CN110006630B - On-site detection method based on multi-period differential sampling and high-speed point motion equipment - Google Patents
On-site detection method based on multi-period differential sampling and high-speed point motion equipment Download PDFInfo
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- CN110006630B CN110006630B CN201910285294.XA CN201910285294A CN110006630B CN 110006630 B CN110006630 B CN 110006630B CN 201910285294 A CN201910285294 A CN 201910285294A CN 110006630 B CN110006630 B CN 110006630B
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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- G06T7/0004—Industrial image inspection
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
- H04N23/00—Cameras or camera modules comprising electronic image sensors; Control thereof
- H04N23/80—Camera processing pipelines; Components thereof
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- H—ELECTRICITY
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- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
- H04N5/00—Details of television systems
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- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
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- H04N7/18—Closed-circuit television [CCTV] systems, i.e. systems in which the video signal is not broadcast
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- G06T2207/00—Indexing scheme for image analysis or image enhancement
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- G06T2207/10056—Microscopic image
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- G06T2207/30—Subject of image; Context of image processing
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Abstract
The invention relates to the field of intelligent processing, in particular to an in-place detection method based on multi-period differential sampling and high-speed point motion equipment, wherein the in-place detection method comprises the following steps: a. clamping and setting the processing raw materials and the shooting device according to requirements; b. the shooting device shoots the processing condition of the processing raw material; c. the integration processing module integrates the multiple periodic samples to obtain a sample image; d. the image processing module processes the image; e. the detection identification module identifies and analyzes the detection image; f. and establishing a digital twin model of the high-speed point motion equipment. The in-situ detection method is characterized in that a digital twin model of high-speed point location motion equipment is established through a multi-period differential sampling technology, an instruction timely downlink channel and an information real-time uplink channel are established, a visual system relative synchronization and control system absolute synchronization mechanism is adopted, equipment, a model, monitoring and system multi-view synchronization are realized, online monitoring and real-time detection are carried out, and physical equipment is fed back to be automatically adjusted in time.
Description
Technical Field
The invention relates to the field of intelligent processing, in particular to an in-place detection method based on multi-period differential sampling and high-speed point motion equipment.
Background
With the development of the mobile phone industry, the competition between mobile phone production industries is more and more intense, and how to improve the production efficiency and quality becomes one of the main research and development directions for improving the competitiveness of each production enterprise. The backlight module of the smart phone mainly comprises an LED, a light guide plate, a reflector plate, a diffusion sheet, a brightness enhancement sheet and the like, wherein the LED emits light, and the light is reintegrated through each layer structure in the backlight module, so that the content is displayed on a screen of the smart phone. The main functions of the light guide plate are to guide the direction of light, enhance the brightness intensity of the panel and determine the uniformity of light, which is a key component for determining the thickness and optical brightness uniformity of the backlight module. The light guide plate is processed by copying a light guide plate mould, a light guide plate mould core in the light guide plate mould is processed by a point hitting machine moving at a high speed, the processing precision of a microstructure array of the light guide plate mould determines the quality of the light guide plate, and a smartphone light guide plate is provided with millions of dense microstructure array mesh points, so that the processing quality and the size precision of the microstructure array micro points are ensured to enable the light guide plate to uniformly emit light. The processing of the microstructure array of the light guide plate mold core is closely related to a high-precision detection technology besides a precision processing technology.
