaic based on dual camera image collecting device includes following
Step：
Step 1: opening shines mounted on the CCD camera and LED of the dual camera image collecting device of lathe workbench
Plate shows CCD camera image on the display of computer；
Step 2: dual camera image collecting device is driven to needing to examine using the workbench of machine tool control system driving lathe
The cutter focusing of survey, shows defocused image on the display of computer；
Step 3: according to being shown in display to defocused image, knife is made by translational worktable band cutter movement
Tool cutting edge is located at dual camera image collecting device field of view center, this position is set as to the initial position of cutter, and is passed through
CCD camera obtains the tool in cutting sword image of initial position, and sends computer to；
Step 4: according to flat-bottom milling cutter blade number, scale division value is set；Indexing rotation is carried out from cutter initial position, is led to
Cross the tool in cutting sword image on each indexing position of CCD camera acquisition of dual camera image collecting device；
Step 5: carrying out anastomosing and splicing to the image that dual camera image acquisition device arrives using SIFT algorithms, obtain
To the wear map picture of each cutting edge；
Step 6: the wear map picture that step 5 obtains is rotated counterclockwise, make cutting edge perpendicular to horizontal direction；
Step 7: the grey level histogram of image column direction that plot step six obtains after rotating, blade in grey level histogram
To knife spine direction the first extreme value and secondary extremal point by survey tool in cutting sword two borders, image is in two borders
Tool in cutting sword image extracts cutting edge image, and the border is perpendicular to horizontal direction.
Step 8: taking the average gray T of step 7 extraction cutting edge image, average gray is set to threshold value to step
The cutting edge image of seven extractions does binary conversion treatment；
Step 9: the pixel number that gray value is 255 in image after binary conversion treatment is calculated, and extracted with step 7
Cutting edge image total pixel number, which is done, to be compared, according to the wear extent of obtained ratio in judgement cutter to get to the degree of wear of cutter.
Beneficial effects of the present invention are：
The shortcomings that it is an object of the invention to overcome the prior art, provides during one kind can realize work and is cut for cutter
The on-line checking of sword is cut, tool in cutting sword wear coefficient is timely and accurately obtained, avoids conventional offline measurement and cause secondary dress
Error is pressed from both sides, realizes the online test method that machining accuracy and efficiency are substantially improved.The present invention is a kind of knife based on pixel extraction
Have abrasion detection, realize the on-line monitoring of Cutter wear situation at any time, and then reduce processing cost, improve processing efficiency.This
Processing efficiency promotes 17% to inventive method compared with prior art；Process time shortens 13%；Machining accuracy promotes 5%.
Description of the drawings
Fig. 1 is apparatus of the present invention right view；
Fig. 2 is apparatus of the present invention left view；
Fig. 3 is that the flat-bottom milling cutter abrasion online test method structure of dual camera image collecting device and image mosaic is shown
It is intended to.
Specific embodiment
Specific embodiment one：As depicted in figs. 1 and 2, a kind of dual camera image collecting device includes：L-shaped mounting bracket
1st, camera fixed case 2, LED lighting board 3, black-white CCD camera 4, camera steering knob 5, transmission line 6, adjusting knob 7 and installing plate
8；
L-shaped mounting bracket 1 includes bottom plate 1-1 and adjusting rod 1-2, and adjusting rod 1-2 is vertically installed in one end of bottom plate 1-1, adjusts
It is threaded on pole 1-2；
Camera fixed case 2 is set on bottom plate 1-1, CCD camera 4 is arranged in camera fixed case 2, and the one of camera fixed case 2
A side is LED lighting board 3, and 2 holes corresponding with 4 camera position of CCD camera are set in LED lighting board 3, and (CCD camera 4 is logical
The hole corresponding with camera position set in LED lighting board 3 is crossed to be shot), CCD camera 4 is real by camera steering knob 5
The rotation of existing camera, the image that CCD camera 4 is shot are transferred to computer by transmission line 6；
Adjusting knob 7 is arranged on installing plate 8, and adjusting rod 1-2 is furnished with slideway, and installing plate 8 is embedded in slideway, adjusting knob
7 are used cooperatively by screw thread and adjusting rod 1-2, realize the relative movement of installing plate 8 and slideway；Make peace by rotating adjusting knob
Loading board 8 is moved up and down along adjusting rod 1-2.
