CN109848989B - Robot execution tail end automatic calibration and detection method based on ruby probe - Google Patents
Robot execution tail end automatic calibration and detection method based on ruby probe Download PDFInfo
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Abstract
The invention relates to a ruby probe-based robot execution tail end automatic calibration and detection method. And establishing a robot kinematic model for analyzing the problem of tail end positioning precision deviation of a robot tail end coordinate system caused by robot tail end clamping errors. In the dynamic process of initial contact between the surface of a workpiece clamped by the tail end of the robot and the probe, utilizing a Search L instruction in an RAPID program language to finish touch stop-and-point coordinate data assignment so as to realize automatic calibration; the surface profile of the workpiece is subjected to touch searching calibration by using a fixed ruby probe, the surface profile of the workpiece before and after processing is calculated, and the calculation result is transmitted to a robot controller, so that the surface profile of the workpiece at the tail end of the robot is calculated and displayed. The invention can realize the automatic calibration of the execution tail end of the robot and automatically complete the surface profile detection before and after the workpiece is processed, and the simplified operation is beneficial to improving the processing efficiency and quality of the robot.
Description
Technical Field
The invention belongs to the technical field of industrial robots, and particularly relates to a robot execution tail end automatic calibration and detection method based on a ruby probe.
Background
The industrial robot technology is widely applied to the manufacturing and processing fields of automobiles, rail transit, aerospace and the like. In the actual machining process, due to the clamping error of the tail end of the robot, the error of a CAD (computer-aided design) model and the like, the virtual coordinate system of the workpiece in the robot simulation workstation is inconsistent with the actual coordinate system, the machining precision of the part is directly influenced, and even the dangers of interference, collision and the like are caused. In order to avoid the adverse effects, the virtual coordinate system and the actual coordinate system need to be calibrated before machining, a quick calibration is sought by calculating a conversion matrix between the two coordinate systems, and a method for automatically detecting the profile of the front surface and the rear surface of the part before machining can be realized.
At present, the calibration method of the robot system mainly comprises three methods: 1) point cloud matching with the aid of a scanner; 2) a nine-point method for calibrating the hands and eyes by using machine vision; 3) semi-active scanner-probe calibration method. The point cloud matching method has the highest precision and the best error compensation effect, but the whole workpiece needs to be scanned, so that the calculation amount is large, the data processing process is complex, and the method is basically not feasible for large-scale construction; the nine-point method for calibrating the hand and the eye by using the machine vision needs to manually operate a robot to touch a projection point for calibration, and certain manual operation errors exist; the semi-active scanner-probe calibration method is characterized in that a to-be-calibrated tail end of a robot is manually operated to be close to a scanner, the scanner scans the to-be-calibrated tail end, a visual signal is processed and transmitted to a moving device at the bottom of a probe, the probe automatically touches and searches the to-be-calibrated tail end, and calibration is completed.
Disclosure of Invention
The invention aims to provide a method for a robot to execute automatic tail end calibration and automatic part surface profile detection. The invention provides direction reference for a touch searching instruction in the automatic calibration process of subsequent similar workpieces by calculating a conversion matrix between a workpiece virtual coordinate system in a robot simulation workstation and a workpiece coordinate system in a robot actual workstation, obtains point position data on the surface contour line/surface of the workpiece by calibrating a ruby probe, and calculates the surface contour degree of the workpiece by data processing of a control cabinet.
The technical scheme adopted by the invention is as follows:
a robot execution tail end automatic calibration and detection method based on a ruby probe is characterized by comprising the following steps:
s10, establishing a simulation workstation and an actual workstation for robot calibration, machining and detection, wherein the simulation workstation and the actual workstation are used for simulation analysis of the robot tail end calibration, machining and detection processes, extracting three-dimensional point location data of robot tail end workpiece calibration, and completing automatic calibration, automatic detection off-line programming and workpiece machining track planning;
s20, determining the coordinates and the calibration points of the same type of workpieces in a simulation workstation according to surface features, enabling the robot to clamp the workpieces in the actual workstation, aligning and fixing the ruby probe, performing touch search on the corresponding calibration points, obtaining the conversion relation of the two sets of calibration points, and calculating the coordinate conversion matrix of the virtual coordinate system and the actual coordinate system of the workpieces according to the conversion relation;
s30, when workpieces of the same type are machined, importing the conversion matrix obtained in the step S20 into an actual workstation, and calculating the coordinates of a primary calibration point under the actual workstation;
s40, searching the workpiece by using the coordinates of the primary calibration point in the actual workstation, recording point location information, and determining a coordinate system of the workpiece in the actual workstation through the conversion relation between two groups of corresponding point locations in the simulation workstation and the actual workstation;
s50, in the process of automatically detecting the profile of the front and rear surfaces of the workpiece, a robot instruction is utilized to enable the robot to clamp the workpiece to be machined, corresponding contour lines/surfaces before and after the workpiece surface is machined are aligned with probes to search, the probes contact points on the contour lines/surfaces, point position coordinate data are recorded, and the profile of the front and rear surfaces of the workpiece is obtained through calculation.
