CN108296880B - CCD-based online detection device and detection method for tool grinding damage - Google Patents
CCD-based online detection device and detection method for tool grinding damage Download PDFInfo
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- CN108296880B CN108296880B CN201810241064.9A CN201810241064A CN108296880B CN 108296880 B CN108296880 B CN 108296880B CN 201810241064 A CN201810241064 A CN 201810241064A CN 108296880 B CN108296880 B CN 108296880B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2452—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces
- B23Q17/2457—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces of tools
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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- Optics & Photonics (AREA)
- Machine Tool Sensing Apparatuses (AREA)
- Length Measuring Devices By Optical Means (AREA)
Abstract
The device comprises a collecting box, an industrial computer and a display, wherein an industrial camera, a double telecentric lens, an annular light source and a triple prism are arranged in the collecting box, and the industrial camera, the double telecentric lens, the industrial computer and the display are sequentially connected. The detection method of the device comprises the following steps: (1) moving the whole device along with the X axial direction and the Y axial direction of the machine tool; (2) running the whole device under the cutter; the cutter descends and passes through the collecting box and is stopped above the triangular prism; (4) After the calibration is finished, the industrial camera is fixed, so that the triangular prism is flush with the industrial camera; (5) collecting all bottom edge images at one time; (6) Adjusting the height of a triangular prism, and collecting side edge images in a low-speed rotation mode; (7) And the industrial personal computer performs data processing on the acquired blade images. The invention is integrated in a camera, visual non-contact on-line detection is realized, secondary clamping is avoided, and precision and efficiency are improved; convenient installation and simple operation.
Description
Technical Field
The invention relates to a detection device and a detection method for accurately obtaining the abrasion length, width, area and the like of a cutter abrasion area on line by a machine tool, and belongs to the technical field of cutter abrasion detection.
Background
The tool is used as a professional tool for machining precise parts of a numerical control machine tool, and the effective monitoring of the abrasion state of the tool can not only play the life potential of the tool, but also be an effective way for promoting intelligent manufacturing development. The existing method for detecting the grinding damage of the cutter has certain limitation:
firstly, in industrial production, abrasion detection is mainly judged by experience of workers, and often the abrasion loss of a cutter exceeds the grinding standard, so that the processing quality of a workpiece is affected; or the tool is changed in a fixed time, and the abrasion loss does not reach the grinding standard to change the tool, so that the waste of the tool is caused;
secondly, in engineering application, signals such as force, vibration, acoustic emission, current and the like are collected by a sensor to indirectly monitor the abrasion state of the cutter, but the abrasion signals cannot be accurately quantified, and powerful support is provided for whether the cutter is replaced or not;
third, the currently adopted detection device is not suitable for actual production conditions, and the display mirror is required to be used for measuring the cutter abrasion loss in an off-line manner. In order to ensure that the spindle system can safely and reliably operate, the combination surface of the spindle, the tool handle and the tool needs to have the characteristics of high geometric precision, high repeated clamping precision, high rigidity and the like, and the combination surface has important influence on the dynamics characteristic of the high-speed spindle system; in addition, in consideration of actual production conditions of factories, the cutters are stored in the cutter store, the combination surface of the main shaft, the cutters and the cutter handle is positioned, according to the existing measurement scheme, the cutters are required to be detached from the cutter store firstly and then detached from the cutter handle, and repeated positioning is required for secondary clamping, so that the efficiency is reduced, the error is increased, and the accuracy of the abrasion loss of the cutters is directly influenced.
Disclosure of Invention
Aiming at the defects of the existing cutter grinding damage detection technology, the invention provides the CCD-based cutter grinding damage online detection device with high measurement precision and high efficiency, and simultaneously provides a detection method of the device.
The invention discloses a CCD-based cutter grinding damage online detection device, which adopts the following technical scheme:
the device comprises a collecting box, an industrial personal computer and a display, wherein a CCD industrial camera, a double telecentric lens, an annular light source and a triple prism are arranged in the collecting box, and the CCD industrial camera, the double telecentric lens, the industrial personal computer and the display are sequentially connected.