As shown in figure 3, apparatus of the present invention use the thought of apery eyes, two figures of a collecting part region overlapping
Piece avoids the variation of common secondary acquisition light, reduces the dependence to picture pretreatment, reduces image mosaic difficulty.First
Open the CCD camera 4 of dual camera image collecting device and LED lighting board 3, by CCD camera image computer display
On shown, then using the workbench of machine tool control system driving lathe mounting bracket 12 and dual camera image is driven to adopt
Acquisition means 13 are completed to focus to cutter 14, by adjusting camera steering knob 5 the big axis in two pictures overlapping regions are controlled to feed work
It is small to make platform；According to being shown in display to defocused image, by translate z-axis Feed table 9, y-axis Feed table 10,
X-axis Feed table 11 makes tool in cutting sword be located at dual camera image collecting device field of view center with the movement of cutter 14, will
This position is set as the initial position of cutter, and the tool in cutting sword image of initial position is obtained by CCD camera, and sends to
Computer；According to flat-bottom milling cutter blade number, scale division value (such as sword number is then turn 90 degrees every time as 4) is set；At the beginning of cutter
Beginning position carries out indexing rotation, and the cutter on each indexing position is obtained by the CCD camera 4 of dual camera image collecting device
Cutting edge image；Picture is handled using computer to obtain tool wear situation.
Specific embodiment two：The online inspection of flat-bottom milling cutter abrasion of image mosaic based on dual camera image collecting device
Survey method comprises the following steps：
Step 1: open the CCD camera 4 of the dual camera image collecting device mounted on lathe workbench and LED hairs
Tabula rasa 3 shows CCD camera image on the display of computer；
Step 2: drive the realization pair of dual camera image collecting device using the workbench of machine tool control system driving lathe
The cutter focusing that need to be detected, shows defocused image on the display of computer；
Step 3: according to being shown in display to defocused image, knife is made by translational worktable band cutter movement
Tool cutting edge is located at dual camera image collecting device field of view center, this position is set as to the initial position of cutter, and is passed through
CCD camera obtains the tool in cutting sword image of initial position, and sends computer to；
Step 4: according to flat-bottom milling cutter blade number, scale division value (such as sword number is then turn 90 degrees every time as 4) is set；
Indexing rotation is carried out from cutter initial position, each indexing position is obtained by the CCD camera 4 of dual camera image collecting device
On tool in cutting sword image；
Step 5: carrying out anastomosing and splicing to the image that dual camera image acquisition device arrives using SIFT algorithms, obtain
To the wear map picture of each cutting edge；
Step 6: the wear map picture that step 5 obtains is rotated by a certain angle counterclockwise, make cutting edge perpendicular to level side
To；
Step 7: the grey level histogram of image column direction that plot step six obtains after rotating, blade in grey level histogram
The first extreme point and secondary extremal point to knife spine direction (left side) by survey tool in cutting sword two borders, in two borders
Image is tool in cutting sword image, extracts cutting edge image, the border is perpendicular to horizontal direction.
Step 8: taking the average gray T of step 7 extraction cutting edge image, average gray is set to threshold value to step
The cutting edge image of seven extractions does binary conversion treatment；
Step 9: the pixel number that gray value is 255 in image after binary conversion treatment is calculated, and extracted with step 7
Cutting edge image total pixel number, which is done, to be compared, according to the wear extent of obtained ratio in judgement cutter to get to the degree of wear of cutter.
Specific embodiment three：The present embodiment is different from the first embodiment in that：CCD camera in the step 1
For black-white CCD camera.
Other steps and parameter are identical with embodiment two.
Specific embodiment four：Present embodiment is unlike specific embodiment two or three：It is needed in the step 2
The two images overlapping region of the cutter of detection should be greater than being equal to 25%.
Other steps and parameter are identical with specific embodiment two or three.
Specific embodiment five：Unlike one of present embodiment and specific embodiment two to four：The step 6
In the angle that rotates counterclockwise be tool in cutting sword helix angle.
Other steps and parameter are identical with one of specific embodiment two to four.
Specific embodiment six：Unlike one of present embodiment and specific embodiment two to five：The step 7
The calculation formula of the grey level histogram of middle column direction is：
Wherein yiFor the sum of the i-th row pixel gray value in image, xI, jFor the gray scale of the i-th row jth row pixel in image
Value.
Other steps and parameter are identical with one of specific embodiment two to five.
Specific embodiment seven：Unlike one of present embodiment and specific embodiment two to six：The step 8
The calculation formula of middle threshold value is：
Wherein m is columns, and n is line number.
Other steps and parameter are identical with one of specific embodiment two to six.
The present invention can also have other various embodiments, without deviating from the spirit and substance of the present invention, this field
Technical staff makes various corresponding changes and deformation in accordance with the present invention, but these corresponding changes and deformation should all belong to
The protection domain of appended claims of the invention.
