CN110454182B - Full-face tunnel boring machine tool changing robot visual positioning structure and method - Google Patents
Full-face tunnel boring machine tool changing robot visual positioning structure and method Download PDFInfo
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- CN110454182B CN110454182B CN201910819248.3A CN201910819248A CN110454182B CN 110454182 B CN110454182 B CN 110454182B CN 201910819248 A CN201910819248 A CN 201910819248A CN 110454182 B CN110454182 B CN 110454182B
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
- E21D9/003—Arrangement of measuring or indicating devices for use during driving of tunnels, e.g. for guiding machines
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
- E21D9/06—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
- E21D9/08—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield
- E21D9/087—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield with a rotary drilling-head cutting simultaneously the whole cross-section, i.e. full-face machines
Abstract
The invention provides a full-face tunnel boring machine tool changing robot visual positioning structure and method, which are used for solving the technical problem that a hob cannot be accurately positioned in the existing automatic tool changing process. The method is based on the actual working condition of the full-section tunnel boring machine, acquires the image of the tool box through the industrial camera and the light source erected on the tool-changing robot end effector, obtains the deviation between the current pose and the calibration pose of the tool-changing robot end effector through an image processing means, and corrects the deviation, so that the tool-changing robot end effector is accurately positioned; the cost is low, the realization is easy, and the possibility is provided for the successful research and development of the automatic tool changing technology of the tool changing robot of the full-face tunnel boring machine; the full-face tunnel boring machine solves the outstanding problems of high difficulty, high risk, low efficiency and the like of manual tool changing of the full-face tunnel boring machine, and has good realizability and economy.
Description
Technical Field
The invention relates to the technical field of automatic tool changing of a full-face tunnel boring machine, in particular to a tool changing robot visual positioning structure and method of the full-face tunnel boring machine.
Background
The full-face tunnel boring machine is a large mechanized, automated and integrated tunnel excavation lining complete equipment integrating multiple technologies such as machine, electricity, light, liquid, sensing and control, and has the outstanding characteristics of high automation degree, high construction speed, safety, economy, small influence on surface subsidence and ground traffic and the like. The cutter head is a core component of the full-face tunnel boring machine, and is directly contacted with a tunnel face in the boring process of the boring machine, and a hob on the cutter head is difficult to avoid serious abrasion and needs to be replaced in time after being abraded to a certain degree. At present, the hob is basically replaced by manual operation, and the risk of hob replacement operation and time cost are very high in the face of high-pressure and high-humidity environments. Aiming at the automatic cutter changing technology of the full-face tunnel boring machine, enterprises and expert scholars at home and abroad start to carry out preliminary research, and the automatic cutter changing technology is not effectively applied to actual working conditions, wherein effective technical means are not seen at present in the research on the problem of accurate positioning of a hob in the automatic cutter changing process.
The cutter head of the full-face tunnel boring machine has the advantages of large size and weight and large inertia due to the fact that the diameter of the cutter head is more than 10 meters, and although a rotary encoder is installed on a main shaft of the cutter head, the cutter head can be stopped accurately relatively, but the cutter head is still difficult to guarantee to be accurate. For the tool changing robot, if the robot moves according to a given program path, small deviations can cause the end effector of the tool changing robot to be incapable of accurately grabbing worn hob tool holders, so that tool changing actions cannot be smoothly completed, and when the deviation is large, the end effector of the tool changing robot can be collided to generate destructive results.
Disclosure of Invention
Aiming at the technical problem that a hob cannot be accurately positioned in the existing automatic tool changing process, the invention provides a tool changing robot visual positioning structure and method of a full-face tunnel boring machine by depending on the actual working condition of the full-face tunnel boring machine, which realize the accurate positioning of a tool changing robot end actuator through an image acquisition processing means and realize the accurate tool changing action of the tool changing robot; and the cost is low, the realization is easy, and the possibility is provided for the successful research and development of the automatic tool changing technology of the tool changing robot of the full-face tunnel boring machine.
In order to achieve the purpose, the technical scheme of the invention is realized as follows: a full-face tunnel boring machine tool changing robot visual positioning structure comprises a camera device, wherein the camera device is fixed on an end effector of the tool changing robot.
The automatic hobbing cutter is characterized by further comprising a light reflecting piece, wherein the light reflecting piece is fixed on a cutter box for accommodating the hobbing cutter, the camera device is connected with an upper computer, and the upper computer is connected with the robot control system.
