CN109030384B - Method for monitoring polishing quality on line - Google Patents

Method for monitoring polishing quality on line Download PDF

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CN109030384B
CN109030384B CN201810725616.3A CN201810725616A CN109030384B CN 109030384 B CN109030384 B CN 109030384B CN 201810725616 A CN201810725616 A CN 201810725616A CN 109030384 B CN109030384 B CN 109030384B
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polishing
grinding
pixel value
quality
qualified
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CN109030384A (en
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李红军
孙立冬
孟玉华
于荣
赵福龙
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AVIC Beijing Aeronautical Manufacturing Technology Research Institute
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AVIC Beijing Aeronautical Manufacturing Technology Research Institute
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/17Systems in which incident light is modified in accordance with the properties of the material investigated
    • G01N21/25Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands
    • G01N21/27Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands using photo-electric detection ; circuits for computing concentration
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84Systems specially adapted for particular applications
    • G01N21/88Investigating the presence of flaws or contamination
    • G01N21/95Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
    • G01N21/9515Objects of complex shape, e.g. examined with use of a surface follower device

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  • Engineering & Computer Science (AREA)
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  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Abstract

The invention relates to a method for monitoring polishing quality on line. The method comprises the following steps: setting the pixel value of the surface color which is qualified in grinding as a standard pixel value for judging that the grinding quality is qualified; collecting different pixel values of a polished monitoring area through a visual detection system; comparing and judging the obtained different pixel values with the standard pixel value, judging that the polishing quality is qualified when the obtained different pixel values fall within the judgment range of the standard pixel value, and judging that the polishing quality is unqualified when the obtained different pixel values fall outside the judgment range; for unqualified monitoring areas, when the pixel value is smaller than the minimum value of the judgment range, the repeated polishing condition is met, and when the pixel value is larger than the maximum value of the judgment range, the repeated polishing condition is not met; the quality of polishing is qualified, keeps former polishing parameter and polishes to next polishing region, to satisfying repeated polishing, adjusts the polishing parameter and repeatedly polishes until qualified, to not being conform to the unqualified monitoring region of repeated polishing, stops the operation of polishing, and the part is scrapped.

Description

Method for monitoring polishing quality on line
Technical Field
The invention relates to the technical field of surface polishing of curved surface parts, in particular to a method for monitoring polishing quality on line.
Background
In the aircraft manufacturing process, the method is applied to a plurality of structural parts made of various types of space curved composite materials (such as carbon fiber and glass fiber), and the surfaces of the structural parts need to be ground before the structural parts are sprayed. Sanding generally involves two processes: one is to directly polish the resin layer with the thickness of about 0.01-0.15 on the outer surface of the carbon fiber layer on the surface of the part, and the resin layer is polished without damaging the fiber layer; the other is to polish the manually-coated shrinkage cavity and pinhole putty packing layer on the outer surface of the resin layer, and the thickness is not uniform, so that the surface before the putty coating is not damaged after polishing (only the putty layer is polished).
To ensure the automatic grinding quality, two problems are mainly solved: firstly, how to control the thickness precision when polishing at every turn, secondly how to measure resin layer or packing layer thickness before polishing, confirm the parameter of polishing according to the thickness value, perhaps detect through the surface quality of polishing, after reaching the requirement for quality, can stop polishing. The first problem has been solved by another patented technology of the present inventors. The second problem is that it is difficult to measure the thickness by the prior art, and a better method must be found to control the polishing thickness value and perform online detection on the surface quality after polishing, so as to solve the problem of robot automatic polishing.
At present, two kinds of manual processes of polishing that mainly adopt, manual polishing controls the quality of polishing through range estimation polishing surface colour, judges through polishing surface colour at the in-process of polishing, and the judgement result divide into three kinds: insufficient grinding, qualified grinding and unqualified grinding (the fiber layer is damaged). And (4) polishing the part which is not polished sufficiently according to the prior experience. Because of serious dust and noise pollution, low efficiency, high labor cost and unstable polishing quality in the manual polishing process, the automatic polishing is the main trend of future development, and a more accurate and efficient method for detecting the polishing quality is required,
accordingly, the inventors provide a method for on-line monitoring of sanding quality.
Disclosure of Invention
The embodiment of the invention provides a method for monitoring polishing quality on line, which can be used for carrying out color identification on the surface quality after polishing, judging the polishing quality through a color pixel value and planning a next polishing procedure according to a monitoring result, thereby realizing high-quality automatic polishing on the surface of a composite structural member and solving the problem of unstable quality of the conventional manual polishing.