Claims (7)
1. a kind of dual camera image collecting device, it is characterised in that：The dual camera image collecting device includes：L-shaped is pacified
Shelve (1), camera fixed case (2), LED lighting board (3), CCD camera (4), camera steering knob (5), transmission line (6), adjusting
Knob (7) and installing plate (8)；
L-shaped mounting bracket (1) includes bottom plate (1-1) and adjusting rod (1-2), and adjusting rod (1-2) is vertically installed in the one of bottom plate (1-1)
It holds, is threaded on adjusting rod (1-2)；
Camera fixed case (2) is set on bottom plate (1-1), and CCD camera (4) is arranged in camera fixed case (2), camera fixed case
(2) a side is LED lighting board (3), set in LED lighting board (3) 2 it is corresponding with CCD camera (4) camera position
Hole, CCD camera (4) realize the rotation of camera by camera steering knob (5), and the image of CCD camera (4) shooting passes through transmission
Line (6) is transferred to computer；
Adjusting knob (7) is arranged on installing plate (8), and adjusting rod (1-2) is furnished with slideway, and installing plate (8) is embedded in slideway, is adjusted
Knob (7) is used cooperatively by screw thread and adjusting rod (1-2), realizes the relative movement of installing plate (8) and slideway, is adjusted by rotating
Section knob (7) makes installing plate (8) be moved up and down along adjusting rod (1-2).
2. the flat-bottom milling cutter abrasion online test method of the image mosaic based on claim 1 described device, it is characterised in that：Base
Comprise the following steps in the flat-bottom milling cutter abrasion online test method of the image mosaic of dual camera image collecting device：
Step 1: opening shines mounted on the CCD camera (4) and LED of the dual camera image collecting device of lathe workbench
Plate (3) shows CCD camera image on the display of computer；
Step 2: dual camera image collecting device is driven to that need to detect using the workbench of machine tool control system driving lathe
Cutter is focused, and defocused image is shown on the display of computer；
Step 3: according to being shown in display to defocused image, cut cutter by translational worktable band cutter movement
It cuts sword and is located at dual camera image collecting device field of view center, this position is set as to the initial position of cutter, and passes through CCD phases
Machine obtains the tool in cutting sword image of initial position, and sends computer to；
Step 4: according to flat-bottom milling cutter blade number, scale division value is set；Indexing rotation is carried out from cutter initial position, by double
The CCD camera (4) of camera image harvester obtains the tool in cutting sword image on each indexing position；
Step 5: carrying out anastomosing and splicing to the image that dual camera image acquisition device arrives using SIFT algorithms, obtain every
The wear map picture of a cutting edge；
Step 6: the wear map picture that step 5 obtains is rotated counterclockwise, make cutting edge perpendicular to horizontal direction；
Step 7: the grey level histogram of image column direction that plot step six obtains after rotating, blade is to knife in grey level histogram
Carry on the back the first extreme point and the secondary extremal point in direction by survey tool in cutting sword two borders, image is knife in two borders
Have cutting edge image, extract cutting edge image, the border is perpendicular to horizontal direction.
Step 8: taking the average gray T of step 7 extraction cutting edge image, average gray is set to threshold value, step 7 is carried
The cutting edge image taken does binary conversion treatment；
Step 9: the pixel number that gray value is 255 in image after binary conversion treatment is calculated, and the cutting extracted with step 7
Sword image total pixel number, which is done, to be compared, according to the wear extent of obtained ratio in judgement cutter to get to the degree of wear of cutter.
3. the flat-bottom milling cutter abrasion of the image mosaic according to claim 2 based on dual camera image collecting device is online
Detection method, it is characterised in that：CCD camera is black-white CCD camera in the step 1.
4. the flat-bottom milling cutter abrasion of the image mosaic according to claim 3 based on dual camera image collecting device is online
Detection method, it is characterised in that：The two images overlapping region of the cutter of detection is needed to should be greater than being equal to 25% in the step 2.
5. the flat-bottom milling cutter abrasion of the image mosaic according to claim 4 based on dual camera image collecting device is online
Detection method, it is characterised in that：The angle rotated counterclockwise in the step 6 is the helix angle of tool in cutting sword.
6. the flat-bottom milling cutter abrasion of the image mosaic according to claim 5 based on dual camera image collecting device is online
Detection method, it is characterised in that：The calculation formula of the grey level histogram of column direction is in the step 7：
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Wherein yiFor the sum of the i-th row pixel gray value in image, xI, jFor the gray value of the i-th row jth row pixel in image.
7. the flat-bottom milling cutter abrasion of the image mosaic according to claim 6 based on dual camera image collecting device is online
Detection method, it is characterised in that：The calculation formula of threshold value is in the step 8：
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| CN109285156B (en) * | 2018-11-16 | 2021-12-21 | 厦门大学 | Method for off-line prediction of service life of integral end mill for machining tractor gearbox |
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