CN111774930B - Vision on-machine tool setting gauge and tool setting method thereof - Google Patents
Vision on-machine tool setting gauge and tool setting method thereof Download PDFInfo
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- CN111774930B CN111774930B CN202010731079.0A CN202010731079A CN111774930B CN 111774930 B CN111774930 B CN 111774930B CN 202010731079 A CN202010731079 A CN 202010731079A CN 111774930 B CN111774930 B CN 111774930B
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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
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/20—Automatic control or regulation of feed movement, cutting velocity or position of tool or work before or after the tool acts upon the workpiece
- B23Q15/22—Control or regulation of position of tool or workpiece
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention relates to a visual on-machine tool setting gauge and a tool setting method thereof. The vision on-machine tool setting gauge comprises: the device comprises a detector, a data processing controller and a cutter data server; the detector is connected with the data processing controller through a signal cable, a cleaning air pipe, a plunger air pipe and a positive pressure protection air pipe; the data processing controller is also respectively connected with the CNC controller and the cutter data server; a telecentric lens and a light source back plate are arranged in the detector, the telecentric lens and the light source back plate are utilized to perform parallel projection imaging on the cutter to form a cutter image sequence, the cutter image sequence is analyzed through a data processing controller, the length and the diameter of the cutter are calculated, and the cutter length and the diameter are transmitted to a CNC controller. By adopting the vision on-machine tool setting gauge, the tool setting efficiency and precision can be improved, and the tracking of historical measurement data is supported, so that the precision of numerical control machining is ensured, and the machining cost is reduced.
Description
Technical Field
The invention relates to the field of numerical control machining on-machine detection instruments, in particular to a visual on-machine tool setting instrument and a tool setting method thereof.
Background
The on-machine detection of the revolving body cutter relates to five mutually independent functions which are respectively as follows: tool setting, multi-view detection of a fine tool, tool jump detection, tooth-by-tooth wear detection of front and rear tool faces, and real-time monitoring of a full machining process, wherein the first four functions can only be operated before and after machining, the fifth function can be used for monitoring the tool state in the whole numerical control machining process in real time, and the five functions are independent from each other and pay attention to a certain specific attribute of the tool in the machine state respectively. The independent function of knife setting is only studied here.
In order to ensure the precision of Numerical Control machining, before cutting machining by using a revolving body cutter, tool setting is carried out, namely, the clamping length of the cutter on a main shaft and the section diameter of a specific axial position of the cutter are detected, and the measured values are transmitted to a tool length register of a Computer Numerical Control (CNC), during cutting machining, the cutter length value in the tool length register is called by a NC program to carry out cutter length compensation, and the cutter diameter is used for cutter radius compensation, so that the machining precision is ensured. The tool setting efficiency directly influences the processing efficiency of the workpiece, and the tool setting precision also directly influences the processing precision and the service performance of the workpiece.
There are currently four tool setting techniques: the device comprises an off-machine tool setting gauge, a contact on-machine tool setting gauge, a laser on-machine tool setting gauge and an on-machine tool setting gauge based on a 3D vision technology. The principle and the existing defects of the technologies are as follows, and the requirement for carrying out tool setting on a rotary cutter which is used in a large amount in engineering is difficult to meet:
(1) the off-line vision detection principle is adopted for the off-machine tool setting gauge, the tool needs to be semi-automatically measured on special equipment outside the numerical control machine, the efficiency is low, and generally, the measured data is input into a tool compensation register of a CNC controller of the numerical control machine in a manual mode, so that errors are easy to occur. More importantly, the tool is not measured on the numerical control machine tool on the machine, so that the tool setting gauge outside the machine cannot detect the size change of the tool after machining in time. In addition, the tool setting gauge outside the machine is too large in size, has no sealing protection design aiming at cutting fluid, and cannot be installed on a numerical control machine tool with compact space and severe environment.
(2) The contact type on-machine tool setting instrument adopts a contact principle, the tool needs to slowly contact the surface of the tool setting instrument, and the measurement efficiency is low. The contact type on-machine tool setting gauge has low precision and is inconvenient to measure the diameter of the tool in a main shaft rotating state due to the sensitivity limit of a contact sensor and the influence of abrasion of a tool setting contact surface. In addition, the radial dimension of other cross-sectional positions cannot be measured, which is limited by the contact measurement principle, and only the end of the cutter can be measured.