The collection case comprises a base and a case body arranged on the base, wherein the case body comprises a front case door, a rear case door, a left case door, a right case door and a top case door, an inlet for on-line detection of a cutter is formed in the top case door, and a hairbrush is arranged at the inlet (for cleaning the cutter for cleaning cutting fluid and cutting chips for the first time by an air pump).
A camera transverse moving mechanism and a triangular prism Y-direction moving mechanism are arranged on a base of the acquisition box, a camera longitudinal moving mechanism is arranged on the camera transverse moving mechanism, and the CCD industrial camera is arranged on the camera longitudinal moving mechanism; the prism Y-direction moving mechanism is provided with a prism X-direction moving mechanism, the prism X-direction moving mechanism is provided with a prism Z-direction moving mechanism, and the prism is arranged on the prism Z-direction moving mechanism.
The camera transverse moving mechanism comprises a transverse guide rail, a transverse sliding block and a transverse sliding block moving mechanism, wherein the transverse sliding block and the transverse sliding block moving mechanism are arranged on the transverse guide rail, and the transverse sliding block is connected with the transverse sliding block moving mechanism. The transverse slide block moving mechanism adopts a screw-nut pair mechanism, and a transverse locking screw for locking the position of the transverse slide block is arranged on the transverse guide rail. The transverse guide rail is also provided with a transverse scale for observing the position of the transverse sliding block.
The camera longitudinal moving mechanism comprises a longitudinal guide rail, a longitudinal sliding block and a longitudinal sliding block moving mechanism, wherein the longitudinal guide rail is arranged on the transverse sliding block, the longitudinal sliding block and the longitudinal sliding block moving mechanism are both arranged on the longitudinal guide rail, and the longitudinal sliding block is connected with the longitudinal sliding block moving mechanism. The longitudinal slide block moving mechanism adopts a screw nut pair mechanism. The longitudinal guide rail is provided with a longitudinal locking screw for locking the position of the longitudinal sliding block, and the longitudinal guide rail is also provided with a longitudinal scale for observing the position of the longitudinal sliding block.
The prism X-direction moving mechanism comprises an X-direction guide rail, an X-direction sliding block and an X-direction sliding block moving mechanism, wherein the X-direction sliding block and the X-direction sliding block moving mechanism are arranged on the X-direction guide rail, and the X-direction sliding block is connected with the X-direction sliding block moving mechanism. The X-direction sliding block moving mechanism adopts a screw nut pair mechanism. An X-direction locking screw for locking the position of the X-direction sliding block is arranged on the X-direction guide rail.
The prism Y-direction moving mechanism comprises a Y-direction guide rail, a Y-direction sliding block and a Y-direction sliding block moving mechanism, wherein the Y-direction sliding block and the Y-direction sliding block moving mechanism are arranged on the Y-direction guide rail, and the Y-direction sliding block is connected with the Y-direction sliding block moving mechanism. The Y-direction slide block moving mechanism adopts a screw nut pair mechanism, and a Y-direction locking screw for locking the position of the Y-direction slide block is arranged on the Y-direction guide rail.
The prism Z-direction moving mechanism comprises a Z-direction guide rail, a Z-direction sliding block and a Z-direction sliding block moving mechanism, wherein the Z-direction sliding block and the Z-direction sliding block moving mechanism are arranged on the Z-direction guide rail, and the Z-direction sliding block is connected with the Z-direction sliding block moving mechanism. The Z-direction sliding block moving mechanism adopts a screw-nut pair mechanism, and a Z-direction locking screw for locking the position of the Z-direction sliding block is arranged on the Z-direction guide rail.
The annular light source is connected with the double telecentric lens, and images of abrasion information of the surface of the cutter are acquired by utilizing illumination of the front light source so as to prepare for subsequent image processing.
The prism is arranged on a Z-direction sliding block of the prism Z-direction moving mechanism, so that collection of the bottom sharpening damage image of the cutter is completed, and collection of the bottom edge and the side edge of the cutter is integrated in one camera, so that the volume of the device is reduced.