As an improvement, when the workpiece is machined, calibration needs to be performed once according to step S20 for different types of workpieces, so as to obtain coordinate transformation matrices of the workpiece under the simulation workstation and the actual workstation.
As an improvement, in step S10, a robot polishing simulation workstation with the same layout as an actual workstation is built in a robot offline programming software, the robot end calibration, the machining trajectory planning, and the robot motion process detection simulation are all performed on the basis of taking the robot polishing simulation workstation as a platform for test verification, and the main devices of the simulation workstation include: industrial robot, abrasive band machine and ruby mark probe.
As an improvement, in step S20, the index point search method includes: in the calibration process of the step S20, a SearchL instruction is used to enable the robot to clamp a workpiece and perform a search contact on the ruby probe, the probe detects a touch signal in real time in the dynamic process of the search contact and transmits an IO signal to the robot controller when the contact occurs, the robot stops the search immediately after receiving the touch signal, and current point location information is assigned and recorded in the PointInEnd point location.
As an improvement, in step S20, the virtual coordinate system { N } of the workpiece and the actual coordinate system { F } of the workpiece are obtained from the calibration point locations, that is:
in the above formula, x, y and z represent three coordinate axes of the coordinate system, respectively, and nx,ox,ax ny,oy,ay nz,oz,azRespectively representing 9 parameters, n, of Euler angle rotation matrix under virtual coordinate system of workpiecex',ox',ax'ny',oy',ay'nz',oz',az' respectively represent 9 parameters, X, of Euler angle rotation matrix under actual coordinate system of workpieceF、YFAnd ZFRespectively representing the displacement of the calibration point in the directions of three coordinate axes of x, y and z, and obtaining a transformation matrix T between a virtual coordinate system { N } and an actual coordinate system { F } of the workpiece obtained by calibrating the point position, namely: { N }. T ═ F }, where T is the transformation matrix between the workpiece virtual coordinate system { N } and the workpiece actual coordinate system { F }, i.e.:
where r is a parameter of the transformation matrix and p is a translation matrix of the actual workpiece coordinate system { F } relative to the virtual workpiece coordinate system { N }.
As a modification, in step S50, the method of calculating the contour degree of the front and rear surfaces of the workpiece before machining is as follows:
s301, finishing off-line programming of surface contour line/surface touch searching calibration of the workpiece in the simulation workstation;
s302, clamping a workpiece by a robot in an actual workstation, and calibrating the contour line/surface of the front and rear surfaces of the workpiece to be machined;
s303, calculating and comparing the measured coordinate data before and after machining, and taking 2 times of the maximum absolute value of the difference value as the profile tolerance value of the part, namely:
L＝2|pi-qi|max
wherein L represents the line profile, piRepresenting the measurement coordinate data of the ith point location on the contour line after the workpiece is machined, qiAnd the coordinate data of the ith point position measurement on the contour line before the workpiece is machined are represented.
The invention has the beneficial effects that:
the invention provides a robot execution tail end automatic calibration and workpiece surface contour degree automatic detection method based on a ruby probe by utilizing the advantages of large rigidity, good durability and low cost of the ruby probe. Starting from the main reasons caused by the clamping precision deviation of the robot, a method for reducing calibration errors and saving calibration cost is sought. The invention provides a direction reference for a touch search instruction in the automatic calibration process of subsequent similar workpieces by calculating a conversion matrix between a workpiece virtual coordinate system in the robot simulation workstation and a workpiece coordinate system in the robot actual workstation.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a schematic structural diagram of an embodiment of the present invention;
FIG. 3 is a schematic diagram of a calibration transformation matrix according to an embodiment of the present invention;
FIG. 4a is a schematic diagram of automatic calibration according to an embodiment of the present invention, and FIG. 4b is a detailed diagram of automatic calibration;
fig. 5a is a schematic view of a polishing process according to an embodiment of the present invention, and fig. 5b is a detailed view of the polishing process.