The number of the light reflecting pieces is at least two, and the light reflecting pieces are fixed on the front face of the knife box; the light reflecting piece comprises a light reflecting sheet, and the light reflecting sheet is fixed on the knife box through a fixing screw.
The camera device comprises an industrial camera and a camera lens, the camera lens is detachably connected to the industrial camera, and the industrial camera is fixed in the middle of a fixing claw of the tool changing robot end effector through a support.
The support is fixed with the camera light source, and the quantity of camera light source is equipped with two, and sets up respectively in the both sides of industry camera.
A visual positioning method for a cutter changing robot of a full-face tunnel boring machine comprises the following steps:
the method comprises the following steps: determining a calibration image: setting a calibration position according to the position of any one tool box, controlling the tool-changing robot end effector to move to a specific position by the robot control system, manually adjusting parameters in the robot control system to enable the tool-changing robot end effector to be right opposite to the tool box, starting an industrial camera and a camera light source by an upper computer, carrying out image acquisition on the tool box where the light reflecting piece is located, and taking the acquired image as a calibration image.
Step two: the tool changing robot end effector moves to the front face of a tool box where a hob to be disassembled is located according to a path set by a robot control system, an upper computer starts an industrial camera and a camera light source, and image acquisition is carried out on the front face of the tool box where a light reflecting piece is located;
step three: the upper computer identifies the image acquired in the second step, determines the current posture of the tool changing robot end effector, calculates the rotation angle deviation value of the current posture and the posture of the calibrated image, transmits the rotation angle deviation value to the robot control system, and adjusts the posture of the tool changing robot end effector;
step four: the industrial camera collects images of a tool box where the light reflecting piece is located after the attitude adjustment, the upper computer identifies the images after the attitude adjustment to determine the current position of the tool changing robot end effector, a distance deviation value between the current position and the calibration position of the calibration image is calculated, the upper computer transmits the distance deviation value to the robot control system, and the position of the tool changing robot end effector is adjusted by using the distance deviation value;
step five: the industrial camera collects images of a tool box where the light reflecting piece is located after position adjustment, the upper computer identifies the images after position adjustment, the current position of the tool changing robot end effector is determined, a deviation value of the current position and a calibration position of the calibration image in an XY plane is calculated, the upper computer transmits the deviation value to a robot control system, and the position of the tool changing robot end effector is adjusted by the deviation value;
step six: and finishing the pose correction of the end effector of the tool changing robot, and carrying out the next tool changing action.
The specific position is positioned on the central line of the knife box, and the distance from the specific position to the front surface of the knife box is 30-50 cm; before image acquisition, the industrial camera washes a tool box of an image to be acquired by using a patrol robot through high-pressure water, and a robot control system adjusts the position of an end effector of the tool changing robot so that the axis of the industrial camera is perpendicular to the plane where the front surface of a cutter head is located.
The number of the light reflecting pieces is 3, and the three light reflecting pieces are respectively fixed on any three corners of the knife box; the centers of the 3 reflectors are used as feature points, and the upper computer identifies the pixel coordinates of the three feature points in the field of view of the acquired image through an image processing method; and the pixel coordinates of three characteristic points in the calibration image in the visual field range are respectively A (x)A,yA)、B(xB,yB) And C (x)C,yC)。
The method for calculating the rotation angular deviation value of the current posture and the posture of the calibration image in the third step comprises the following steps:
s31: the upper computer identifies the three characteristic points in the image acquired in the step two through an image processing method to obtain pixel coordinates A of the three characteristic points in the visual field range of the tool changing robot end effector under the current posture1'(x'1A,y'1A) And B1'(x'1B,y'1B) And C1'(x'1C,y'1C)；
S32: computing
Solving the included angle of the straight line by using a vector method; in the formula [ theta ]1Is line segment AB and line segment A1′B1' the included angle of the straight line is,
is a vector of points A, B and is,
is A1′、B1' the vector of points is,
is a vector
The die of (a) is used,
is a vector
The mold of (4);
s33: included angle theta1For the rotation angle deviation value, pass through line segment AB and line segment A1′B1The slope of the straight line judges the rotation direction of the current attitude of the end effector of the tool changing robot relative to the calibration attitude, namely a line segment A1′B1If the slope of the straight line is greater than that of the straight line of the line segment AB, the rotation direction is positive, otherwise, the rotation direction is negative.