(3) The laser on-machine tool setting gauge adopts a single-point measurement principle based on laser shielding, in order to ensure the measurement accuracy, the cutter needs to reciprocate at a low speed to approach a laser beam so as to accurately detect the shielding position of the edge of the cutter, the measurement time is long, and the efficiency is low. The accuracy of the measurement also depends on the accuracy of the machine tool movement and the size of the laser beam focus. In addition, the laser tool setting gauge cannot measure a plurality of cross-sectional positions at the same time, and the efficiency is low when contour detection and measurement of a formed tool are performed.
(4) The on-machine tool setting technology based on 3D vision carries out tool setting through image analysis under the rotating state of a main shaft, and the problems exist: the online automatic tool setting and damage detection device for the micro milling cutter aims at detection of the micro milling cutter and has no universality on other types of cutters; on the other hand, by adopting a non-telecentric imaging principle, a virtual three-dimensional calibration target is formed by utilizing the target installed on the main shaft through the movement of each shaft of the numerical control machine tool, the accurate calibration of a camera coordinate system and a machine tool coordinate system is carried out, the three-dimensional reconstruction of the maximum swept body of the cutter is carried out according to the constraint of a revolving body, the measurement efficiency is low, the calculation is complex, and the measurement error links are multiple. The on-machine automatic detection device for the video and laser fused rotary cutter is also based on a non-telecentric imaging principle, three-dimensional reconstruction is carried out by using revolving body constraint of the cutter, a rough measurement position is determined according to a three-dimensional model, and cutter compensation measurement is completed by using a laser shielding principle, so that the measurement efficiency is low. The existing technology of visual on-machine tool setting has the problem of difficult light path protection, and an optical window mirror is very easily polluted by cutting fluid and oil mist in actual cutting processing and cannot work reliably.
(5) In addition, the existing on-machine tool setting gauge only transmits the current measurement result to the tool compensation register and is covered by new data after the next measurement, so that historical data detected by the tool cannot be stored and traced, and the management of tool measurement data and the parameter optimization of a machining process based on tool failure and service life are not facilitated.
Therefore, the existing on-machine tool setting technology has low efficiency, wherein the contact type tool setting gauge can measure the tool only by requiring the tool to be in contact with the surface of the tool setting gauge, and the speed of the tool approaching the tool setting gauge is very low for ensuring safety; the laser on-machine tool setting gauge adopts a single-point measurement principle based on laser shielding, and in order to ensure the measurement accuracy, the position of the edge of the cutter shielding laser can be accurately detected only by requiring the cutter to slowly reciprocate close to a laser beam, so that the measurement time is very long; the existing solution based on the vision technology adopts a non-telecentric imaging principle, a machine tool coordinate system and a camera coordinate system need to be calibrated firstly, and then 3D reconstruction and measurement of a tool swept body are carried out according to geometrical constraint of a revolving body by an image sequence and calibration parameters, so that the measurement process is complicated. Therefore, the existing on-machine tool setting system has the problems of very low tool setting efficiency, low measurement precision and no support for tracing historical measurement data.
Disclosure of Invention
The invention aims to provide a visual on-machine tool setting gauge and a tool setting method thereof, and aims to solve the problems that the existing on-machine tool setting system is low in tool setting efficiency and measurement accuracy and does not support historical measurement data tracing.
In order to achieve the purpose, the invention provides the following scheme:
a vision on-machine tool setting gauge comprising: the device comprises a detector, a data processing controller and a cutter data server;
the detector is connected with the data processing controller through a signal cable; the data processing controller is also respectively connected with the CNC controller and the cutter data server; the utility model discloses a numerical control machine tool setting device, including detector, telecentric lens, light source in a poor light, data processing controller, CNC controller, be equipped with telecentric lens and light source in a poor light in the detector, utilize telecentric lens and the light source in a poor light carries out parallel projection imaging to the cutter, acquires cutter image sequence at the cutter rotation in-process, through data processing controller analysis cutter image sequence calculates cutter length and cutter diameter to the sword mends register of transmission to CNC controller, accomplishes the tool setting.