The detection method of the CCD-based cutter grinding damage on-line detection device comprises the following steps:
(1) The whole device is arranged on a machine tool workbench, so that the whole device moves along with the X-axis and Y-axis of the machine tool;
(2) Switching on a power supply, connecting the CCD industrial camera with an industrial personal computer and a display, and turning on an annular light source;
(3) The machine tool is adjusted, the cutter is lifted, and then the X-axis workbench of the machine tool and the Y-axis slide carriage of the machine tool are adjusted, so that the whole device runs below the cutter; the machine tool is regulated, so that the cutter descends and passes through the collecting box and is stopped above the triangular prism to finish rough adjustment;
(4) The CCD industrial camera moves up and down and moves back and forth, after calibration is finished, the CCD industrial camera is fixed, and the prism is finely adjusted, so that the CCD industrial camera is level with the prism, and fine adjustment is finished;
(5) Collecting images after the adjustment is finished, and collecting all bottom edges at one time; adjusting a triangular prism, enabling a cutter to descend, collecting side blade sharpening images, rotating the cutter, continuously collecting 4 images at different positions on each blade, and setting a rotation angle according to the rotation speed and the number of the blades to enable each blade to be collected in sequence until all side blade images are collected;
(6) And the industrial personal computer performs data processing on the acquired blade images.
The process of the industrial personal computer for processing the data of the blade part image in the step (6) is as follows: and carrying out gray level transformation and binarization preprocessing on the blade image, and then carrying out image processing on the preprocessed image by adopting a self-matching algorithm, wherein the self-matching image processing algorithm uses the information of the cutter as a reference, and the maximum abrasion value of the cutter is represented by the maximum abrasion value of each blade, and the self-matching algorithm comprises a connected domain segmentation algorithm, a rotation positioning algorithm, a local angle threshold algorithm and a least square method.
(1) And the connected domain segmentation algorithm, namely the connected domain mark, realizes the connected domain mark by scanning the binarized image line by line and detecting the connected image anticlockwise. The algorithm principle of the connected domain labeling is as follows: marking a pixel point B (i, j), a connected domain label l (i, j) of the pixel point B (i, j), and marking by adopting a 4-neighborhood connected rule, wherein B (i-1, j), B (i+1, j), B (i, j-1) and B (i, j+1) are pixel points on the upper, lower, left and right sides of the four neighborhood; when B (i, j) is scanned, B (i-1, j) and B (i, j-1) are scanned, and l (i-1, j) and l (i, j-1) are known numbers. Therefore, in the four neighborhoods, the pixel point communicating region labels l (i, j) of the B (i, j) are only related to the pixel points B (i-1, j), B (i, j-1) and the pixel point communicating region labels l (i-1, j), l (i, j-1).
Wherein: i is a pixel row; j is a pixel column; b (i, j) is the current pixel.
(2) The rotation positioning algorithm adopts a rotation algorithm based on principal component analysis (principal component analysis, PCA) to ensure that the divided blades are regularly distributed and the abrasion loss of each blade is more accurately calculated. The rotation method based on PCA carries out correction rotation according to the inclination angle of the main direction by finding the main direction of the area where the back tool face of each blade is located. The algorithm principle is as follows: assuming that the number of pixel points in the area where the rear surface is located is m, the covariance matrix A of the area is shown as formula (2).
Wherein: x is X i Is a vector of any point(s),is an average vector.
Assuming that the transformed matrix is B and the eigenvector Q, D of matrix a, the transformed matrix P can be derived from equations (3) - (8).
B＝PA, (3)
BB T ＝(PA)(PA) T ＝PAA T P T , (5)
AA T ＝QDQ T , (6)
(m-1)s(B)＝PAA T P T ＝PQDQ T P T ＝(PQ)D(PQ) T , (7)
P＝Q T , (8)
The direction angle of the transformation matrix P is the tilt angle of the main direction.
(3) The local angle threshold algorithm is to calculate the slope of each pixel point and the cutter point and realize the extraction of the cutting edge according to the local angle threshold. Tool tip coordinates O (x) 0 ,y 0 ) Any point p (x) of the flank boundary p ,y p ) Any point t (x) t ,y t ) All points satisfying the formulas (9) to (11) are cutting edges of the edge.
Wherein: θ p Is the included angle between the point p and the tool tip O;the average value of the included angles between all boundary points and the tool nose O is the degree; θ t Is the included angle between the point t and the tool nose O; θ t-1 Is the included angle between the point (t-1) and the tool tip O.