In the figure: 1-abrasive belt grinding and polishing machine, 2-grinding wheel grinding machine, 3-robot, 4-ruby probe, 5-transmission shell, 6-robot control cabinet and 7-central control operation table.
Detailed Description
The invention is further described below with reference to the figures and examples.
The simulation workstation built by the invention has the same structure as an actual workstation, and comprises a sand belt grinding and polishing machine, a grinding wheel grinding machine, a robot, a ruby probe, a robot control cabinet and a central control operation platform, wherein a processing object is a transmission shell.
A robot execution tail end automatic calibration and detection method based on a ruby probe comprises the following steps:
and S10, establishing a robot calibration, machining and detection simulation workstation and an actual workstation for simulation analysis of the robot tail end calibration, machining and detection processes, extracting three-dimensional point location data of the robot tail end transmission shell calibration, and completing automatic calibration, automatic detection off-line programming and transmission shell machining track planning.
S20, determining the coordinates and the calibration points of the same type of workpieces in a simulation workstation according to the surface characteristics, then enabling the robot to clamp the workpieces in an actual workstation, aligning and fixing the ruby probe, performing touch search on the corresponding calibration points to obtain the conversion relation of the two sets of calibration points, and calculating the coordinate conversion matrix of the virtual coordinate system and the actual coordinate system of the workpieces according to the conversion relation, wherein the search method comprises the following steps:
in the calibration process, the robot is enabled to clamp the transmission shell to search the probe for contact by utilizing the robot command. And detecting a touch signal in real time by the probe in the dynamic contact searching process, transmitting the touch signal to the robot controller, stopping searching by the robot when the robot receives the touch signal, and recording point position information.
And S30, in the automatic detection process of the contour degree of the front and rear surfaces of the transmission shell (the processing workpiece in the embodiment), on the premise that the tail end of the robot is calibrated, the robot is enabled to clamp the transmission shell by using a robot instruction, a contour line/surface corresponding to the transmission shell before and after surface processing is searched by aligning a probe, the probe contacts a point on the contour line/surface, the coordinate data of the point position is recorded, and the contour degree of the front and rear surfaces of the transmission shell before processing is calculated.
And S40, conveying the calculation result to a robot controller to realize automatic calibration of the execution tail end of the robot and automatic detection of the contour degree of the front and rear surfaces of the transmission shell before machining.
In step S10, an ABB robot simulation software robottstudio is used to build a robot polishing simulation workstation with the same layout as the actual workstation, as shown in fig. 2, the robot execution terminal calibration, the processing track planning, and the robot motion process detection simulation are all performed on the basis of the robot polishing simulation workstation as a platform for test verification. The main equipment that it includes has: ABB IRB6700 industrial robot, an abrasive belt machine and a ruby calibration probe.
S101, under an ideal condition, the contact condition of a robot machining tool-workpiece in an actual workstation is consistent with the clamping position and the clamping posture of a workpiece at the tail end of a robot in a simulation workstation, but due to the clamping error of the tail end of the robot, a certain translational and rotational deviation is inevitably generated between a virtual coordinate system of the workpiece and an actual coordinate system of the workpiece, and the deviation can be expressed by a conversion matrix T;
s102, establishing a transformation relation { N } · T ═ F } between the virtual coordinate system { N } and the actual coordinate system { F } from the marked virtual coordinate system { N } and the actual coordinate system { F }, and obtaining a transformation matrix T, where a schematic diagram of the transformation matrix T is shown in fig. 3;
and S103, when the actual coordinate system of the workpiece with the same shape is calibrated subsequently, after the virtual coordinate system { N } of the workpiece is calibrated in the simulation workstation, the actual coordinate system { F } of the workpiece is calculated out as an automatic searching direction by { N }. T ═ F } to perform automatic calibration.
In the calibration process of step S20, the robot clamps the transmission housing and makes a probing contact with the ruby probe by using the SearchL command, and the calibration process is schematically illustrated in fig. 4a and 4 b. And detecting a touch signal in real time by the probe in the dynamic contact searching process, transmitting an IO signal to the robot controller when the contact occurs, stopping searching immediately after the robot receives the signal, assigning the current point location information and recording the current point location information in the PointInEnd point location.
