CN110814398A - Machine vision auxiliary curved surface machining device and method - Google Patents
Machine vision auxiliary curved surface machining device and method Download PDFInfo
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- CN110814398A CN110814398A CN201911003439.9A CN201911003439A CN110814398A CN 110814398 A CN110814398 A CN 110814398A CN 201911003439 A CN201911003439 A CN 201911003439A CN 110814398 A CN110814398 A CN 110814398A
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- 238000003754 machining Methods 0.000 title claims abstract description 37
- 238000000034 method Methods 0.000 title claims abstract description 20
- 238000005520 cutting process Methods 0.000 claims abstract description 108
- 238000003801 milling Methods 0.000 claims abstract description 89
- 230000007246 mechanism Effects 0.000 claims abstract description 11
- 238000003672 processing method Methods 0.000 claims abstract description 7
- 230000000007 visual effect Effects 0.000 claims description 65
- 238000001514 detection method Methods 0.000 claims description 54
- 238000011179 visual inspection Methods 0.000 claims description 6
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
- B23C3/02—Milling surfaces of revolution
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C9/00—Details or accessories so far as specially adapted to milling machines or cutter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/22—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring existing or desired position of tool or work
- B23Q17/2233—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring existing or desired position of tool or work for adjusting the tool relative to the workpiece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2428—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring existing positions of tools or workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q3/00—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine
- B23Q3/02—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine for mounting on a work-table, tool-slide, or analogous part
- B23Q3/06—Work-clamping means
- B23Q3/062—Work-clamping means adapted for holding workpieces having a special form or being made from a special material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q7/00—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting
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Abstract
The invention discloses a machine vision auxiliary curved surface machining device and method. The device comprises a vision sensing device, a vision device adjusting mechanism, a horizontal milling machine, a workpiece conveying mechanism and a computer, wherein the vision sensing device comprises two red linear lasers, an area array camera, a lens and a filter; the area array camera collects images on the workpiece and transmits the images into the computer, and the computer sends out an instruction to command the conveying mechanism to convey the workpiece and control the milling cutter to finish curved surface cutting. The height of the milling cutter is automatically adjusted by approximately fitting the curved surface in the cutting process, and the curved surface is machined. The method is a high-efficiency curved surface processing method, adopts the line laser combined vision sensing system as a reference integral curved surface processing method for the first time, has high response speed, can accurately identify the height change of the curved surface of a workpiece, reasonably controls the cutting depth of a cutter, and can efficiently finish the curved surface processing.
Description
Technical Field
The invention relates to the technical field of mechanical automatic processing, in particular to a machine vision auxiliary curved surface processing device and a machine vision auxiliary curved surface processing method related to the processing device.
Background
In recent years, with the development of industrial automation, machine vision technology has appeared, so that the methods of machining tend to be diversified. In the prior art, complex curved surface machining is carried out by adopting a multi-axis numerical control machining center, and the numerical control machining center can meet the machining precision, shorten the machining time and efficiently and quickly finish various curved surface machining. And for some curved surface workpieces with insufficient precision requirements and large volume, if a numerical control machining center is adopted, the machining price is high. Therefore, for some curved surface workpieces with insufficient precision requirements and large volume, the curved surface machining is finished by manually operating the numerical control milling machine. The height of the milling cutter is continuously adjusted in the process of machining a curved surface workpiece by a manually operated milling machine so as to meet the machining requirement, the machining condition of the surface of the workpiece is continuously observed at the same time, excessive machining and insufficient cutting are prevented, and polishing is needed after machining is finished. Such processing methods not only waste a lot of manpower, but also do not fully meet the processing requirements. Therefore, the machine vision-assisted curved surface machining method is an efficient machining method.
Disclosure of Invention
The invention aims to improve the efficiency of the existing manual curved surface machining technology, provides a method for assisting curved surface machining based on machine vision, and particularly provides a system for assisting curved surface machining.