(4) And the least square method is used for carrying out fitting reconstruction on the worn cutting edges, so that the maximum wear amount of each edge is more accurate. Let any point (x, y) on the unworn cutting edge be on the formula y=αx+β, note any point k (x k ,y k ) (k=1, 2,3 … … N). The fitted cutting edge can be obtained by the formulas (12) to (14).
Wherein:the average value of the abscissa of each point of the worn cutting edge is mm; />The average value of the ordinate of each point of the worn cutting edge is mm.
The invention detects the grinding state of the cutter on line based on visual non-contact, calculates the length, width, area and the like of the cutter abrasion belt, avoids secondary clamping, and improves the precision and efficiency; the detection of the bottom and the side edges of the cutter is integrated in one camera, so that the volume of the device is reduced, the installation is convenient, the operation is simple, the manpower and material resources are saved, and the device is more suitable for intelligent manufacturing and processing.
Drawings
Fig. 1 is a schematic diagram of the internal structure of the online detection device based on the CCD cutter wear loss.
Fig. 2 is a schematic diagram of the online detection device for wear and tear based on the CCD cutter, which is installed on a machine tool.
In the figure: 1. longitudinal screw adjustment knob, 2. Longitudinal guide, 3. Longitudinal slide, 4. Longitudinal locking screw, 5. Longitudinal scale, 6. Transverse slide, 7. Transverse scale, 8. Transverse guide, 9. Transverse screw adjustment knob, 10. Transverse locking screw, 11. Base, 12. Y-screw adjustment knob, 13. Y-guide, 14. Y-slide, 15. X-locking screw, 16. X-guide, 17. X-screw adjustment knob, 18. X-slide, 19. Z-locking screw, 20. Z-slide, 21. Z-screw adjustment knob, 22. Triple prism, 23. Annular light source, 24. Double telecentric lens, 25.CCD industrial camera, 26. Brush mouth, 27. Acquisition box, 28. Machine Y-axis slide, 29. Machine X-axis table, 30. Cutter.
Detailed Description
As shown in fig. 1, the online detection device based on the abrasion and damage of the CCD cutter according to the present invention comprises a collection box 27, an industrial personal computer (not shown) and a display (not shown). The collection box 27 is mainly provided with a CCD industrial camera 25, a double telecentric lens 24, an annular light source 23, a triple prism 22, and the CCD industrial camera 25, the double telecentric lens 24, an industrial personal computer and a display are connected in sequence.
The collecting box 27 is formed by arranging a box body on the base 11, wherein the box body comprises a front box door, a rear box door, a left box door, a right box door and a top box door, each door can be opened, and a brush opening 26 for cleaning again during online detection of a cutter is arranged on the top box door. The base 11 of the collecting box 27 is provided with a camera transverse moving mechanism and a triangular prism Y-direction moving mechanism, the camera transverse moving mechanism is provided with a camera longitudinal moving mechanism, and the CCD industrial camera 25 is arranged on a longitudinal sliding block 3 of the camera longitudinal moving mechanism. The prism Y-direction moving mechanism is provided with a prism X-direction moving mechanism, the prism X-direction moving mechanism is provided with a prism Z-direction moving mechanism, and the prism 22 is mounted on a Z-direction sliding block 20 of the prism Z-direction moving mechanism.
The camera transverse moving mechanism comprises a transverse guide rail 8, a transverse sliding block 6 and a transverse sliding block moving mechanism, wherein the transverse sliding block 6 and the transverse sliding block moving mechanism are arranged on the transverse guide rail 8, the transverse sliding block 6 and the transverse sliding block moving mechanism are connected through a screw nut pair, and one end of a screw is provided with a transverse screw adjusting knob 9. The transverse guide rail 8 is provided with a transverse locking screw 10 for locking the position of the transverse slide 6. The transverse guide rail 8 is also provided with a transverse scale 7 for observing the position of the transverse slider 6 for reference for the next adjustment.