Optionally, the detector specifically includes: the device comprises a protective shell, a camera module, a telecentric lens, a 45-degree reflector, a window mirror, a pneumatic plunger and an optical fiber sensor;
the optical fiber sensor comprises an optical fiber sensor transmitting end and an optical fiber sensor receiving end; the protective shell is a concave protective shell; a camera module, a telecentric lens, a 45-degree reflector, a window mirror, a pneumatic plunger and an emitting end of the optical fiber sensor are arranged in the first side cavity of the concave protective shell; the optical fiber sensor receiving end is arranged in the second side cavity of the protection shell; the transmitting end and the receiving end of the optical fiber sensor are symmetrically arranged by taking the cutter as the center; the backlight source is arranged in the second side cavity and used for providing uniform background illumination during imaging to form a cutter image with good light and shade contrast;
the telecentric lens is arranged on a lens interface of the camera module, and the axis of the telecentric lens is parallel to the axis of the cutter; the camera module and the telecentric lens are used for acquiring parallel projection images of the rotary cutter; the 45-degree reflector is arranged at the upper part of the telecentric lens; the 45-degree reflector is used for performing 90-degree steering on the imaging light path; the window mirror is arranged at the reflecting end of the 45-degree reflector; the window mirror is used for sealing the camera module, the telecentric lens and the 45-degree reflector; the pneumatic plunger and the window mirror are arranged on the same imaging light path, the axis of the pneumatic plunger is perpendicular to the normal direction of the plane of the window mirror, and the pneumatic plunger is used for controlling the camera module to collect cutter images and protecting the imaging light path.
Optionally, high-pressure gas is introduced into an imaging light path between the window mirror and the pneumatic plunger, so that positive pressure protection of the imaging light path between the window mirror and the pneumatic plunger is formed.
Optionally, a connecting line between the transmitting end of the optical fiber sensor and the receiving end of the optical fiber sensor is perpendicular to the axis of the cutter.
Optionally, the detector further includes: cleaning the nozzle;
the cleaning nozzle is arranged on the surface of the groove area of the concave protective shell; the cutter corresponds to the cleaning nozzle; the cleaning nozzle is used for cleaning the cutter before imaging, and removing residual cuttings and cutting fluid on the cutter.
Optionally, a pneumatic protective door is arranged in the groove area.
Optionally, the data processing controller specifically includes: the device comprises a calculation module, a light source control module and a gas path control module;
the computing module, the light source control module and the gas circuit control module are sequentially connected through the signal cable; the calculation module is also connected with the CNC controller; the computing module and the light source control module are also respectively connected with the signal cable; and the computing module is connected with the cutter data server through a workshop local area network.
Optionally, the method further includes: cleaning an air pipe, a plunger air pipe and a positive pressure protection air pipe;
the cleaning air pipe is used for connecting the cleaning nozzle and the air path control module;
the plunger air pipe is used for connecting the pneumatic plunger and the air path control module;
the positive pressure protection air pipe is used for connecting high-pressure air in the imaging light path and the air path control module.
A tool setting method of a visual on-machine tool setting gauge, comprising the following steps:
firstly, after the vision on-machine tool setting instrument is electrified, a kernel program in a computing module is automatically started and is in a waiting measuring state, a pneumatic plunger is in a normally closed state, and positive air pressure protection is always started;
secondly, before machining, running a measurement macro program in a numerical control machining NC main program in a subprogram calling mode, and transmitting parameters when calling the measurement macro program for specifying the specific section position of diameter measurement on the cutter;
thirdly, the measuring macro program controls the cutter to move to a cutter setting starting point, the cutter setting starting point is a fixed position designated by a user, and the cutter setting starting point is positioned above the detector; under the control of a measurement macro program, the cutter descends to a concave measurement area in the middle of the shell from the cutter setting starting point; in the descending process of the cutter, the end part of the cutter can firstly shield a laser beam emitted by the emitting end of the optical fiber sensor, a step triggering signal is generated at the receiving end of the optical fiber sensor, the step triggering signal is sent to a CNC controller of a numerical control machine, a measuring macro program is triggered to run a G31 jump instruction, the cutter stops descending according to the G31 jump instruction, and the macro program sets the value of a first macro variable to be 1;
fourthly, the kernel program inquires the state of the first macro variable, and if the value of the first macro variable is 1, the gas circuit control module opens the cleaning nozzle through the cleaning gas pipe and cleans the cutter through jetting high-pressure gas flow; otherwise, continuing to wait;
fifthly, the macro program is measured to safely move the cutter to a focusing position in front of a field of view of the telecentric lens, namely a cutter setting point, and meanwhile, the macro program sets the value of a second macro variable to be 1;
sixthly, the kernel program inquires the value of a second macro variable, if the value of the second macro variable is 1, the kernel program opens the camera module, and simultaneously opens the backlight light source through the light source control module; otherwise, continuing to clean the cutter;
the seventh step, the gas circuit control module closes the cleaning nozzle through the cleaning gas pipe, opens the pneumatic plunger through the plunger gas pipe, and the camera module performs parallel projection through the telecentric lens in the rotation process of the cutter to obtain a cutter image sequence;
eighthly, after shooting is finished, the kernel program closes the camera module, the light source control module closes the backlight light source, the pneumatic control module closes the pneumatic plunger through the plunger air tube, and the kernel program sets the value of the third macro variable to be 1; and if the measuring macro program detects that the value of the third macro variable is 1, controlling the cutter to return to the cutter setting starting point to complete the cutter setting action.