In order to solve the technical problems, the invention adopts the following technical scheme:
a machine vision auxiliary curved surface processing device comprises a vision detection device, a horizontal milling machine, a workpiece conveying mechanism and a workpiece clamp;
the visual detection device comprises a filter, a lens, a left side line laser adjusting plate, a line laser mounting seat, an area-array camera mounting plate, a right side line laser adjusting plate, a right side line laser, a visual detection device adjusting plate, a visual detection device box body and a visual detection device fixing frame; the area-array camera is arranged on an area-array camera mounting plate in a visual detection device box body, the upper and lower positions of the area-array camera can be adjusted, the left line laser and the right line laser are respectively arranged on a left line laser adjusting plate and a right line laser adjusting plate in the visual detection device box body and can adjust the angles, the left line laser and the right line laser are symmetrically distributed on the left side and the right side of the area-array camera mounting plate at equal intervals, and the filter glass is arranged at the lower end of the visual detection device box body; the rear end of a visual detection device fixing frame is arranged on a horizontal milling machine, the front end of the visual detection device fixing frame is connected with a visual detection device adjusting plate with an adjustable position, and a visual detection device box body is arranged on the visual detection device adjusting plate;
further, the spectrum of the line laser emitted by the left line laser and the spectrum of the line laser emitted by the right line laser are consistent with the band pass of the filter.
Furthermore, an adjusting groove is arranged on the adjusting plate of the visual detection device, and the position of the adjusting plate can be adjusted along the groove hole on the adjusting plate according to the working height requirement of the visual detection device;
furthermore, the visual detection device is positioned right above the milling cutter, and the laser line on the curved surface workpiece is always in the visual field range of the area array camera;
further, the left side line laser adjusting plate and the right side line laser adjusting plate are respectively arranged on the line laser mounting seats at two sides of the area array camera mounting plate, and the adjusting angles of the left side line laser adjusting plate and the right side line laser adjusting plate relative to the vertical direction are 30-60 degrees;
further, the horizontal milling machine is provided with a current sensor, when the cutter contacts a workpiece, the current sensor is triggered, and then the control system can acquire the position information of the cutter at the moment.
A machine vision auxiliary curved surface processing method is based on the processing device to realize curved surface processing and comprises the following steps:
Step 2: initialization and adjustment of processing equipment: adjusting the workpiece according to the working requirement to enable the workpiece to be positioned below the milling cutter, adjusting the initial position of the milling cutter to enable the distance between the initial position and the outermost side contour line of the curved surface workpiece to be L (mm), adjusting the visual sensing device to enable the visual sensing device to be positioned at a distance above the milling cutter, enabling line laser generated by the left linear laser and the right linear laser to be irradiated on the surface of the workpiece and be positioned in the middle of the visual field of the area array camera, and enabling the coincident line of the two laser lines and the cutting point at the lowest part of the milling cutter to;
and step 3: setting the theoretical cutting depth of the workpiece to be He(mm), the feeding step length of the workpiece in the X direction is S (mm); defining the cutting depth of the cutter in the vertical direction as Ha(mm), the cutting angle of the tool at the current cutting point is θ, tan (θ) ═ Xk-Xj)/((Xk+Xj) Tan (β)), when the workpiece is cut from right end to left end and the milling cutter does not reach the lowest point (the slope of cutting point is 0), the milling cutter downwards performs cutting motion at a certain speed v (mm/s) along the Y direction, the area array camera acquires images at a certain frame rate, and when the height of the milling cutter from the curved surface changesMeanwhile, the distance between the left laser line and the right laser line on the curved surface is also changed, the separation of the laser lines at the moment is called as reverse separation because the lowest end tangent point of the cutter does not contact the workpiece at the moment, and the separation of the laser lines at the moment is called as forward separation when the right lower part of the cutter contacts the workpiece;
and 4, step 4: when the milling cutter contacts a curved surface workpiece, the current sensor is excited and feeds back a signal to the control system, and the system records the current time node t1(s) the area-array camera takes the image M at this time1；
And 5: the cutter continues to move downwards, and when the image sensor detects that the laser lines on the curved surface are overlapped, the area-array camera takes down the image M at the moment2Feeding back the information to the visual inspection system, which records the current time node t2(s) calculating the vertical movement distance H of the milling cutter between the time when the cutter contacts the workpiece and the time when the laser line is coincident with the curved surfaceb，Hb＝ν*(t2-t1) After that, the cutting distance of the cutter in the vertical direction is recorded as HsThe cutter cuts vertically downwards at a certain speed until H is mete＝(Hs+Hb) Stopping cutting and moving downwards when the cos (theta) is reached, then moving the workpiece to the X negative half shaft direction by a step length s (mm), meanwhile, continuing to cut downwards by the milling cutter along the vertical direction, and executing the step 6 after the movement of the step length is completed;