The camera longitudinal moving mechanism comprises a longitudinal guide rail 2, a longitudinal sliding block 3 and a longitudinal sliding block moving mechanism, wherein the longitudinal guide rail 2 is arranged on a transverse sliding block 6, the longitudinal sliding block 3 and the longitudinal sliding block moving mechanism are both arranged on the longitudinal guide rail 2, the longitudinal sliding block 3 and the longitudinal sliding block moving mechanism are also connected by adopting a screw-nut pair, and the upper end of a screw is provided with a longitudinal screw adjusting knob 1. The longitudinal guide rail 2 is provided with a longitudinal locking screw 4 for locking the position of the longitudinal slide block 3, and the longitudinal guide rail 2 is also provided with a longitudinal scale 5 for observing the position of the longitudinal slide block 3 so as to be used as a reference for the next adjustment.
The prism X-direction moving mechanism comprises an X-direction guide rail 16, an X-direction sliding block 18 and an X-direction sliding block moving mechanism, wherein the X-direction sliding block 18 and the X-direction sliding block moving mechanism are both arranged on the X-direction guide rail 16, the X-direction sliding block 18 and the X-direction sliding block moving mechanism are connected by adopting a screw nut pair, and one end of a screw is provided with an X-direction screw adjusting knob 17. An X-direction locking screw 15 for locking the position of the X-direction sliding block 18 is arranged on the X-direction guide rail 16.
The prism Y-direction moving mechanism comprises a Y-direction guide rail 13, a Y-direction slide block 14 and a Y-direction slide block moving mechanism, wherein the Y-direction slide block 14 and the Y-direction slide block moving mechanism are both arranged on the Y-direction guide rail 13, and the Y-direction slide block 14 and the Y-direction slide block moving mechanism are connected by adopting a screw nut pair. The Y-guide rail 13 is provided with a Y-lock screw for locking the position of the Y-slider 14.
The prism Z-direction moving mechanism comprises a Z-direction guide rail, a Z-direction sliding block 20 and a Z-direction sliding block moving mechanism, wherein the Z-direction sliding block 20 and the Z-direction sliding block moving mechanism are arranged on the Z-direction guide rail, the Z-direction sliding block 20 and the Z-direction sliding block moving mechanism are connected by adopting a screw nut pair, and one end of a screw is provided with a Z-direction screw adjusting knob 21. The Z-direction guide rail is provided with a Z-direction locking screw 19 for locking the position of the Z-direction sliding block 20.
As shown in fig. 2, the collecting tank 27 is mounted on a machine tool, and the collecting tank 27 is selected to be movable with the machine tool X-axis and Y-axis in consideration of the movability of the machine tool spindle, which is held by the machine tool itself program control to move up and down and rotate in the Z-axis. The specific process of the online detection of the cutter grinding damage is as follows:
1. the CCD industrial camera 25 is connected with the industrial computer and the display by switching on the power supply, and the annular light source switch is turned on to adjust the illumination intensity;
2. adjusting a hand wheel of a numerical control machine tool, lifting a cutter 30, and then adjusting an X-axis workbench 29 of the machine tool and a Y-axis slide carriage 28 of the machine tool to enable a collecting box 27 to run to a proper position below the cutter 30; adjusting a hand wheel of the numerical control machine tool to enable a cutter 30 to descend and pass through a hairbrush opening 26 of the upper box door and to be stopped at a position 10mm above the prism 22, so as to finish rough adjustment;
3. the longitudinal screw rod adjusting knob 1 is rotated to enable the CCD industrial camera 25 to move up and down, and the longitudinal locking screw 4 is screwed to lock the position of the longitudinal guide rail 2; the transverse screw rod adjusting knob 9 is rotated to enable the CCD industrial camera 25 to move back and forth, and the transverse locking screw 10 is screwed to fix the transverse guide rail 8; after calibration is completed, the CCD industrial camera 25 is fixed, and the three-way movement mechanism of the prism 22 is finely adjusted to enable the CCD industrial camera 25 to be flush with the prism 22, so that fine adjustment is completed;
4. collecting images after the adjustment is finished, and collecting all bottom edges at one time; and regulating a Y-direction moving mechanism and a Z-direction moving mechanism of the triangular prism, enabling the cutter 30 to descend by 30mm, collecting side blade sharpening images, enabling the cutter 30 to rotate at a low speed, continuously collecting 4 images at different positions on each blade, and setting a rotation angle according to the rotation speed and the number of the blades to enable each blade to be collected in sequence until collection of all side blade images is completed.