S201, a workpiece virtual coordinate system { N } can be obtained through calibration of a transmission shell point position in a simulation workstation, and a workpiece actual coordinate system { F } can be obtained through calibration of a workpiece point position in an actual workstation, namely:
wherein, the { N } is expressed as a virtual coordinate system of the workpiece, and is obtained by calibrating that a robot in a simulation workstation clamps the workpiece and touches a ruby probe; { F } is an actual coordinate system of the workpiece, and is obtained by calibrating when the robot in the actual workstation clamps the workpiece and touches the ruby probe;
s202, obtaining a conversion matrix T between a virtual coordinate system { N } and an actual coordinate system { F } of the workpiece through calibrating point positions, namely:
{ N }. T ═ F } equation (1)
Wherein, T is a transformation matrix between the virtual coordinate system { N } of the workpiece and the actual coordinate system { F } of the workpiece, and is composed of a rotation matrix R and a translation matrix P, that is:
then:
in the process of measuring the surface profile in step S30, on the premise that the calibration of the end of the robot is completed, the robot is made to clamp the transmission case by using the Search L command, the surface contour line/surface of the workpiece before and after machining is searched by aligning the probe, the probe contacts a point on the contour line/surface, the point position coordinate data is recorded, and the profile deviation of the surface before and after machining of the transmission case is calculated. The schematic diagram of the process of calibrating the transmission housing surface contour/surface is the same as that of fig. 4a and 4 b.
S301, completing off-line programming of the surface contour line/surface touch searching calibration of the transmission shell in the simulation workstation;
s302, clamping a transmission shell by a robot in an actual workstation, and calibrating the surface contour line/surface of the cast-forged piece before machining;
s303, grinding and polishing the surface of the transmission shell clamped at the tail end of the robot by using a fixed abrasive belt processing machine, wherein the processing schematic diagram is shown in FIGS. 5a and 5 b;
s304, clamping the transmission shell by a robot in an actual workstation, and calibrating the surface contour line/surface of the machined cast-forged piece;
s305, calculating and comparing the measured coordinate data before and after machining, and taking 2 times of the maximum absolute value of the difference value as the profile tolerance value of the part, namely:
L＝2|pi-qi|maxformula (3)
Wherein L represents the line profile, piRepresenting the measurement coordinate data of the ith point location on the contour line after the workpiece is machined, qiAnd the coordinate data of the ith point position measurement on the contour line before the workpiece is machined are represented.
In step S40, the calculation result is transmitted to the robot controller, so that automatic calibration of the end workpiece of the robot and automatic detection of the contour degree of the front and rear surfaces of the workpiece before and after machining are realized.
The invention starts from the main reasons generated by the clamping precision deviation of the robot and analyzes the method for reducing the clamping error. And on the basis of finishing the calibration, a robot instruction is utilized to enable the robot to clamp a workpiece to be machined, the surface of the workpiece is aligned with a contour line/surface corresponding to the three-dimensional model and is searched by a probe, the probe contacts points on the contour line/surface, point position coordinate data are recorded, and the deviation between the actual contour and the three-dimensional contour is calculated, so that the contour degree of the front surface and the rear surface of the workpiece before machining is automatically detected.
It will be understood that modifications and variations can be made by persons skilled in the art in light of the above teachings and all such modifications and variations are intended to be included within the scope of the invention as defined in the appended claims.