step 6: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if tan (theta) is not 0 and H is less than HeI.e. not reaching the cutting depth, step 7 is executed; if tan (theta) is not 0 and H is equal to HeIf the cutting depth is reached, step 8 is executed; if tan (theta) is not 0 and H is greater than HeIf the cutting is excessive, step 9 is executed; if tan (θ) is 0, i.e. the lowest point is reached, step 10 is executed;
and 7: the milling cutter continues to cut downwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
and 8: moving the workpiece by one step length s (mm) in the direction of the negative X half shaft, simultaneously cutting the workpiece downwards along the vertical direction by the milling cutter, and executing the step 6 after the step length movement is finished;
and step 9: the milling cutter moves upwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
step 10: when the milling cutter reaches the lowest end (the slope of the cutting point is 0) of the curved surface workpiece, the area array camera acquires the laser line information on the curved surface at the moment, the cutting depth H of the current point in the vertical direction is calculated, and if the H is smaller than HeThe mill continues to cut down in the vertical direction until H equals He，HeSetting the cutting depth for the current point workpiece; if H is equal to HeThen, go to step 11;
step 11: the milling cutter upwards cuts at a certain speed in the vertical direction, meanwhile, the workpiece moves by a step length s (mm) in the direction of the negative X half axis, and after the step length movement is finished, the step 12 is executed;
step 12: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece and the information of a current sensor, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if H is less than HeAnd the cutter contacts with the workpiece to make the current sensor excited, i.e. the milling cutter does not reach the set cutting depth, then step 13 is executed; if H is equal to HeAnd the cutter contacts with the workpiece to enable the current sensor to be excited, namely the milling cutter reaches the set cutting depth, and then step 14 is executed; if H is greater than HeAnd the cutter contacts with the workpiece to make the current sensor excited, namely the milling cutter cuts excessively, then step 15 is executed; if the tool does not contact the workpiece, so that the current sensor is not excited, namely the cutting is finished, executing step 16;
step 13: the milling cutter cuts downwards along the vertical direction until H is equal to He＝(Hs+Hb) Cos (θ), then step 12 is performed;
step 14: moving the workpiece to the direction of the negative X half shaft by a step length s (mm), simultaneously cutting the workpiece upwards by the milling cutter along the vertical direction, and executing the step 12 after the step length movement is finished;
step 15: the milling cutter moves upwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 12 is performed;
step 16: and returning the milling cutter to the initial position to finish the processing of the target workpiece.
Furthermore, in the process of machining the vision-assisted curved surface of the machine, the milling cutter only carries out feeding motion in the vertical direction, the horizontal feeding motion of the workpiece is completed by the workpiece conveying mechanism, and the workpiece conveying mechanism always ensures that the workpiece finishes feeding at a certain speed and step length according to actual working requirements.
Further, the value of L in the step 2 is 20-25 mm.
After the scheme is adopted, because the machine vision auxiliary curved surface processing method is adopted, the method only needs to acquire the image of the linear laser on the surface of the curved surface workpiece when the milling cutter cuts or retracts and obtain the distance of the linear laser, and then the cutting depth (H) of the cutter at the moment can be calculated by using the formulaC) The cutting track of the milling cutter can be conveniently detected and tracked in real time; the tracking machining method overcomes the limitation of the existing manual machining, can control and detect the milling cutter constantly, has higher machining precision than manual machining, and can finish the curved surface machining efficiently.
Drawings
FIG. 1 is a schematic diagram of a machine vision-assisted curved surface machining apparatus according to the present invention;
FIG. 2 is a three-dimensional structure diagram of a machine vision-aided curved surface processing apparatus according to the present invention;
FIG. 3 is a schematic view of a partial structure of a vision inspection apparatus of a machine vision-aided curved surface processing apparatus according to the present invention;
FIG. 4 is a schematic view of the initial cutting process of the tool according to the present invention;
FIG. 5 is a schematic diagram of the calculation of the depth of cut of the tool according to the present invention moving down the slope;
FIG. 6 is a schematic view of the cutting process with the tool according to the present invention at the lowermost end;
FIG. 7 is a schematic diagram of the calculation of the depth of cut of the tool according to the present invention moving up the slope;
FIG. 8 is an outline view of a curved surface part processed in example 1 of the present invention;
FIG. 9 is an elevation view of the machined curved surface part of FIG. 8;
the reference numbers in the figures are as follows:
1-a curved surface workpiece; 2-milling cutter; 3-a filter, 4-a lens, 5-a left line laser, 6-a left line laser adjusting plate, 7-a line laser mounting seat, 8-an area-array camera, 9-an area-array camera mounting plate, 10-a right line laser adjusting plate, 11-a visual detection device adjusting plate, 12-a visual detection device box body and 13-a visual detection device fixing frame; 14-a workpiece transport table; 15-a workpiece holder; 16-a horizontal milling machine; 17-a workpiece conveying mechanism; 18-right line laser.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments. The following description is only for the purpose of explanation and is not intended to limit the invention.