The embodiment of the invention provides a method for monitoring polishing quality on line, which comprises the following steps:
setting a standard pixel value, taking the pixel value of the polished qualified surface color as an inspection standard, and setting the pixel value as the standard pixel value for judging the polished qualified quality;
collecting pixel values of a monitoring area, and collecting the color of the polished surface through a visual detection system in the polishing process to obtain different pixel values of the monitoring area;
judging whether the polishing quality is qualified or not, comparing and judging the obtained different pixel values of the monitoring area with the set standard pixel value, judging that the polishing quality of the monitoring area is qualified when the pixel value of the monitoring area is within the judging range of the standard pixel value, and judging that the polishing quality of the monitoring area is unqualified when the pixel value difference of the monitoring area is outside the judging range of the standard pixel value;
judging whether repeated polishing is met, judging that the unqualified monitoring area meets repeated polishing conditions when the pixel value of the polished surface color of the monitoring area judged to be unqualified is smaller than the minimum value of the judgment range of the standard pixel value, and judging that the unqualified monitoring area does not meet the repeated polishing conditions when the pixel value is larger than the maximum value of the judgment range of the standard pixel value;
and processing the judgment result, keeping the original polishing parameters to polish the next polishing area for the monitoring area judged to be qualified in polishing quality, adjusting the polishing parameters to polish the monitoring area repeatedly until the monitoring area is qualified for the unqualified monitoring area judged to be qualified in repeated polishing, and terminating the polishing operation and scrapping the part for the unqualified monitoring area judged to be not qualified in repeated polishing.
Further, the pixel value of the color of the polished qualified surface is a, the judgment range of the standard pixel value is X, X belongs to [ a-b, a + b ], wherein a > b, and a and b are positive integers.
Furthermore, the vision detection system comprises a CCD color camera and a multispectral light source, wherein the multispectral light source and the CCD color camera are both arranged beside the polishing head through a mounting frame, and the multispectral light source is arranged right below the CCD color camera.
Furthermore, the polishing head and the mounting frame of the vision detection system are detachably mounted at the output end of the constant force actuator of the automatic polishing robot.
Further, the vision detection system is installed on the multi-coordinate moving mechanism through an installation frame and used for collecting the color of the polished surface after polishing and obtaining the pixel value of the polished surface.
Further, the method for collecting the pixel values of the monitoring area further comprises the steps of carrying out multispectral shooting on the monitoring area through the multispectral light source, and obtaining different pixel values for color analysis according to the gray level image which is shot for 8 times while changing the wavelength.
Further, the method for judging whether the grinding quality is qualified further comprises the steps of setting an unqualified alarm signal, and triggering the unqualified alarm signal when judging the detection area with unqualified grinding quality.
Further, the method for judging whether the repeated grinding is met also comprises the steps of setting a part scrapping alarm signal, and triggering the part scrapping alarm signal when the part scrapping alarm signal is judged not to meet the unqualified monitoring area of the repeated grinding.
Further, the method for processing the judgment result further comprises the steps of recording the position information of the monitoring region for the unqualified monitoring region which meets the repeated polishing condition, and adjusting polishing parameters to continuously polish the detection region, wherein the adjustment of the polishing parameters at least comprises the steps of increasing polishing positive pressure, increasing the rotating speed of a polishing head or reducing the feeding speed of the polishing head.
Further, the method for processing the judgment result further comprises the steps of terminating the grinding operation on the unqualified monitoring area which does not accord with the repeated grinding condition, and after the part is scrapped, adjusting grinding parameters to grind the next part, wherein the adjustment of the grinding parameters at least comprises the steps of reducing the grinding positive pressure, reducing the rotating speed of the grinding head or increasing the feeding speed.
In conclusion, the robot automatic grinding is provided with the visual detection system carrying the multi-spectrum mode, the grinding state of the surface of the part is distinguished through a color camera binarization color identification method, the qualified surface color after grinding is accurately calibrated by the pixel value (plus tolerance range), in the grinding process, the camera can track the surface of the ground surface of the grinding head in real time to shoot, the detected ground surface pixel value is compared with the qualified surface pixel value in real time, the comparison result can be used for controlling the robot automatic grinding program in a closed-loop mode, the problems that the thickness of the coating of the surface of the composite material cannot be measured and the grinding quality cannot be measured are solved, the grinding efficiency and quality are improved, and the high-quality automatic grinding of the surface of the composite material is realized. The technology of the invention can also be used for the robot grinding quality on-line detection of plane or curved surface parts made of different materials such as wind power blades, locomotive bodies, yachts, locomotive carriages and the like.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
Fig. 1 is a schematic view of an application scenario of a method for monitoring polishing quality on line according to an embodiment of the present invention.