5. Data processing is carried out on the collected cutter grinding damage image:
and carrying out image processing on the preprocessed images such as gray level conversion, binarization and the like by adopting a self-matching algorithm. The self-matching image processing algorithm is characterized by taking the information of the cutter as a reference and the maximum abrasion value of each edge as the maximum abrasion value of each edge. The self-matching algorithm mainly comprises a connected domain segmentation algorithm, a rotation positioning algorithm, a local angle threshold algorithm and a least square method.
(1) And the connected domain segmentation algorithm, namely the connected domain mark, realizes the connected domain mark by scanning the binarized image line by line and detecting the connected image anticlockwise. The algorithm principle of the connected domain labeling is as follows: marking a pixel point B (i, j), a connected domain label l (i, j) of the pixel point B (i, j), and marking by adopting a 4-neighborhood connected rule, wherein B (i-1, j), B (i+1, j), B (i, j-1) and B (i, j+1) are pixel points on the upper, lower, left and right sides of the four neighborhood; when B (i, j) is scanned, B (i-1, j) and B (i, j-1) are scanned, and l (i-1, j) and l (i, j-1) are known numbers. Therefore, in the four neighborhoods, the pixel point communicating region labels l (i, j) of the B (i, j) are only related to the pixel points B (i-1, j), B (i, j-1) and the pixel point communicating region labels l (i-1, j), l (i, j-1).
Wherein: i is a pixel row; j is a pixel column; b (i, j) is the current pixel.
(2) A rotation positioning algorithm, which adopts a rotation algorithm based on principal component analysis (principal component analysis, PCA) to ensure that the divided blades are regularly distributed and the abrasion loss of each blade is more accurately calculated; the rotation method based on principal component analysis performs correction rotation according to the inclination angle of the principal direction by finding the principal direction of the area where the rear tool face of each blade is located. The algorithm principle is as follows: assuming that the number of pixel points in the area where the rear surface is located is m, the covariance matrix A of the area is shown as formula (2).
Wherein: xi is a vector of any point,is an average vector.
Assuming that the transformed matrix is B and the eigenvector Q, D of matrix a, the transformed matrix P can be derived from equations (3) - (8).
B＝PA, (3)
BB T ＝(PA)(PA) T ＝PAA T P T , (5)
AA T ＝QDQ T , (6)
(m-1)s(B)＝PAA T P T ＝PQDQ T P T ＝(PQ)D(PQ) T , (7)
P＝Q T , (8)
The direction angle of the transformation matrix P is the tilt angle of the main direction.
(3) The local angle threshold algorithm is to calculate the slope of each pixel point and the cutter point and realize the extraction of the cutting edge according to the local angle threshold. Tool tip coordinates O (x) 0 ,y 0 ) Any point p (x) of the flank boundary p ,y p ) Any point t (x) t ,y t ) All points satisfying the formulas (9) to (11) are cutting edges of the edge.
Wherein: θ p An included angle (°) between the point p and the tool tip O;an average value (°) of included angles between all boundary points and the tool tip O; θ t Is the included angle (DEG) between the point t and the tool tip O; θ t-1 Is the included angle (°) between the point (t-1) and the nose O.
(4) And the least square method is used for carrying out fitting reconstruction on the worn cutting edges, so that the maximum wear amount of each edge is more accurate. Providing that any point (x, y) on the unworn cutting edge is on the formula (12), recording any point k (x) on the unworn cutting edge k ,y k ) (k=1, 2,3 … … N). The fitted cutting edge can be obtained by the formulas (13) - (15).
y＝αx+β, (12)
Wherein:the average value of the abscissa of each point of the worn cutting edge is mm; />The average value of the ordinate of each point of the worn cutting edge is mm.
And comparing the abrasion loss parameter value of the cutter obtained by the algorithm with the abrasion parameter value measured by the handheld microscope to calculate an error, so that the reliability and the accuracy of the algorithm can be verified.