The method for calculating the distance deviation value between the current position and the calibration position of the calibration image in the fourth step comprises the following steps:
s41: the upper computer identifies the three characteristic points in the image after the posture adjustment acquired in the fourth step by an image processing method to obtain the pixel coordinates of the three characteristic points of the tool-changing robot end effector in the current position in the visual field range, wherein the pixel coordinates are A2'(x'2A,y'2A) And B2'(x'2B,y'2B) And C2'(x'2C,y'2C)；
S42: according to the principle that the photographing distance is inversely proportional to the imaging size, the distance d between the end effector of the tool changing robot and the front surface of the hob box of the hob is changed at the current position1Is calculated as:
wherein d is0For calibrating the distance between the calibration position of the image and the distance from the end effector of the tool changing robot to the front face of the tool box of the hob, A2'B2' denotes A in the currently captured image2'、B2' pixel distance of two points, AB represents the pixel distance of A, B two points in the calibration image;
s43: the deviation value of the distance between the current position and the calibration is as follows: d ═ d1-d0。
In the step five, the method for calculating the deviation value between the current position in the XY plane and the calibration position of the calibration image comprises the following steps:
step S51: the upper computer identifies the three characteristic points in the image after the position adjustment acquired in the step five through an image processing method, and pixel coordinates of the three characteristic points in the visual field range of the tool changing robot end effector at the current position are respectively A3'(x'3A,y'3A) And B3'(x'3B,y'3B) And C3'(x'3C,y'3C)；
Step S52: then, the deviation value Δ X, Δ y between the current position of the tool-changing robot end effector in the XY plane and the calibration position of the calibration image in the X direction is respectively:
calculating and respectively calculating an included angle theta between the straight line BC and the straight line B 'C' according to the principle of the step S322The angle theta between the straight line AC and the straight line A' C3Taking the angle theta1、θ2And theta3The average value of (a) is used as a rotation angle deviation value; from the principle of step S42, segment BC and segment B'2C'2And line segments AC and A'2C'2Respectively calculating a distance deviation value according to the length relation of the line segments, and taking the average value calculated three times as the final distance deviation value; and calculating the deviation value of the tool-changing robot end effector in the XY plane through the point B and the point C according to the principle in the step S52, and taking the average value calculated three times as the deviation value of the tool-changing robot end effector in the XY plane and the calibration position.
The invention has the beneficial effects that: the method solves the outstanding problems of high difficulty, high risk, low efficiency and the like of manual tool changing of the full-face tunnel boring machine, and obtains and corrects the deviation between the current pose and the calibrated pose of the tool changing robot end effector by adopting an image recognition processing method through an industrial camera and a light source erected on the tool changing robot end effector on the basis of the actual working condition of the full-face tunnel boring machine, so that the accurate positioning of the tool changing robot end effector is realized, and the accurate tool changing action of the tool changing robot is finally realized. The invention provides possibility for the accurate positioning of the end effector of the robot in the automatic tool changing process of the tool changing robot of the full-face tunnel boring machine, has good realizability and economy and lays a foundation for the successful development of the tool changing robot of the full-face tunnel boring machine.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic diagram of a full-face tunnel boring machine tool changing robot for dismounting and mounting a hob, wherein (a) is a relative position of a tool box before tool removal and an end effector of the tool changing robot, and (b) is a relative position of the tool box after tool removal and the end effector of the tool changing robot.
Fig. 2 is a schematic structural view of the tool-changing robot end effector and the camera light source device of the present invention.
Fig. 3 is a schematic structural diagram of the reflector of the present invention.
Fig. 4 is a schematic structural diagram of a camera light source device according to the present invention.
Fig. 5 is a front view of the knife box of the present invention.
FIG. 6 is a flowchart of a visual positioning method according to the present invention.
Fig. 7 is a schematic diagram of the rotation angle and distance deviation calculation of the present invention.
FIG. 8 is a schematic diagram of the calculation of the position deviation in the XY plane according to the present invention.