Fig. 2 is a schematic flow diagram of a method for on-line monitoring of grinding quality.
In the figure:
100-a robotic arm; 200-constant force actuator; 300-polishing head; 400-a visual inspection system;
401-a mounting frame; 402-CCD color camera; 403-multispectral light source; 500-a part to be polished; 600-part tooling.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following detailed description of the embodiments and the accompanying drawings are provided to illustrate the principles of the invention and are not intended to limit the scope of the invention, i.e., the invention is not limited to the embodiments described, but covers any modifications, alterations, and improvements in the parts, components, and connections without departing from the spirit of the invention.
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present application will be described in detail below with reference to the embodiments with reference to the attached drawings.
FIG. 1 is a schematic view of sanding a large-sized curved panel. As shown in the figure, taking polishing of a large-size curved plane wallboard as an example, generally, the tail end of a mechanical arm 100 of an automatic polishing robot is connected with a constant force actuator 200, a polished part 500 is installed on a part tool 600, practice proves that polishing quality is related to surface color after polishing, pixel values of different colors of a polished surface correspond to different polishing qualities, and the quality can be accurately monitored by analyzing the color of the polished surface.
Fig. 2 is a schematic diagram of a method for on-line monitoring of grinding quality according to an embodiment of the present invention. The method for monitoring the grinding quality on line is described by taking grinding of a white bottom carbon fiber filler layer as an example, and as shown in a combined figure 1 and a figure 2, the method comprises the following steps S210-S250:
step S210 is a step of setting a standard pixel value, and sets the pixel value of the qualified polished surface color as an inspection standard as a standard pixel value for judging that the polishing quality is qualified.
Step S220 is a step of collecting pixel values of the monitored area, and in the polishing process, the color of the polished surface is collected by the visual inspection system, so as to obtain different pixel values of the monitored area.
Step S230 is a step of determining whether the polishing quality is qualified, and compares the obtained different pixel values of the monitoring area with the set standard pixel value, and determines that the polishing quality of the monitoring area is qualified when the pixel value of the monitoring area falls within the determination range of the standard pixel value, and determines that the polishing quality of the monitoring area is not qualified when the pixel value difference of the monitoring area falls outside the determination range of the standard pixel value.
Step S240 is a step of determining whether or not the repeated polishing is satisfied, and for a monitoring region determined to be unqualified, when the pixel value of the polished surface color of the monitoring region is smaller than the minimum value of the determination range of the standard pixel value, determining that the unqualified monitoring region is satisfied with the repeated polishing condition, and when the pixel value is larger than the maximum value of the determination range of the standard pixel value, determining that the unqualified monitoring region is not satisfied with the repeated polishing condition.
Step S250, processing the judgment result, keeping the original polishing parameters to polish the next polishing area for the monitoring area judged to be qualified in polishing quality, adjusting the polishing parameters to polish the monitoring area until the monitoring area is qualified for the unqualified monitoring area judged to be qualified in repeated polishing, and stopping polishing operation and scrapping the part for the unqualified monitoring area judged to be not qualified in repeated polishing.
Wherein if the pixel value of the ground qualified surface color is a and the judgment range of the standard pixel value is X, X belongs to [ a-b, a + b ], wherein a > b, and a and b are positive integers. That is to say, the determination range of the qualified grinding quality is within the allowable tolerance range of the standard pixel value, and when the determination range exceeds the allowable tolerance range, the grinding quality is determined to be unqualified, whether the unqualified grinding area meets the repeated grinding condition can be further determined, when the pixel value of the color of the unqualified grinding area is smaller than the lowest value of the determination range, namely, is far smaller than the standard pixel value, the part with the qualified grinding quality can be determined to be obtained through repeated grinding, and when the pixel value of the color of the unqualified grinding area is larger than the highest value of the determination range, namely, is far larger than the standard pixel value, the grinding is excessive, and the part cannot be qualified any more and can only be scrapped.
Specifically, the vision inspection system 400 includes a CCD color camera 402 and a multispectral light source 403, the multispectral light source 403 and the CCD color camera 402 are both mounted beside the polishing head 300 through a mounting frame 401, and the multispectral light source 403 is disposed right below the CCD color camera 402.