Claims (5)
1. A robot execution tail end automatic calibration and detection method based on a ruby probe is characterized by comprising the following steps:
s10, establishing a simulation workstation and an actual workstation for robot calibration, machining and detection, wherein the simulation workstation and the actual workstation are used for simulation analysis of the robot tail end calibration, machining and detection processes, extracting three-dimensional point location data of robot tail end workpiece calibration, and completing automatic calibration, automatic detection off-line programming and workpiece machining track planning;
s20, determining the coordinates and the calibration points of the same type of workpieces in a simulation workstation according to surface features, enabling the robot to clamp the workpieces in the actual workstation, aligning and fixing the ruby probe, performing touch search on the corresponding calibration points, obtaining the conversion relation of the two sets of calibration points, and calculating the coordinate conversion matrix of the virtual coordinate system and the actual coordinate system of the workpieces according to the conversion relation;
s30, when workpieces of the same type are machined, importing the conversion matrix obtained in the step S20 into an actual workstation, and calculating the coordinates of a primary calibration point under the actual workstation;
s40, searching the workpiece by using the coordinates of the primary calibration point in the actual workstation, recording point location information, and determining a coordinate system of the workpiece in the actual workstation through the conversion relation between two groups of corresponding point locations in the simulation workstation and the actual workstation;
s50, in the automatic detection process of the contour degree of the front and rear surfaces of the workpiece, a robot instruction is utilized to enable the robot to clamp the workpiece to be machined, corresponding contour lines/surfaces before and after the workpiece surface is machined are searched by aligning probes, the probes contact points on the contour lines/surfaces, point position coordinate data are recorded, and the contour degree of the front and rear surfaces of the workpiece is obtained through calculation;
in step S50, the method for calculating the contour degree of the front and rear surfaces of the workpiece before machining is as follows:
s301, finishing off-line programming of surface contour line/surface touch searching calibration of the workpiece in the simulation workstation;
s302, clamping a workpiece by a robot in an actual workstation, and calibrating the contour line/surface of the front and rear surfaces of the workpiece to be machined;
s303, calculating and comparing the measured coordinate data before and after processing, and taking 2 times of the maximum absolute value of the difference value as the profile tolerance value of the workpiece, namely:
L＝2|pi-qi|max
wherein L represents a profile error value, piRepresenting the measurement coordinate data of the ith point location on the contour line after the workpiece is machined, qiAnd the coordinate data of the ith point position measurement on the contour line before the workpiece is machined are represented.
2. The robot-implemented end automatic calibration and detection method of claim 1, wherein: when the workpieces are machined, calibration needs to be performed once according to step S20 for different types of workpieces, so as to obtain coordinate transformation matrices of the workpieces under the simulation workstation and the actual workstation.
3. The robot-implemented end automatic calibration and detection method of claim 1, wherein: in step S10, a robot polishing simulation workstation with the same layout as the actual workstation is built in the robot offline programming software, the robot end calibration, the processing track planning, and the robot motion process detection simulation are all performed by taking the robot polishing simulation workstation as a platform basis for test verification, and the main equipment of the simulation workstation includes: industrial robot, abrasive band machine and ruby mark probe.
4. The robot-implemented end automatic calibration and detection method of claim 3, wherein: in step S20, the method for searching for the index point includes: in the calibration process of the step S20, a SearchL instruction is used to enable the robot to clamp a workpiece and perform a search contact on the ruby probe, the probe detects a touch signal in real time in the dynamic process of the search contact and transmits an IO signal to the robot controller when the contact occurs, the robot stops the search immediately after receiving the touch signal, and current point location information is assigned and recorded in the PointInEnd point location.
5. The robot-implemented end automatic calibration and detection method of claim 4, wherein: in step S20, the virtual coordinate system { N } of the workpiece and the actual coordinate system { F } of the workpiece are obtained from the calibration point locations, that is:
in the above formula, x, y and z represent three coordinate axes of the coordinate system, respectively, and nx,ox,ax ny,oy,ay nz,oz,azRespectively representing 9 parameters, n, of Euler angle rotation matrix under virtual coordinate system of workpiecex',ox',ax'ny',oy',ay'nz',oz',az' respectively represent 9 parameters, X, of Euler angle rotation matrix under actual coordinate system of workpieceF、YFAnd ZFRespectively representing the displacement of the calibration point in the directions of three coordinate axes of x, y and z, and obtaining a transformation matrix T between a virtual coordinate system { N } and an actual coordinate system { F } of the workpiece obtained by calibrating the point position, namely: { N }. T ═ F }, where T is the transformation matrix between the workpiece virtual coordinate system { N } and the workpiece actual coordinate system { F }, i.e.:
where r is a parameter of the transformation matrix and p is a translation matrix of the actual workpiece coordinate system { F } relative to the virtual workpiece coordinate system { N }.
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| CN110900379B (en) * | 2019-11-26 | 2021-08-17 | 华中科技大学 | Robot abrasive belt grinding and polishing processing method for compressor blade |
| CN113360964A (en) * | 2021-08-09 | 2021-09-07 | 武汉理工大学 | Convergence type binocular vision guided robot positioning method under high dynamic range |
| CN114012724B (en) * | 2021-11-02 | 2024-04-05 | 上海发那科机器人有限公司 | Automatic calibration method for industrial robot coordinate system based on probe |
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