In the figure, 1 is an end effector of the tool changing robot, 1-1 is a fixed claw, 2 is a reflector, 2-1 is a fixed bolt, 2-2 is a reflector, 3 is a tool box, 4 is a hob base, 5 is a hob, 6 is a camera light source device, 6-1 is a bracket, 6-2 is an industrial camera, 6-3 is a camera lens, and 6-4 is a camera light source.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
Still include reflection of light piece 2, reflection of light piece 2 is fixed on the front of the tool box 3 that holds hobbing cutter 5, and reflection of light piece 2 is corresponding with camera device 6, and camera device 6 shoots the positive image of tool box 3 and can conveniently gather reflection of light piece, regard as the characteristic point with reflection of light piece 2 in the subsequent image processing, conveniently discern the image of shooing. The camera device 6 is connected with an upper computer, the size of the images shot by the camera device 6 is equal, the camera device 6 transmits the shot images on the front face of the knife box 3 to the upper computer, the upper computer performs image recognition processing, a deviation value of the current pose of the tool changing robot end effector 1 relative to the calibration pose is calculated, and the pose of the tool changing robot end effector 1 is adjusted by the tool changing robot control system according to the deviation value to be opposite to the hob seat 4.
The quantity of the light reflecting pieces 2 is at least two and the light reflecting pieces are all fixed on the front surface of the knife box 3; as shown in fig. 3, the light reflecting piece 2 comprises a light reflecting piece 2-2, the light reflecting piece 2-2 is fixed on the knife box 3 through a fixing screw 2-1, the light reflecting piece 2-2 is embedded in a fixing bolt 2-1 to prevent the light reflecting piece 2-2 from falling off under actual severe working conditions, and the light reflecting piece 2-1 is fixed at the positions of three corners on the front surface of the knife box through the fixing bolt 2-1 to serve as a feature identification point for visual positioning.
As shown in fig. 4, the camera device 6 comprises an industrial camera 6-2 and a camera lens 6-3, the camera lens 6-3 is detachably connected to the industrial camera 6-2, the industrial camera 6-2 and the camera lens 6-3 are connected through threads, the industrial camera 6-2 is fixed to the middle of a fixing claw 1-1 of the tool-changing robot end effector 1 through a support 6-1, and the support 6-1 is fixed to the fixing claw 1-1 of the tool-changing robot end effector 1 through a bolt.
The camera light sources 6-4 are fixed on the support 6-1, the number of the camera light sources 6-4 is two, and the two camera light sources are respectively arranged on two sides of the industrial camera 6-2, so that the influence of nonuniform illumination on image acquisition can be effectively eliminated, and the image data processing at the later stage is facilitated. The industrial camera 6-2 and the camera light source 6-4 are both fixed on the bracket 6-1 through screws. The upper computer is connected with the robot control system, when the robot control system detects that the tool-changing robot end effector 1 moves to a position near a preset tool-changing position, the robot control system sends a signal to the upper computer, the upper computer triggers the signal, and the industrial camera 6-2 and the camera light source 6-4 are started to collect images.
Embodiment 2, as shown in fig. 6, a method for visually positioning a tool-changing robot of a full face tunnel boring machine includes the following steps:
the method comprises the following steps: determining a calibration image: setting a calibration position according to the position of any one tool box 3, controlling the tool-changing robot end effector 1 to move to a specific position by the robot control system, manually adjusting parameters in the robot control system to enable the tool-changing robot end effector 1 to be right opposite to the tool box 3, starting an industrial camera 6-2 and a camera light source 6-4 by an upper computer, carrying out image acquisition on the tool box 3 where the reflector 2 is located, and taking the acquired image as a calibration image.
Before image acquisition, the industrial camera 6-2 washes the tool box to be acquired by using high-pressure water by an inspection robot arranged on the development machine, so that the surfaces of the tool box, the tool apron and the tool are clean, and preparation is made for next image acquisition and data processing. The tool-changing robot end effector 1 moves to the position near a tool-changing position according to a path set by a robot control system, and the robot control system adjusts the position of the tool-changing robot end effector 1 to enable the axis of the industrial camera 6-2 to be perpendicular to the plane where the front face of the cutter head 3 is located. After the tool changing robot end effector 1 reaches a preset position, the industrial camera 6-2 and the light source 6-4 are triggered to be started, and image acquisition is started. The distance between the specific position and the front face of the knife box 3 is 30-50cm and is located in the range of 1m multiplied by 1m around the center of the front face of the knife box 3, and subsequent image processing is facilitated. The number of the light reflecting pieces 2 is 3, and the three light reflecting pieces 2 are respectively fixed on any three corners of the knife box 3, as shown in fig. 5, two corners of the upper part of the knife box 3 are respectively provided with one light reflecting piece, and one corner of the lower part of the knife box 3 is provided with one light reflecting piece, so that a right triangle is formed.