As shown in fig. 1, fig. 2 and fig. 3, the machine vision auxiliary curved surface processing device of the present invention includes a vision detection device 17, a horizontal milling machine 16, a workpiece conveying mechanism 14, and a workpiece fixture 15; the visual detection device comprises a filter 3, a lens 4, a left side line laser 5, a left side line laser adjusting plate 6, a line laser mounting seat 7, an area array camera 8, an area array camera mounting plate 9, a right side line laser adjusting plate 10, a right side line laser 18, a visual detection device adjusting plate 11, a visual detection device box body 12 and a visual detection device fixing frame 13; the area array camera 8 is arranged on an area array camera mounting plate 9 in a visual detection device box body 12, the up-down position of the area array camera can be adjusted, the left line laser 5 and the right line laser 18 are respectively arranged on a left line laser adjusting plate 6 and a right line laser adjusting plate 10 in the visual detection device box body 12, the angle of the left line laser 5 and the right line laser 18 can be adjusted, the left line laser 5 and the right line laser 18 are symmetrically distributed on the left side and the right side of the area array camera mounting plate 9 at equal intervals, and the filter glass 3 is arranged at the lower end of the visual detection device box body 12; the rear end of a visual detection device fixing frame 13 is arranged on a horizontal milling machine 16, the front end of the visual detection device fixing frame 13 is connected with a visual detection device adjusting plate 11 with an adjustable position, and a visual detection device box body 12 is arranged on the visual detection device adjusting plate 11;
during use, the laser spectrums emitted by the left line laser 5 and the right line laser 18 are consistent with the band pass of the filter 3. The visual detection device 17 is positioned right above the milling cutter 2, and the laser line on the curved surface workpiece is always in the visual field range of the area array camera;
the visual detection device adjusting plate 11 is provided with an adjusting groove, and the position of the adjusting groove can be adjusted along the groove hole according to the working height requirement of the visual detection device; the visual inspection device regulating plate 11, left sideline laser regulating plate 6, right sideline laser regulating plate 10, area array camera mounting panel 9 that relate to among this application technical scheme all can adjusting position or angle, and these adjusting device are being prior art, and no longer detail here.
The left side line laser adjusting plate 6 and the right side line laser adjusting plate 10 are respectively arranged on the line laser mounting seats 7 at two sides of the area array camera mounting plate 9, and the adjusting angles of the left side line laser adjusting plate 6 and the right side line laser adjusting plate 10 relative to the vertical direction are 30-60 degrees;
the horizontal milling machine is provided with a current sensor, when the cutter contacts a workpiece, the current sensor is triggered, and then the control system can acquire the position information of the cutter at the moment.
In the following, according to the technical solution of the present invention, some of the accompanying drawings of the specification are explained:
FIG. 4 is a schematic view of the initial cutting process of the tool; as shown in fig. 4, S is the step size of the workpiece movement, p1 is the initial position of the tool, a distance above the contour of the curved workpiece, a distance L from the edge of the cut contour, then the tool moves from position p1 to position p2 at a certain rate, position p2 is the position where the tool contacts the curved workpiece, then the tool cuts from position p2 to position 3 at a certain rate, position p3 is the final cut position in the vertical direction, and the slope of the cutting point of the tool at position p3 is calculated, and then the tool continues to move downward at a certain rate, while the workpiece moves one step in the direction of the negative x-axis at a certain rate, due to the compound motion of the workpiece and the tool, the tool reaches the position p4 from the position p3, the motion direction of the compound motion is consistent with the tangential direction of the current cutting point, so the final direction of the compound motion is referred to as the tangential direction of the current point hereinafter; then the cutter moves from a position p4 to a position p5 in the vertical Y direction at a certain speed, the position p5 is a final position which meets the cutting depth in the vertical direction, and then the change from the position p3 to the position p5 is repeated until the lowest end position is machined;