For the microstructure array detection method, the traditional detection mode is mostly off-line detection, as shown in fig. 1, that is, a workpiece is taken down from a processing machine tool and then placed under high-precision off-line detection equipment for detection, a complete light guide plate mold core can be processed only in dozens of hours, from the time of tool setting in the test processing stage to the time of processing the whole light guide plate mold core, the light guide plate mold core is placed on the processing machine tool and cannot be taken down, because the processing conditions have changed after the microstructure array micro-point processed by the light guide plate mold core is taken down from the off-line detection of the processing machine tool and then placed back, a Y-axis adjusting platform is required to repeatedly adjust and tool setting for many times, and secondary clamping causes low processing efficiency. The diameter of the micro-point of the microstructure dense array is generally determined by an analog voltage value input by a piezoelectric ceramic driver, in order to process the required diameter of the micro-point, in the process of programming a test processing program, an analog quantity voltage value is input for a plurality of times, then the diameter of the micro-point of the microstructure is measured by an in-situ detection system, the diameter is not suitable for adjusting the input voltage value again until the required micro-structure is processed, and then the micro-point enters long-time formal point-hitting processing, so that the point-hitting machine adopting the traditional off-line detection method has low processing efficiency and the processing quality can be easily influenced by manual operation.
Disclosure of Invention
In view of the above defects, the present invention provides an in-situ detection method based on multi-period differential sampling and a high-speed point motion device, which can greatly improve the processing speed and the processing precision in the process of producing a microstructure dense array mold by the high-speed point motion device.
In order to achieve the purpose, the invention adopts the following technical scheme:
the on-site detection method based on multi-period differential sampling is applied to the processing process of high-speed point motion equipment, and comprises the following steps:
a. clamping a processing raw material for manufacturing a mold on high-speed point motion equipment, and setting a shooting device according to shooting requirements;
b. starting the high-speed point motion equipment and a shooting device, and shooting the processing raw materials obtained after a plurality of processing cycles by the shooting device to obtain a plurality of cycle samples;
c. the integration processing module samples a plurality of periods and integrates the samples into a sample image of one period by utilizing a differential sampling technology spanning the reciprocating period;
d. the image processing module processes the sample image to obtain a detection image;
e. the detection identification module identifies and analyzes the detection image to obtain detection data;
f. and the associated communication device establishes a digital twin model of the high-speed point motion equipment by using the detection data, and further synchronously detects to obtain a detection result of real-time processing of the high-speed point motion equipment.
Specifically, in the step c, the specific steps of integrating the sample image into one period by using the differential sampling technology across the reciprocating periods are as follows:
the processing period of the same processing unit on the processing path is represented by T (ms), and the sampling period of the industrial camera is set to be
Where n represents the response speed of the industrial camera with respect to the processing cycle and m is a number that averages one processing unit cycle according to the accuracy requirement of digital twin synchronization.
Preferably, n is an integer obtained by rounding up a ratio of the camera time to the processing period.
Preferably, the setting of m depends on the requirement of digital twin synchronization precision, a processing cycle is divided, m time point images are used for indirectly representing the state of processing equipment and the processing quality of the processing equipment in the processing cycle, image data acquisition is respectively carried out on a plurality of similar cycles, each cycle acquires an image of a time point, a first time point image is acquired in the first cycle, a second time point image is acquired in the second cycle, and so on, the m time point image is acquired in the last cycle, and finally m real-time states acquired in the processing process are combined into a sampling state of one cycle according to a time sequence.
Preferably, the step d of processing the sample image by the image processing module includes: and converting the sample image into a gray-scale image, and then carrying out noise reduction and contrast adjustment processing.
Preferably, the step f is followed by a judging step f1, wherein the judging device compares the detection data with the processing setting data; when the detected data exceeds the threshold value set by the processing set data, the judgment result is unqualified, the digital twin model feeds back and controls the high-speed point motion equipment to perform test processing, the operations of the steps b to e are completed in the process of test processing, the step f1 is performed again for judgment, and if the judgment result is still unqualified, the machine needs to be stopped for adjustment; and when the detection data does not exceed the threshold set by the processing set data, judging that the detection data is qualified, and finishing the on-site detection operation at the stage.