And after the tool-changing robot end effector moves to a specified specific position according to a programmed path, image acquisition and data processing are started, the image recognition adopts the Canny algorithm of OpenCV to detect the contour, and characteristic center coordinates are searched. The centers of the 3 reflectors 2 are used as feature points, and the upper computer identifies the pixel coordinates of the three feature points in the field of view of the acquired image through an image processing method; and the pixel coordinates of three characteristic points in the calibration image in the visual field range are respectively A (x)A,yA)、B(xB,yB) And C (x)C,yC) Points A, B and C are pixel coordinates of three light reflecting pieces serving as three feature recognition points in a calibration image respectively, the position of the tool changing robot end effector 1 for shooting the calibration image is a calibration position, and the posture is a calibration posture. The image at points A, B and C in FIG. 7 is a calibration image, point A1'、B1' and C1The' image is an image acquired from the current position of the tool changing robot end effector 1.
Step two: the tool changing robot end effector 1 moves to the front face of a tool box 3 where a hob 5 to be disassembled is located according to a path set by a robot control system, an upper computer starts an industrial camera 6-2 and a camera light source 6-4, and image collection is conducted on the front face of the tool box 3 where the light reflecting piece 2 is located.
Acquiring an image and performing data processing, identifying and distinguishing three characteristic points, calculating an included angle between a connecting line of any two characteristic points in the current image and a connecting line of corresponding characteristic points in a calibration image to obtain a rotation angle deviation between the current posture and the calibration posture of the tool-changing robot end effector 1, transmitting a rotation angle deviation signal to a robot control system, and rotating the tool-changing robot end effector 1 to the calibration posture by the robot control system.
Step three: and (4) the upper computer identifies the image acquired in the step two, determines the current posture of the tool changing robot end effector 1, calculates the rotation angle deviation value of the current posture and the posture of the calibrated image, and transmits the rotation angle deviation value to the robot control system to adjust the posture of the tool changing robot end effector 1.
The method for calculating the rotation angular deviation value of the current posture and the posture of the calibration image in the third step comprises the following steps:
s31: the upper computer identifies the three characteristic points in the image acquired in the step two through an image processing method to obtain pixel coordinates A of the three characteristic points in the visual field range of the tool changing robot end effector 1 under the current posture1'(x'1A,y'1A) And B1'(x'1B,y'1B) And C1'(x'1C,y'1C)；
S32: computing
Solving the included angle of the straight line by using a vector method; in the formula [ theta ]1Is line segment AB and line segment A1′B1' the included angle of the straight line is,
is a vector of points A, B and is,
is A1′、B1' the vector of points is,
is a vector
The die of (a) is used,
is a vector
The mold of (4);
s33: included angle theta1For the rotation angle deviation value, pass through line segment AB and line segment A1′B1' determination of slope of straight lineThe rotation direction of the current posture of the human end effector 1 relative to the calibration posture, line segment A1′B1If the slope of the straight line is greater than that of the straight line of the selected section AB, the rotating direction is positive, otherwise, the rotating direction is negative.
Calculating and respectively calculating an included angle theta between the straight line BC and the straight line B 'C' according to the principle of the step S322The angle theta between the straight line AC and the straight line A' C3Taking the angle theta1、θ2And theta3The average value of (a) is used as the rotation angle deviation value.
Step four: the industrial camera 6-2 collects images of the tool box 3 where the light reflecting piece 2 is located after the attitude adjustment, the upper computer identifies the images after the attitude adjustment to determine the current position of the tool changing robot end effector 1, the distance deviation value between the current position and the calibration position of the calibration image is calculated, the upper computer transmits the distance deviation value to the robot control system, and the position of the tool changing robot end effector 1 is adjusted by the distance deviation value.
Acquiring an image and performing data processing, identifying and distinguishing three characteristic points, calculating the ratio of the distance between any two characteristic points of the current image to the distance between corresponding characteristic points in a calibration image, calculating the offset of the current position and the calibration position of the tool-changing robot end effector 1 according to the principle that the image acquisition distance is in inverse proportion to the image imaging size, transmitting an offset signal to a robot control system, and moving the end effector 1 to the calibration distance by the robot control system.