FIG. 5 is a schematic diagram of calculation of the cutting depth of the tool moving downward along the slope, as shown in FIG. 5, JB and EB are incident laser lines, angle JBO and angle EBO are laser incident angles β, point O is a center point of the tool, point H is a point where the lowermost part of the tool contacts a curved workpiece, and point OH is a moving distance of the tool in the vertical direction from when the tool contacts the curved workpiece to when the lowermost part of the tool starts cutting the workpiece, and is marked as HbThe corresponding OM is the actual cutting depth which is the maximum cutting depth of the cutter in the period from the time when the cutter contacts the curved surface workpiece to the time when the cutter starts to cut the workpiece at the lowest part; HB is the cutting depth of the cutter in the vertical direction and is marked as HsHK is the maximum cutting depth corresponding to HB, namely the actual cutting depth; QP is a tangent line corresponding to the current cutting point when the cutter reaches the cutting depth line; passing a cutting point B at the lowest part of the cutter as a horizontal tangent of the cutter, intersecting the tangent with an incident laser line at a point B, intersecting a workpiece contour line at a point J and a point E, passing the point J as JA vertical AC to A, passing the point E as EC vertical AC to C, passing the point J as JD vertical EC to a point D; angle theta is the cutting angle of the current cutting point, Xj、XkIs the pixel length, X, of the corresponding line segment AB, BC in the imagerIs the physical distance of the unit pixel in the AB direction, and v is the descending speed of the cutter;
then it can be obtained:
AB＝Xj*X r①
BC＝ XK*X r②
OH＝ν*(t2-t1) ③
available from formula ①②③:
HB≈(AJ+EC)/2＝(Xj+XK)*Xr/(2*tan(β))
slope of current cutting point of workpiece: tan (θ) ═ DE/JD ═ XK-Xj)/((Xk+Xj)*tan(β))
Vertical cutting depth of the workpiece: ha＝Hb+Hs
Maximum cutting depth of the workpiece: he＝OM+HK＝(Hb+Hs)*cos(θ)
FIG. 6 is a schematic view of the cutting process with the tool at the lowermost end (cutting angle 0); as shown in fig. 6, the position p-1 is the lowest cutting point position of the cutter at the right side of the lowest point, the position p-2 is the actual cutting position of the cutter in the vertical direction, and the position p-3 is the lowest cutting point position of the cutter at the left side of the lowest point; the specific movement process is that after the cutter moves to a position p-1, the cutter moves downwards along the slope direction of the current cutting point to reach a position p-2, and the cutting angle of the cutter at the position p-1 is recorded as theta1Slope k 1; the tool will follow the cutting angle theta after reaching position p-22From position p-2 to position p-3, recording theta2＝(180°—θ1) Slope-k 1;
FIG. 7 is a schematic diagram of the calculation of the cutting depth on the right side of the cutter; as shown in fig. 7, the change of the related parameter during the upward movement of the tool is the same as the calculation of the related parameter during the downward movement of the tool, but the moving direction of the tool is moved upward along the direction of the slope, wherein S1, S2, S3 indicate the positions of different cutting points where the tool is located.
In the following, according to the technical solution of the present invention, the following contents of examples are provided:
example 1
As shown in fig. 8 and 9, the part is processed, the part is a curved part, the radius of the curved surface is 3800mm, the chord length is 4800mm, and the thickness of the workpiece is 150mm, the method for realizing curved surface processing with the aid of the machine vision described in this patent, in combination with the schematic diagrams of the apparatus and the method described in fig. 1 to 9, states the following steps:
Step 2: initialization and adjustment of processing equipment: adjusting the workpiece according to the working requirement, so that the workpiece is positioned below the milling cutter, adjusting the initial position of the milling cutter to enable the initial position to be away from the outermost side contour line L (mm) of the curved surface workpiece (the value of L is 20-25 mm), adjusting the visual sensing device to enable the visual sensing device to be positioned at a distance above the milling cutter, enabling line laser generated by the left and right line lasers to be irradiated on the surface of the workpiece and positioned in the middle of the visual field of the area array camera, and enabling the coincident line of the two laser lines to be coincident with the cutting point at the lowest part of the milling cutter and to be;
and step 3: setting the cutting depth of the workpiece to HeIs 20mm, and the feeding step length S of the workpiece in the X direction is 2 mm; defining the cutting depth of the cutter in the vertical direction as Hs(mm), the slope of the tool at the current cutting point is tan (θ), tan (θ) ═ Xk-Xj)/((Xk+Xj) Tan (β)), when the workpiece is cut from the right end to the left end and the milling cutter does not reach the lowest point, the milling cutter downwards performs cutting motion at a certain speed v (mm/s) along the Y direction, wherein v is 5mm/s, the area array camera acquires images at a certain frame rate, when the height of the milling cutter from the curved surface changes, the distance between the left laser line and the right laser line on the curved surface also changes, because the lowest end tangent point of the cutter does not contact the workpiece at the moment, the separation of the laser lines at the moment is called as reverse separation, and when the workpiece is contacted right below the cutter, the separation of the laser lines at the moment is called as forward separation;