The high-speed point motion equipment which applies the on-site detection method based on the multicycle differential sampling comprises a processing machine tool, a shooting device, an integration processing module, an image processing module, a detection identification module and a related communication device;
the processing machine tool is used for processing the microstructure array mesh points on the processing raw material so as to obtain a light guide plate mold; the shooting device is used for shooting the processing raw materials obtained after a plurality of processing periods to obtain a plurality of period samples; the integration processing module is used for sampling a plurality of periods and integrating the sampled images into a sample image of one period by using a differential sampling technology spanning a reciprocating period; the image processing module is used for processing the sample plate image to obtain a detection image; the detection identification module is used for identifying and analyzing the detection image to obtain detection data; and the associated communication device is used for establishing a digital twin model of the high-speed point motion equipment by using the detection data, further synchronously detecting to obtain a detection result of real-time processing of the high-speed point motion equipment, and performing feedback control on the high-speed point motion equipment according to the requirement.
More specifically, the processing machine tool is a point hitting machine; the shooting device is an industrial camera.
The invention has the beneficial effects that: the invention provides an on-site detection method and high-speed point motion equipment based on multi-period differential sampling, which surround the processing and on-line detection of a light guide plate mold core, realize a high-precision on-site detection system with the precision of 2 mu m, micro-structure array processing and process improvement and error analysis and compensation in the processing process, establish a digital twin model of high-speed point motion equipment through a multi-period differential sampling technology, establish an instruction timely downlink channel and an information real-time uplink channel, adopt a visualization system relative synchronization and control system absolute synchronization mechanism to realize equipment, model, monitoring and system multi-view synchronization, perform on-line monitoring and real-time detection, and feed back physical equipment for automatic adjustment in time.
Drawings
FIG. 1 is a schematic flow chart of a conventional offline inspection method in the prior art;
FIG. 2 is a flow chart of the in-situ detection method according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a digital twin model established for in-situ detection during a process of machining a light guide plate mold by a collision point according to an embodiment of the present invention.
Detailed Description
The technical solution of the present invention is further explained by the following embodiments with reference to fig. 2 and 3.
Digital twinning: the method fully utilizes data such as a physical model, sensor updating, operation history and the like, integrates a multidisciplinary, multi-physical quantity, multi-scale and multi-probability simulation process, and finishes mapping in a virtual space so as to reflect the full life cycle process of corresponding entity equipment, and is also called as digital mirror image, digital twins or digital mapping.
The digital twin model mainly relates to a simulation model and physical equipment, the butt joint of the simulation model and the physical equipment is the key for realizing the digital twin model, the butt joint of the low-speed machining equipment model is usually bound by PLC point locations in Ethernet, and the transmission of cloud router data drives the simulation model and the physical equipment to carry out cooperative motion. Aiming at the high-speed point location motion equipment, the real-time sampling of the state of the physical motion equipment is completed by adopting a multi-period differential sampling technology, the state of the processing equipment and the processing quality are indirectly represented by using the processing equipment position and the processing precision data obtained by uniformly arranging sampling point locations in a plurality of periods, namely, the working state of the physical equipment is mapped onto a virtual simulation model in real time, and the performance of the high-speed point location motion equipment can be analyzed by the virtual model and fed back to a physical system. Thus, a digital twin model for the high-speed point location movement equipment is established. On the basis of the digital twin model, the production line can be quickly customized, high-fidelity semi-physical simulation and transparent monitoring can be carried out, the model and the system are fed back in real time according to field information, and the synchronous full-view-angle and granularity-crossing real-time monitoring of the whole line and the digital twin model operation is realized. The intelligent operation and maintenance system simulates the putting and production process, collects process data, performs statistics and analysis on equipment utilization rate, production balance rate, bottleneck process and the like in the manufacturing process, and predicts the manufacturing period and the manufacturing cost.