The method for calculating the distance deviation value between the current position and the calibration position of the calibration image in the fourth step comprises the following steps:
s41: the upper computer identifies the three characteristic points in the image after the posture adjustment acquired in the fourth step by an image processing method to obtain the pixel coordinates of the three characteristic points of the tool-changing robot end effector 1 in the current position in the visual field range, wherein the pixel coordinates are A2'(x'2A,y'2A) And B2'(x'2B,y'2B) And C2'(x'2C,y'2C)；
S42: according to the principle that the photographing distance is inversely proportional to the imaging sizeThen, the distance d between the end effector 1 of the tool changing robot and the front surface of the tool box 3 of the hob is changed at the current position1Is calculated as:
wherein d is0For calibrating the distance between the calibration position of the image and the distance from the end effector 1 of the tool changing robot to the front side of the tool box 3 of the hob, A2'B2' denotes A in the currently captured image2'、B2' pixel distance of two points, AB represents the pixel distance of A, B two points in the calibration image;
s43: the deviation value of the distance between the current position and the calibration is as follows: d ═ d1-d0。
From the principle of step S42, segment BC and segment B'2C'2And line segments AC and A'2C'2And respectively calculating a distance deviation value according to the length relation of the line segments, and taking the average value calculated three times as the final distance deviation value.
Step five: the industrial camera 6-2 collects images of the knife box 3 where the light reflecting piece 2 is located after position adjustment, the upper computer identifies the images after position adjustment, the current position of the tool changing robot end effector 1 is determined, a deviation value of the current position and a calibration position of the calibration image in an XY plane is calculated, the upper computer transmits the deviation value to the robot control system, and the position of the tool changing robot end effector 1 is adjusted by the deviation value.
The method comprises the steps of collecting an image, carrying out data processing, identifying and distinguishing three characteristic points, calculating the offset of the distance between any characteristic point in the current image and the corresponding characteristic point in a calibration image on an X axis and a Y axis, transmitting an offset signal to a robot control system, and moving the end effector 1 to a calibration position by the robot control system. In FIG. 8, the image where ABC is located is a calibration image, A3'B3'C3' the image is the image collected by the current position of the tool changing robot end effector after the adjustment of the three steps and the four positions, and A, B, C are three feature recognition points.
In the step five, the method for calculating the deviation value between the current position in the XY plane and the calibration position of the calibration image comprises the following steps:
step S51: the upper computer identifies the three characteristic points in the image after the position adjustment acquired in the step five through an image processing method, and pixel coordinates of the three characteristic points in the visual field range of the tool changing robot end effector 1 at the current position are respectively A3'(x'3A,y'3A) And B3'(x'3B,y'3B) And C3'(x'3C,y'3C)；
Step S52: then, the deviation value Δ X, Δ y between the current position of the tool-changing robot end effector 1 in the XY plane and the calibration position of the calibration image in the X direction is:
and calculating the deviation value of the tool-changing robot end effector 1 in the XY plane through the point B and the point C according to the principle in the step S52, and taking the average value calculated three times as the deviation value of the tool-changing robot end effector 1 in the XY plane and the calibration position.
Step six: and finishing the correction of the pose of the end effector 1 of the tool changing robot, and carrying out the next tool changing action.
Before tool changing, repeating the steps from two to six, accurate positioning of the tool changing robot end effector 1 can be achieved, tool removing is smoothly completed, the tool changing robot end effector 1 stores the removed old hob in a tool storage box according to a preset path of a robot control system, a new hob is taken out from another storage box, the new hob is accurately installed in the tool storage box according to the last tool removing path recorded by the robot control system, the whole tool changing process is completed, and the image acquisition and processing process can be achieved through a high-level programming language of a computer, and is easy to achieve and expand.
The invention aims to solve the outstanding problems of high difficulty, high risk, low efficiency and the like of manual tool changing of a full-face tunnel boring machine, and provides a visual positioning structure and a method of the tool changing robot of the full-face tunnel boring machine based on the actual working condition of the full-face tunnel boring machine.