and 4, step 4: when millingWhen the knife contacts the curved surface workpiece, the current sensor is excited to feed back a signal to the visual detection system, and the system records the current time node t1(s) the area-array camera takes the image M at this time1；
And 5: the cutter continues to move downwards, and when the image sensor detects that the laser lines on the curved surface are overlapped, the area-array camera takes down the image M at the moment2Feeding back the information to the visual inspection system, which records the current time node t2(s) calculating the vertical movement distance H of the milling cutter between the time when the cutter contacts the workpiece and the time when the laser line is coincident with the curved surfaceb，Hb＝ν*(t2-t1) After that, the cutting distance of the cutter in the vertical direction is recorded as HsThe cutter cuts vertically downwards at a certain speed until H is mete＝(Hs+Hb) Stopping cutting and moving downwards when the cos (theta) is reached, then moving the workpiece to the X negative half shaft direction by a step length s (mm), meanwhile, continuing to cut downwards by the milling cutter along the vertical direction, and executing the step 6 after the movement of the step length is completed;
step 6: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if tan (theta) is not 0 and H is less than HeI.e. not reaching the cutting depth, step 7 is executed; if tan (theta) is not 0 and H is equal to HeIf the cutting depth is reached, step 8 is executed; if tan (theta) is not 0 and H is greater than HeIf the cutting is excessive, step 9 is executed; if tan (θ) is 0, i.e. the lowest point is reached, step 10 is executed;
and 7: the milling cutter continues to cut downwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
and 8: moving the workpiece by one step length s (mm) in the direction of the negative X half shaft, simultaneously cutting the workpiece downwards along the vertical direction by the milling cutter, and executing the step 6 after the step length movement is finished;
and step 9: the milling cutter is carried out upwards along the vertical directionMoving until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
step 10: when the milling cutter reaches the lowest end (the slope of the cutting point is 0) of the curved surface workpiece, the area array camera acquires the laser line information on the curved surface at the moment, the cutting depth H of the current point in the vertical direction is calculated, and if the H is smaller than HeThe mill continues to cut down in the vertical direction until H equals He，HeSetting the cutting depth for the current point workpiece; if H is equal to HeThen, go to step 11;
step 11: the milling cutter upwards cuts at a certain speed in the vertical direction, meanwhile, the workpiece moves by a step length s (mm) in the direction of the negative X half axis, and after the step length movement is finished, the step 12 is executed;
step 12: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece and the information of a current sensor, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if H is less than HeAnd the current sensor has excitation (the cutter has contact with the workpiece), namely the milling cutter does not reach the set cutting depth, then step 13 is executed; if H is equal to HeAnd the current sensor is excited (the cutter is in contact with the workpiece), namely the milling cutter reaches the set cutting depth, then step 14 is executed; if H is greater than HeAnd the current sensor is excited (the cutter is in contact with the workpiece), namely the milling cutter is over-cut, then step 15 is executed; if the current sensor is not excited (the tool is not in contact with the workpiece), that is, the cutting is finished, step 16 is executed;
step 13: the milling cutter cuts downwards along the vertical direction until H is equal to He＝Hs*cos(θ)+HbCos (θ) then performs step 12;
step 14: moving the workpiece to the direction of the negative X half shaft by a step length s (mm), simultaneously cutting the workpiece upwards by the milling cutter along the vertical direction, and executing the step 12 after the step length movement is finished;
step 15: the milling cutter moves upwards along the vertical direction until H is satisfiede＝Hs*cos(θ)+HbCos (θ) thenExecuting step 12;
step 16: and returning the milling cutter to the initial position to finish the processing of the target workpiece.
The above steps can be completed by a computer, the image processing algorithm and the computer software are not the key points of the patent protection, and the technical scheme of the application focuses on the hardware device and the method related to the hardware and the principle process.
The present invention has been described in terms of some embodiments, and is not intended to be limited to the embodiments, but rather, is intended to cover all modifications, improvements, equivalents, and alternatives falling within the spirit and scope of the invention.