As shown in fig. 2, the in-place detection method based on multi-cycle differential sampling, which is applied to the machining process of a collision point machine, includes the following steps:
a. clamping a processing raw material for manufacturing a mold on high-speed point motion equipment, and setting a shooting device according to shooting requirements;
b. starting the high-speed point motion equipment and a shooting device, and shooting the processing raw materials obtained after a plurality of processing cycles by the shooting device to obtain a plurality of cycle samples;
c. the integration processing module samples a plurality of periods and integrates the samples into a sample image of one period by utilizing a differential sampling technology spanning the reciprocating period;
the high-frequency reciprocating motion of a point-of-impact machining device is generally limited by the fact that the response speed of an industrial camera is not matched with the machining process speed, the machining device can complete a plurality of work cycles when the industrial camera collects a picture, real-time monitoring of the high-frequency reciprocating motion cannot be met, multi-cycle sampling is needed, and then data of one cycle are integrated, so that a differential sampling technology crossing reciprocating cycles is provided.
d. The image processing module processes the sample image to obtain a detection image;
e. the detection identification module identifies and analyzes the detection image to obtain detection data;
f. and the associated communication device establishes a digital twin model of the high-speed point motion equipment by using the detection data, and further synchronously detects to obtain a detection result of real-time processing of the high-speed point motion equipment.
The specific method for integrating the differential sampling technology spanning the reciprocating period into the sample image of one period in the step c is as follows: considering the particularity of the processing process path, the processing period of the same processing unit on the processing path is represented by T (ms), and the sampling period of the industrial camera is set to be
n is determined by the response speed of the industrial camera and m is a number that averages one processing unit cycle according to the accuracy requirement of digital twin synchronization.
According to the method, different sampling points are skillfully arranged at intervals, the parameter n is mainly used for solving the problem of low response speed of the industrial camera, a plurality of periods may already run in the processing process within one response time of the industrial camera, n is the ratio of the response time of the camera to the processing period and is rounded upwards, and the acquisition period of the industrial camera is set as
Can ensureThe work period of the industrial camera is longer than the response time, the industrial camera can work normally, and the work period is shown in the formula
The stepping effect can be realized, so that the distance between each sampling point and the processing starting point is increased by a certain distance in an equal difference manner, and the difference meaning is achieved; the setting of m depends on the requirement of digital twin synchronous precision, a processing cycle is divided, m time point images are used for indirectly representing the state and the processing quality of processing equipment in the processing cycle, image data acquisition is respectively carried out on a plurality of similar cycles, an image of a time point is acquired in each cycle, a first time point image is acquired in the first cycle, a second time point image is acquired in the second cycle, an mth time point image is acquired in the last cycle, m real-time states acquired in the processing process are finally combined according to a time sequence, the position and the processing precision data of the processing equipment obtained by uniformly arranging sampling points in the plurality of cycles are used for indirectly representing the state and the processing quality of the processing equipment, namely the working state of the physical equipment is mapped to a virtual simulation model in real time, and the existing wireless, high-speed and high-speed are solved, The method can realize digital twinning of high-frequency reciprocating motion, can establish a digital twinning model of high-speed motion equipment, and realizes feedback of a virtual space to physical equipment.
The digital twinborn model established by the cross-period differential sampling technology can monitor high-speed processing equipment in real time, solve the synchronization problem caused by low response speed of an industrial camera, realize digital twinning in the process of high-frequency reciprocating motion, realize visualization pair synchronization and control absolute synchronization.
The step of processing the sample image by the image processing module in the step d comprises the following steps: and converting the sample image into a gray-scale image, and then carrying out noise reduction and contrast adjustment processing.
A judging step f1 is carried out after the step f, and the judging device compares the detection data with the processing setting data; when the detected data exceeds the threshold value set by the processing set data, the judgment result is unqualified, the digital twin model feeds back and controls the high-speed point motion equipment to perform test processing, the operations of the steps b to e are completed in the process of test processing, the step f1 is performed again for judgment, and if the judgment result is still unqualified, the machine needs to be stopped for adjustment; and when the detection data does not exceed the threshold set by the processing set data, judging that the detection data is qualified, and finishing the on-site detection operation at the stage.