The visual positioning structure of the full-face tunnel boring machine tool changing robot can realize the accurate positioning of the tool changing robot end effector and provide a structural basis for the tool changing robot to adopt the visual positioning. The invention has good realizability and economy and provides reference for the automatic tool changing technology of the tool changing robot of the full-face tunnel boring machine.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (12)
1. A full-face tunnel boring machine tool changing robot visual positioning method is characterized by comprising the following steps:
the method comprises the following steps: determining a calibration image: setting a calibration position according to the position of any one tool box (3), controlling a tool changing robot end effector (1) to move to a specific position by a robot control system, manually adjusting parameters in the robot control system to enable the tool changing robot end effector (1) to be over against the tool box (3), starting an industrial camera (6-2) and a camera light source (6-4) by an upper computer, carrying out image acquisition on the tool box (3) where the light reflecting piece (2) is located, and taking the acquired image as a calibration image;
step two: the tool changing robot end effector (1) moves to the front face of a tool box (3) where a hob (5) to be disassembled is located according to a path set by a robot control system, an upper computer starts an industrial camera (6-2) and a camera light source (6-4), and image collection is carried out on the front face of the tool box (3) where the light reflecting piece (2) is located;
step three: the upper computer identifies the image acquired in the step two, determines the current posture of the tool changing robot end effector (1), calculates the rotation angle deviation value of the current posture and the posture of the calibrated image, and transmits the rotation angle deviation value to the robot control system to adjust the posture of the tool changing robot end effector (1);
step four: the method comprises the following steps that an industrial camera (6-2) collects images of a tool box (3) where a light reflecting piece (2) is located after gesture adjustment, an upper computer identifies the images after the gesture adjustment to determine the current position of a tool changing robot end effector (1), a distance deviation value between the current position and the calibrated position of the calibrated image is calculated, the upper computer transmits the distance deviation value to a robot control system, and the position of the tool changing robot end effector (1) is adjusted by the distance deviation value;
step five: the industrial camera (6-2) collects images of a knife box (3) where the light reflecting piece (2) is located after position adjustment, the upper computer identifies the images after position adjustment, determines the current position of the tool changing robot end effector (1), calculates a deviation value between the current position and a calibration position of a calibration image in an XY plane, transmits the deviation value to the robot control system, and adjusts the position of the tool changing robot end effector (1) by using the deviation value;
step six: finishing the correction of the pose of the tool changing robot end effector (1) and carrying out the next tool changing action.
2. The positioning structure of the visual positioning method of the full face tunnel boring machine tool changing robot according to claim 1 is characterized by comprising a camera device (6), wherein the camera device (6) is fixed on an end effector (1) of the tool changing robot.
3. The positioning structure according to claim 2, further comprising a reflector (2), wherein the reflector (2) is fixed on the hob case (3) accommodating the hob (5), and the camera device (6) is connected with an upper computer.
4. The positioning structure according to claim 3, characterized in that the number of said reflectors (2) is provided with at least two, each fixed on the front face of the magazine (3); the light reflecting piece (2) comprises a light reflecting sheet (2-2), and the light reflecting sheet (2-2) is fixed on the knife box (3) through a fixing screw (2-1).
5. The positioning structure according to claim 2 or 3, wherein the camera device (6) comprises an industrial camera (6-2) and a camera lens (6-3), the camera lens (6-3) is detachably connected to the industrial camera (6-2), and the industrial camera (6-2) is fixed in the middle of a fixing claw (1-1) of the tool-changing robot end effector (1) through a bracket (6-1).
6. The positioning structure according to claim 5, characterized in that the bracket (6-1) is fixed with two camera light sources (6-4), and the two camera light sources (6-4) are respectively arranged at two sides of the industrial camera (6-2).
7. The visual positioning method of the full face tunnel boring machine tool changing robot according to claim 1, characterized in that the specific position is located on a center line of the cutter box (3), and the distance from the front face of the cutter box (3) ranges from 30cm to 50 cm; before image acquisition, the industrial camera (6-2) utilizes the inspection robot to wash a tool box of an image to be acquired by utilizing high-pressure water, and the robot control system adjusts the position of the tool changing robot end effector (1) to ensure that the axis of the industrial camera (6-2) is vertical to the plane where the front surface of the cutter head (3) is located.