Claims (9)
1. A machine vision auxiliary curved surface processing device is characterized by comprising a vision detection device (17), a horizontal milling machine (16), a workpiece conveying mechanism (14) and a workpiece clamp (15);
the visual detection device comprises a filter (3), a lens (4), a left side line laser (5), a left side line laser adjusting plate (6), a line laser mounting seat (7), an area-array camera (8), an area-array camera mounting plate (9), a right side line laser adjusting plate (10), a right side line laser (18), a visual detection device adjusting plate (11), a visual detection device box body (12) and a visual detection device fixing frame (13); the area-array camera (8) is arranged on an area-array camera mounting plate (9) in a visual detection device box body (12) and can adjust the up-down position, the left line laser (5) and the right line laser (18) are respectively arranged on a left line laser adjusting plate (6) and a right line laser adjusting plate (10) in the visual detection device box body (12) and can adjust the angle, the left line laser (5) and the right line laser (18) are equidistantly and symmetrically distributed on the left side and the right side of the area-array camera mounting plate (9), and the filter glass (3) is arranged at the lower end of the visual detection device box body (12); the rear end of a visual detection device fixing frame (13) is installed on a horizontal milling machine (16), the front end of the visual detection device fixing frame (13) is connected with a visual detection device adjusting plate (11) with an adjustable position, and a visual detection device box body (12) is installed on the visual detection device adjusting plate (11).
2. The machine-vision assisted curved surface machining device of claim 1, wherein: and the spectrum of the linear laser emitted by the left linear laser (5) and the right linear laser (18) is consistent with the band pass of the filter (3).
3. The machine-vision assisted curved surface machining device of claim 1, wherein: the visual detection device adjusting plate (11) is provided with an adjusting groove, and the position of the adjusting groove can be adjusted along a groove hole on the visual detection device according to the working height requirement of the visual detection device.
4. The machine-vision assisted curved surface machining device of claim 1, wherein: the visual detection device (17) is positioned right above the milling cutter (2), and the laser line on the curved surface workpiece is always in the visual field range of the area-array camera.
5. The machine-vision assisted curved surface machining device of claim 1, wherein: the left side line laser adjusting plate (6) and the right side line laser adjusting plate (10) are respectively installed on line laser installation seats (7) on two sides of an area array camera installation plate (9), and the adjusting angles of the left side line laser adjusting plate (6) and the right side line laser adjusting plate (10) relative to the vertical direction are 30-60 degrees.
6. The machine-vision assisted curved surface machining device of claim 1, wherein: the horizontal milling machine (16) is provided with a current sensor, when the cutter contacts a workpiece, the current sensor is triggered, and then the control system can acquire the position information of the cutter at the moment.
7. A machine vision auxiliary curved surface processing method is characterized in that: the machining device of any one of claims 1 to 6 for realizing curved surface machining comprises the following steps:
step 1, calibrating relevant parameters of a visual detection device, namely, the field angle of an area-array camera (8) is α, the included angle between the axes of a left line laser (5) and a right line laser (18) and the vertical direction is β, adjusting the two sides of the area-array camera to be in a right angle state, and adjusting the two sides of the area-array camera to be in a right angle stateThe incident angle β of the line laser makes the laser lines at both sides coincide on the workpiece as a straight line, and the intersection line coincides with the center line of the image obtained by the area-array camera, XnThe number of pixels, X, of the distance between the left and right laser lines when the laser lines are separatedjThe number of pixels from the left laser line to the image center line, XkThe number of pixels from the right laser line to the central line of the acquired image and satisfies the condition that Xn is Xj+XkThe physical distance of the unit pixel is Xr(pixel/mm)；
Step 2: initialization and adjustment of processing equipment: adjusting the workpiece according to the working requirement to enable the workpiece to be positioned below the milling cutter, adjusting the initial position of the milling cutter to enable the distance between the initial position and the outermost side contour line of the curved surface workpiece to be L (mm), adjusting the visual sensing device to enable the visual sensing device to be positioned at a distance above the milling cutter, enabling line laser generated by the left linear laser and the right linear laser to be irradiated on the surface of the workpiece and be positioned in the middle of the visual field of the area array camera, and enabling the coincident line of the two laser lines and the cutting point at the lowest part of the milling cutter to;