The high-speed point motion equipment which applies the on-site detection method based on the multicycle differential sampling comprises a processing machine tool, a shooting device, an integration processing module, an image processing module, a detection identification module and a related communication device;
the processing machine tool is used for processing the microstructure array mesh points on the processing raw material so as to obtain a light guide plate mold; the shooting device is used for shooting the processing raw materials obtained after a plurality of processing periods to obtain a plurality of period samples; the integration processing module is used for sampling a plurality of periods and integrating the sampled images into a sample image of one period by using a differential sampling technology spanning a reciprocating period; the image processing module is used for processing the sample plate image to obtain a detection image; the detection identification module is used for identifying and analyzing the detection image to obtain detection data; and the associated communication device is used for establishing a digital twin model of the high-speed point motion equipment by using the detection data, further synchronously detecting to obtain a detection result of real-time processing of the high-speed point motion equipment, and performing feedback control on the high-speed point motion equipment according to the requirement.
The processing machine tool is a point hitting machine; the shooting device is an industrial camera. In the embodiment, a digital twinning model based on multi-period differential sampling and a point-of-impact machine is provided by taking a point-of-impact machining micro-perforation system as a realization scene.
Aiming at the defects of the traditional offline detection mode in the prior art, the invention mainly researches a high-precision in-situ detection system with the precision of 2 mu m, micro-structure array processing and process improvement and error analysis and compensation in the processing process around the processing and online detection of the light guide plate mold core, establishes a digital twin model of high-speed point location motion equipment through a multi-period differential sampling technology, establishes a command timely downlink channel and an information real-time uplink channel, adopts a relative synchronization of a visualization system and an absolute synchronization mechanism of a control system to realize the synchronization of the equipment, the model, the monitoring and the system multiple views, carries out online monitoring and real-time detection, and feeds back physical equipment for automatic adjustment in time.
The established digital twin model is applied to the on-line detection of the microstructure mesh point processing, so that the problems of time and resource waste caused by the fact that the processing position needs to be determined again in the off-line detection are solved, and the stamping speed and the positioning accuracy (the two most important indexes in batch production) of the micro point processed on the optimized digital twin model machine tool are superior to those of an original sample machine.
The improvement is that a digital twinning method is adopted in the traditional point collision machine, a differential sampling technology is adopted in the image acquisition process of an in-place detection process, and the proposed digital twinning model directly performs logic verification and control in a digital model of the point collision machine equipment, so that the fault reason is quickly positioned, and whether the system can meet the quality control requirement is actively checked. Therefore, after the digital twinning is realized, the positioning accuracy of the initial striking point machine tool is improved from 4.0m to 2.0 m. The stamping speed is improved from 20-25 o ' clock seconds to 20-65 o ' clock seconds, which is also better than 20-40 o ' clock seconds of the main machine tool. The processing experimental result is in accordance with the actual requirement, which shows that the developed digital twin system is suitable for the micro-point processing of the ultra-precision machine tool. The traditional compensation strategy of the dot detection directly determines the displacement output of the piezoelectric ceramic through analog input. However, in the proposed digital twinning process compensation, the nonlinearity of the piezo-ceramic is compensated by the on-line optimized input value of the piezo-ceramic, and the use of the digital twinning model helps the hit point machine to make more intelligent control decisions. The digital twin system platform may optimize the dynamic execution mechanism. The performance of the whole collision point machine can be virtually analyzed and fed back to a physical system. Once the performance is insufficient, the operations may be adjusted and iterated until an optimum condition is obtained. And forming a device-level context-aware solution, evaluating and making all control decisions of the machine by using a context analysis method, and supporting online optimization of performance indexes. The proposed dotting machine model is relatively flexible, which provides a large option variant to meet individual requirements by having different individualized machining parameters and quality requirements for the online setup of each dotting machine.
The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.