The invention adopts a mode of detecting the grinding damage of the cutter on line based on visual non-contact, and has high precision and high response speed. The bottom and side edge grinding detection is integrated into the same camera through an optical system consisting of a CCD industrial camera, a double telecentric lens, an annular light source, a triple prism and the like, so that the size of the device is reduced, the space of a workbench is saved, a shot image is transmitted to an industrial personal computer in real time, and the image processing technology is utilized, so that parameters such as the abrasion length, the width, the area and the like of the abrasion strips of the bottom and the side edge of a cutter are obtained, intelligent detection is realized, manpower and material resources are saved, and the processing efficiency is improved. The whole detection process is automatically completed according to the detection program, manual intervention is not needed, and the device has a simple structure, is easy to operate and master.
Claims (1)
1. Based on CCD cutter wear-and-tear on-line measuring device, characterized by: the device comprises a collecting box, an industrial personal computer and a display, wherein a CCD industrial camera, a double telecentric lens, an annular light source and a triple prism are arranged in the collecting box, and the CCD industrial camera, the double telecentric lens, the industrial personal computer and the display are sequentially connected;
the collection box comprises a base and a box body arranged on the base, the box body comprises a front box door, a rear box door, a left box door, a right box door and a top box door, an inlet for online detection of a cutter is formed in the top box door, and a hairbrush is arranged at the inlet;
a camera transverse moving mechanism and a triangular prism Y-direction moving mechanism are arranged on a base of the acquisition box, a camera longitudinal moving mechanism is arranged on the camera transverse moving mechanism, and the CCD industrial camera is arranged on the camera longitudinal moving mechanism; the prism Y-direction moving mechanism is provided with a prism X-direction moving mechanism, the prism X-direction moving mechanism is provided with a prism Z-direction moving mechanism, and the prism is arranged on the prism Z-direction moving mechanism;
the annular light source is connected with the double telecentric lens, and images of abrasion information of the surface of the cutter are acquired by utilizing illumination of the front light source so as to prepare for subsequent image processing;
the triangular prism is arranged on a Z-direction sliding block of the triangular prism Z-direction moving mechanism, so that collection of a cutter bottom sharpening damage image is completed, and collection of a cutter bottom edge and a side edge is integrated in one camera, so that the volume of the device is reduced;
the detection process of the device comprises the following steps:
(1) The whole device is arranged on a machine tool workbench, so that the whole device moves along with the X-axis and Y-axis of the machine tool;
(2) Switching on a power supply, connecting the CCD industrial camera with an industrial personal computer and a display, and turning on an annular light source;
(3) The machine tool is adjusted to lift up the cutter, and then the X-axis workbench of the machine tool and the Y-axis slide carriage of the machine tool are adjusted to enable the whole device to run below the cutter; the machine tool is regulated, so that the cutter descends and passes through the collecting box and is stopped above the triangular prism to finish rough adjustment;
(4) The CCD industrial camera is enabled to move up and down and back and forth, after calibration is completed, the CCD industrial camera is fixed, the prism is finely adjusted, the CCD industrial camera is enabled to be level with the prism, and fine adjustment is completed;
(5) Collecting images after the adjustment is finished, and collecting all bottom edges at one time; adjusting a triangular prism, enabling a cutter to descend, collecting side blade sharpening images, rotating the cutter, continuously collecting 4 images at different positions on each blade, and setting a rotation angle according to the rotation speed and the number of the blades to enable each blade to be collected in sequence until all side blade images are collected;
(6) The industrial personal computer performs data processing on the acquired blade images;
the process of the industrial personal computer for processing the data of the blade part image in the step (6) is as follows: and carrying out gray level conversion and binarization pretreatment on the blade image, and then carrying out image processing on the pretreated image by adopting a self-matching algorithm, wherein the self-matching image processing algorithm uses the information of the cutter as a reference, and the maximum abrasion value of each blade represents the maximum abrasion value of the cutter.
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| CN111069976B (en) * | 2020-01-19 | 2021-08-17 | 南京理工大学 | Intelligent mobile monitoring system and method for damage of cutter for workshop or production line |
| CN112247674B (en) * | 2020-10-10 | 2021-09-21 | 北京理工大学 | Cutter wear prediction method |
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