8. The visual positioning method of the full face tunnel boring machine tool changing robot as claimed in claim 1 or 7, characterized in that the number of the light reflecting pieces (2) is 3, and three light reflecting pieces (2) are respectively fixed on any three corners of the cutter box (3); the centers of 3 reflectors (2) are used as characteristic points, and an upper computer recognizes through an image processing methodThe pixel coordinates of the other three characteristic points in the field of view of the acquired image; and the pixel coordinates of three characteristic points in the calibration image in the visual field range are respectively A (x)A,yA)、B(xB,yB) And C (x)C,yC)。
9. The visual positioning method for the tool-changing robot of the full face tunnel boring machine according to claim 8, wherein the method for calculating the rotation angular deviation value between the current attitude and the attitude of the calibration image in the third step is as follows:
s31: the upper computer identifies the three characteristic points in the image acquired in the step two through an image processing method to obtain the pixel coordinates A of the three characteristic points in the visual field range of the tool changing robot end effector (1) under the current posture1'(x'1A,y'1A) And B1'(x'1B,y'1B) And C1'(x'1C,y'1C)；
S32: computing
In the formula, theta1Is line segment AB and line segment A'1B′1The included angle of the straight line is formed,
is a vector of the point A and the point B,
is A'1Point, B'1The vector of the points is then calculated,
is a vector
The die of (a) is used,
is a vector
The mold of (4);
s33: included angle theta1Is a rotation angle deviation value and is defined by line segment AB and line segment A'1B′1Judging the rotation direction of the current attitude of the tool-changing robot end effector (1) relative to the calibration attitude, namely a line segment A 'from the slope of the line'1B′1The slope of the straight line is greater than the slope of the straight line of the line segment AB, the rotating direction is positive, and otherwise, the rotating direction is negative.
10. The visual positioning method for the tool changing robot of the full face tunnel boring machine according to claim 9, wherein the method for calculating the distance deviation value between the current position and the calibration position of the calibration image in the fourth step comprises the following steps:
s41: the upper computer identifies the three characteristic points in the image after the posture adjustment acquired in the fourth step by an image processing method to obtain the pixel coordinates A of the three characteristic points of the tool-changing robot end effector (1) in the current position in the visual field range2'(x'2A,y'2A) And B2'(x'2B,y'2B) And C2'(x'2C,y'2C)；
S42: according to the principle that the photographing distance is inversely proportional to the imaging size, the distance d between the end effector (1) of the tool changing robot and the front surface of the tool box (3) is changed at the current position1Is calculated as:
wherein d is0For calibrating the distance between the calibration position of the image and the distance from the end effector (1) of the tool changing robot to the front surface of the tool box (3), A2'B2' denotes A in the currently captured image2'、B2' pixel distance of two points, AB represents the pixel distance of A, B two points in the calibration image;
s43: current positionThe deviation from the nominal distance is: d ═ d1-d0。
11. The visual positioning method of the tool changing robot of the full face tunnel boring machine according to claim 10, wherein the method for calculating the deviation value of the current position from the calibration position of the calibration image in the XY plane in the step five comprises:
step S51: the upper computer identifies the three characteristic points in the image after the position adjustment acquired in the step five through an image processing method, and pixel coordinates of the three characteristic points in the visual field range of the tool changing robot end effector (1) at the current position are A respectively3'(x'3A,y'3A) And B3'(x'3B,y'3B) And C3'(x'3C,y'3C)；
Step S52: the deviation value delta X, delta y between the current position of the tool-changing robot end effector (1) in the XY plane and the calibration position of the calibration image in the X direction are respectively as follows:
12. the visual positioning method for the full face tunnel boring machine tool changing robot according to claim 11, characterized in that the included angle θ between the straight line BC and the straight line B 'C' is calculated according to the principle of step S322The angle theta between the straight line AC and the straight line A' C3Taking the angle theta1、θ2And theta3The average value of (a) is used as a rotation angle deviation value; from the principle of step S42, segment BC and segment B'2C'2And line segments AC and A'2C'2Respectively calculating a distance deviation value according to the length relation of the line segments, and taking the average value calculated three times as the final distance deviation value; calculating the deviation value of the tool-changing robot end effector (1) in the XY plane through the point B and the point C according to the principle in the step S52, and taking the average value of the three calculations as the value of the tool-changing robot end effector (1)Deviation value from the calibration position in the XY plane.
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| CN111691891B (en) * | 2020-06-30 | 2022-04-29 | 中国铁建重工集团股份有限公司 | Tool changing device for replacing hob of shield machine |
| CN113090276B (en) * | 2021-04-21 | 2021-12-03 | 中交天和机械设备制造有限公司 | Detection method and system for normal-pressure tool changing tool of shield machine |
| CN113984569A (en) * | 2021-10-26 | 2022-01-28 | 深圳市地铁集团有限公司 | Hob abrasion image identification and measurement method, hob detection system and shield machine |
| CN116475815B (en) * | 2023-05-17 | 2023-12-15 | 广州里工实业有限公司 | Automatic tool changing method, system and device of numerical control machine tool and storage medium |
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