Claims (7)
1. The on-site detection method based on multi-period differential sampling is applied to the processing process of high-speed point motion equipment, and is characterized by comprising the following steps of:
a. clamping a processing raw material for manufacturing a mold on high-speed point motion equipment, and setting a shooting device according to shooting requirements;
b. starting the high-speed point motion equipment and a shooting device, and shooting the processing raw materials obtained after a plurality of processing cycles by the shooting device to obtain a plurality of cycle samples;
c. the integration processing module samples a plurality of periods and integrates the samples into a sample image of one period by utilizing a differential sampling technology spanning the reciprocating period;
d. the image processing module processes the sample image to obtain a detection image;
e. the detection identification module identifies and analyzes the detection image to obtain detection data;
f. the related communication device is used for establishing a digital twin model of the high-speed point motion equipment by using the detection data, and further synchronously detecting to obtain a detection result of real-time processing of the high-speed point motion equipment;
in the step c, the specific steps of integrating the sample images into a sample image of one cycle by using a differential sampling technology spanning the reciprocating cycle are as follows:
processing the same processing unit on the processing pathThe period is denoted by T (ms), and the sampling period of the industrial camera is set to be
Where n represents the response speed of the industrial camera with respect to the processing cycle and m is a number that averages one processing unit cycle according to the accuracy requirement of digital twin synchronization.
2. The on-site detection method based on multi-cycle differential sampling according to claim 1, wherein n is an integer obtained by rounding up a ratio of a camera time to a processing cycle.
3. The on-site detection method based on multi-period differential sampling as claimed in claim 1, wherein m is set depending on the requirement of digital twin synchronization precision, a processing period is divided, m time point images are used to indirectly characterize the state of processing equipment and the processing quality of the processing equipment in the processing period, image data acquisition is respectively performed on a plurality of similar periods, each period acquires an image of a time point, a first time point image is acquired in the first period, a second time point image is acquired in the second period, and so on, the m time point image is acquired in the last period, and finally m real-time states acquired in a processing process are combined into a sampling state of one period according to a time sequence.
4. The bit detection method based on multicycle differential sampling according to claim 1, wherein the step of processing the sample image by the image processing module in step d is: and converting the sample image into a gray-scale image, and then carrying out noise reduction and contrast adjustment processing.
5. The on-site detection method based on multicycle differential sampling according to claim 1, wherein said step f is further followed by a determination step f1, wherein the determination means compares the detection data with the processing setting data;
when the detected data exceeds the threshold value set by the processing set data, the judgment result is unqualified, the digital twin model feeds back and controls the high-speed point motion equipment to perform test processing, the operations of the steps b to e are completed in the process of test processing, the step f1 is performed again for judgment, and if the judgment result is still unqualified, the machine needs to be stopped for adjustment;
and when the detection data does not exceed the threshold set by the processing set data, judging that the detection data is qualified, and finishing the on-site detection operation at the stage.
6. High-speed point motion equipment applying the on-site detection method based on multicycle differential sampling according to claims 1-5, characterized by comprising a processing machine, a shooting device, an integrated processing module, an image processing module, a detection identification module and a related communication device;
the processing machine tool is used for processing the microstructure array mesh points on the processing raw material so as to obtain a light guide plate mold;
the shooting device is used for shooting the processing raw materials obtained after a plurality of processing periods to obtain a plurality of period samples;
the integration processing module is used for sampling a plurality of periods and integrating the sampled images into a sample image of one period by using a differential sampling technology spanning a reciprocating period;
the image processing module is used for processing the sample plate image to obtain a detection image;
the detection identification module is used for identifying and analyzing the detection image to obtain detection data;
and the associated communication device is used for establishing a digital twin model of the high-speed point motion equipment by using the detection data, further synchronously detecting to obtain a detection result of real-time processing of the high-speed point motion equipment, and performing feedback control on the high-speed point motion equipment according to the requirement.
7. The high-speed point motion device of claim 6, wherein the processing machine is a point-hitting machine; the shooting device is an industrial camera.
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