In one embodiment, the sanding head 300 and the mounting bracket 401 of the vision inspection system 400 are removably mounted to the output of the constant force actuator 200 of the automated sanding robot. The vision inspection system 400 may further include a vision control unit, a power source for the light source, a cable for the light source, and the like.
As another embodiment, the vision inspection system 400 may be mounted on a multi-coordinate moving mechanism through a mounting block 401, and is used for acquiring the color of the polished surface after polishing, and obtaining the pixel value of the polished surface. That is, one robot may be used alone for polishing and another robot or a servo-motor controlled multi-coordinate movement mechanism may be used to mount vision inspection system 400 alone. After the robot finishes a round of polishing procedure, independent visual measurement is carried out, data analysis is carried out on the measurement result, and qualified areas, unqualified areas and regions which are not polished in place are judged, so that repeated polishing procedures can be planned again, and supplementary polishing is carried out.
In step S210, a photo taken after the grinding is qualified may be captured by the vision inspection system 400, a part of the area is extracted from the picture of the surface considered to be qualified for grinding, and registered as an extracted color, for example, for grinding of the white underfill layer, the pixel value 46258 of the color of the qualified grinding area may be registered as a standard pixel value.
In step S220, in the polishing process, the CCD color camera 402 in the vision inspection system 400 is used to follow the polishing head 300, so that multispectral high-speed shooting can be performed on the polished surface in real time, and different colors of the polished surface of the part are collected to obtain different pixel values in the monitored area. Specifically, multispectral imaging may be performed on the monitored area by the multispectral light source 403, and different pixel values are obtained for color analysis from the grayscale image obtained by performing imaging 8 times while changing the wavelength.
In step S230, for example, for polishing of the white underfill layer, the standard pixel value is 46258, the determination range of the standard pixel value can be set to be X, that is, the monitored areas with the color within the range of 46258 ± 500 pixel values after polishing are all qualified areas of polishing quality, and polishing can be continued according to the original set parameters and trajectories, and online monitoring is performed. And monitoring areas with colors outside the range of 46258 +/-500 pixel values after grinding are areas with unqualified grinding quality. In this step, can also set up unqualified alarm signal, when judging the unqualified detection area of quality of polishing, can trigger unqualified alarm signal.
In step S240, the area with unqualified polishing quality is further determined to determine whether the repeated polishing condition is met or not so that the polishing is qualified, when the pixel value is smaller than the minimum value of the determination range, the determination is made that the repeated polishing can reach the qualification through repeated polishing, the repeated polishing parameter is determined according to the value, the supplemented polishing process parameter is determined according to the pixel value difference, the parameter setting is more accurate, and the polishing quality control precision is higher. And when the pixel value is larger than the maximum value of the judgment range, judging that the part cannot be qualified by repeated grinding, discarding the part, and quickly adjusting the grinding parameters so as to grind the next part. In the step, a part scrapping alarm signal can be set, and when the part scrapping alarm signal is judged not to be in accordance with the unqualified monitoring area of repeated grinding, the part scrapping alarm signal is triggered. Can terminate polishing in advance, avoid the large-scale part to polish the time waste that the back detects unqualified and cause.
In step S250, for an unqualified monitoring region that meets the repeated polishing condition, recording position information of the monitoring region, and polishing the detection region by adjusting polishing parameters, wherein adjusting the polishing parameters at least may include adjusting manners such as increasing polishing positive pressure, increasing polishing head rotation speed, or decreasing polishing head feed speed.
And for the unqualified monitoring area which does not accord with the repeated grinding condition, stopping grinding operation, and after the part is scrapped, adjusting grinding parameters according to the pixel value to grind the next part, wherein the adjustment of the grinding parameters at least comprises reducing the positive grinding pressure, reducing the rotating speed of a grinding head or increasing the feeding speed.
The invention takes the grinding online visual detection of the white bottom carbon fiber packing layer as an example, and other materials can also be carried out according to the grinding color identification principle of the white bottom packing layer. The method is suitable for online visual detection of the surface polishing quality of all plane or curved surface parts made of different materials and in different colors. When the pixel value deviates from the pixel value of the qualified area, the next area can be continuously polished by adjusting the process parameters on line in real time, so that intelligent control can be realized, and the polishing quality and efficiency can be improved.