and step 3: setting the theoretical cutting depth of the workpiece to be He(mm), the feeding step length of the workpiece in the X direction is S (mm); defining the cutting depth of the cutter in the vertical direction as Ha(mm), the cutting angle of the tool at the current cutting point is θ, tan (θ) ═ Xk-Xj)/((Xk+Xj) Tan (β)), when the workpiece is cut from the right end to the left end and the milling cutter does not reach the lowest point (the slope of the cutting point is 0), the milling cutter downwards performs cutting motion along the Y direction at a certain speed v (mm/s), and the area array camera acquires images at a certain frame rate;
and 4, step 4: when the milling cutter contacts a curved surface workpiece, the current sensor is excited and feeds back a signal to the control system, and the system records the current time node t1(s) the area-array camera takes the image M at this time1；
And 5: the cutter continues to move downwards, and when the image sensor detects that the laser lines on the curved surface are overlapped, the area-array camera takes down the image M at the moment2Feeding back the information to the visual inspection system, which records the current time node t2(s) calculating the vertical movement distance H of the milling cutter between the time when the cutter contacts the workpiece and the time when the laser line is coincident with the curved surfaceb，Hb＝ν*(t2-t1) After that, the cutting distance of the cutter in the vertical direction is recorded as HsThe cutter cuts vertically downwards at a certain speed until H is mete＝(Hs+Hb) Stopping cutting and moving downwards when the cos (theta) is reached, then moving the workpiece to the X negative half shaft direction by a step length s (mm), meanwhile, continuing to cut downwards by the milling cutter along the vertical direction, and executing the step 6 after the movement of the step length is completed;
step 6: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if tan (theta) is not 0 and H is less than HeI.e. not reaching the cutting depth, step 7 is executed; if tan (theta) is not 0 and H is equal to HeIf the cutting depth is reached, step 8 is executed; if tan (theta) is not 0 and H is greater than HeIf the cutting is excessive, step 9 is executed; if tan (θ) is 0, i.e. the lowest point is reached, step 10 is executed;
and 7: the milling cutter continues to cut downwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
and 8: moving the workpiece by one step length s (mm) in the direction of the negative X half shaft, simultaneously cutting the workpiece downwards along the vertical direction by the milling cutter, and executing the step 6 after the step length movement is finished;
and step 9: the milling cutter moves upwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 6 is performed;
step 10: when the milling cutter reaches the lowest end (cutting point) of the curved workpieceThe slope of the surface of the curved surface is 0), the area array camera obtains the laser line information on the curved surface at the moment, the cutting depth H in the vertical direction of the current point is calculated, and if the H is smaller than the H, the cutting depth H is not larger than the HeThe mill continues to cut down in the vertical direction until H equals He，HeSetting the cutting depth for the current point workpiece; if H is equal to HeThen, go to step 11;
step 11: the milling cutter upwards cuts at a certain speed in the vertical direction, meanwhile, the workpiece moves by a step length s (mm) in the direction of the negative X half axis, and after the step length movement is finished, the step 12 is executed;
step 12: calculating the slope tan (theta) and the cutting depth H of the current cutting point of the workpiece and the information of a current sensor, wherein tan (theta) is equal to (X)K-Xj)/((Xk+Xj)tan(β))，H＝(Hs+Hb) Cos (θ); if H is less than HeAnd the cutter contacts with the workpiece to make the current sensor excited, i.e. the milling cutter does not reach the set cutting depth, then step 13 is executed; if H is equal to HeAnd the cutter contacts with the workpiece to enable the current sensor to be excited, namely the milling cutter reaches the set cutting depth, and then step 14 is executed; if H is greater than HeAnd the cutter contacts with the workpiece to make the current sensor excited, namely the milling cutter cuts excessively, then step 15 is executed; if the tool does not contact the workpiece, so that the current sensor is not excited, namely the cutting is finished, executing step 16;
step 13: the milling cutter cuts downwards along the vertical direction until H is equal to He＝(Hs+Hb) Cos (θ), then step 12 is performed;
step 14: moving the workpiece to the direction of the negative X half shaft by a step length s (mm), simultaneously cutting the workpiece upwards by the milling cutter along the vertical direction, and executing the step 12 after the step length movement is finished;
step 15: the milling cutter moves upwards along the vertical direction until H is satisfiede＝(Hs+Hb) Cos (θ), then step 12 is performed;
step 16: and returning the milling cutter to the initial position to finish the processing of the target workpiece.
8. The machine-vision aided curve machining method of claim 7, wherein: in the process of machining the vision-assisted curved surface of the machine, the milling cutter (2) only carries out feeding motion in the vertical direction, the horizontal feeding motion of the workpiece is completed by the workpiece conveying mechanism (14), and the workpiece conveying mechanism (14) always ensures that the workpiece finishes feeding at a certain speed and step length according to actual working requirements.
9. The machine-vision aided curve machining method of claim 7, wherein: the value of L in the step 2 is 20-25 mm.
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