It should be clear that the embodiments in this specification are described in a progressive manner, and the same or similar parts in the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. The present invention is not limited to the specific steps and structures described above and shown in the drawings. Also, a detailed description of known process techniques is omitted herein for the sake of brevity.
The above description is only an example of the present application and is not limited to the present application. Various modifications and alterations to this application will become apparent to those skilled in the art without departing from the scope of this invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.

Claims (10)

1. A method for monitoring grinding quality on line is characterized by comprising the following steps:
setting a standard pixel value, taking the pixel value of the polished qualified surface color as an inspection standard, and setting the pixel value as the standard pixel value for judging the polished qualified quality;
collecting pixel values of a monitoring area, and collecting the color of the polished surface through a visual detection system in the polishing process to obtain different pixel values of the monitoring area;
judging whether the polishing quality is qualified or not, comparing and judging the obtained different pixel values of the monitoring area with the set standard pixel value, judging that the polishing quality of the monitoring area is qualified when the pixel value of the monitoring area falls within the judging range of the standard pixel value, and judging that the polishing quality of the monitoring area is unqualified when the pixel value of the monitoring area falls outside the judging range of the standard pixel value;
judging whether repeated polishing is met, judging that the unqualified monitoring area meets repeated polishing conditions when the pixel value of the polished surface color of the monitoring area judged to be unqualified is smaller than the minimum value of the judgment range of the standard pixel value, and judging that the unqualified monitoring area does not meet the repeated polishing conditions when the pixel value is larger than the maximum value of the judgment range of the standard pixel value;
and processing the judgment result, keeping the original polishing parameters to polish the next polishing area for the monitoring area judged to be qualified in polishing quality, adjusting the polishing parameters to polish the monitoring area repeatedly until the monitoring area is qualified for the unqualified monitoring area judged to be qualified in repeated polishing, and terminating the polishing operation and scrapping the part for the unqualified monitoring area judged to be not qualified in repeated polishing.
2. The method for on-line monitoring of grinding quality as claimed in claim 1, wherein the pixel value of the grinding qualified surface color is a, the determination range of the standard pixel value is X, X is [ a-b, a + b ], wherein a > b, and a and b are positive integers.
3. The method according to claim 1, wherein the vision inspection system comprises a CCD color camera and a multispectral light source, the multispectral light source and the CCD color camera are both mounted by a mounting frame beside the polishing head, and the multispectral light source is disposed directly below the CCD color camera.
4. The method of claim 3, wherein the polishing head and the mounting bracket of the vision inspection system are removably mounted to the constant force actuator output of the automated polishing robot.
5. The method of claim 3, wherein the vision inspection system is mounted on the multi-coordinate moving mechanism through a mounting frame, and is used for acquiring the color of the polished surface after polishing to obtain the pixel value of the polished surface.
6. The method of claim 3 further comprising multispectral capturing of the monitored area by said multispectral light source, wherein different pixel values are obtained for color analysis based on a gray scale image obtained by performing 8 captures while changing the wavelength.
7. The method for on-line monitoring of grinding quality as claimed in claim 1, further comprising setting a fail alarm signal in the method for determining whether grinding quality is acceptable, and triggering the fail alarm signal when determining the detection area that grinding quality is not acceptable.
8. The method for on-line monitoring of grinding quality as claimed in claim 1, wherein the method for determining whether the grinding is in accordance with the repeated grinding further comprises setting an alarm signal for part scrapping, and triggering the alarm signal for part scrapping when the unqualified monitoring area is determined not to be in accordance with the repeated grinding.
9. The method for on-line monitoring of grinding quality as claimed in claim 1, wherein the method for processing the determination result further comprises recording the position information of the unqualified monitoring area meeting the repeated grinding condition, and adjusting grinding parameters to continue grinding the detection area, wherein the adjustment of the grinding parameters at least comprises increasing grinding positive pressure, increasing grinding head rotation speed or reducing grinding head feed speed.
10. The method for on-line monitoring of grinding quality as claimed in claim 1, wherein the method for processing the determination result further comprises terminating the grinding operation for the unqualified monitoring area which does not meet the repeated grinding condition, and grinding the next part after the part is scrapped by adjusting the grinding parameters, wherein the adjustment of the grinding parameters at least comprises reducing the grinding positive pressure, reducing the grinding head rotation speed or increasing the feed speed.
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CN111774962A (en) * 2020-07-06 2020-10-16 无锡中车时代智能装备有限公司 Robot polishing control method, industrial personal computer and system for high-speed rail body end wall
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