Optionally, after the eighth step, the method further includes:
and ninthly, processing the cutter image sequence acquired by the camera module and the telecentric lens by the kernel program, and determining the length and the diameter of the cutter.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects: the invention provides a visual on-machine tool setting instrument and a tool setting method thereof, wherein a single camera is only used, a telecentric lens is adopted to perform parallel projection imaging on a tool, the edge position of the tool outline is efficiently and accurately determined from a 2D image through direct analysis of a tool image sequence, the measurement principle is simple, the radius of a plurality of section positions is simultaneously measured, the tool setting measurement efficiency and precision are further improved, and the tracing of historical measurement data is supported.
The vision on-machine tool setting gauge provided by the invention has a dual-protection design of positive air pressure and a pneumatic plunger, and ensures that an optical element is not polluted and runs reliably in a severe machining environment with cutting fluid, oil mist and cutting chips.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a diagram of a visual on-machine tool setting gauge provided by the present invention;
FIG. 2 is a schematic view of the working principle of the on-machine tool setting gauge according to the present invention;
FIG. 3 is a flow chart of a tool image sequence processing algorithm provided by the present invention;
fig. 4 is a schematic diagram of networking implementation provided by the present invention.
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 derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a visual on-machine tool setting gauge and a tool setting method thereof, which can improve tool setting efficiency and precision and support the tracing of historical measurement data.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Fig. 1 is a structural diagram of an on-machine vision tool setting gauge provided by the present invention, and as shown in fig. 1, the on-machine vision tool setting gauge includes: the device comprises a detector, a data processing controller and a cutter data server;
the detector is connected with the data processing controller through a signal cable; the data processing controller is also respectively connected with the CNC controller and the cutter data server; the utility model discloses a numerical control machine tool setting device, including detector, telecentric lens, light source in a poor light, data processing controller, CNC controller, be equipped with telecentric lens and light source in a poor light in the detector, utilize telecentric lens and the light source in a poor light carries out parallel projection imaging to the cutter, acquires cutter image sequence at the cutter rotation in-process, through data processing controller analysis cutter image sequence calculates cutter length and cutter diameter to the sword mends register of transmission to CNC controller, accomplishes the tool setting.
The detector is installed on a workbench of the numerical control machine tool and consists of a camera module, a telecentric lens, a 45-degree reflector, a window mirror, a pneumatic plunger, an optical fiber sensor, a backlight light source, a cleaning nozzle and a protective shell. The telecentric lens is arranged on a lens interface of the camera module, the axis of the telecentric lens is parallel to the axis of the cutter, and the camera module and the telecentric lens are used for obtaining parallel projection images of the rotary cutter. The 45-degree reflector is arranged on the upper part of the telecentric lens and used for carrying out 90-degree steering on an imaging light path, so that the more compact structure size is realized. The window mirror is attached to the outside of the 45-degree mirror, and seals the optical elements. The pneumatic plunger is located on the outer side of the light path and has an opening position and a closing position, the camera module is allowed to acquire a cutter image when the pneumatic plunger is opened, and the light path is protected when the pneumatic plunger is closed. High-pressure gas is introduced into a light path between the window mirror and the pneumatic plunger, the high-pressure gas flows towards the direction of the cutter through a matching gap at the outer side of the cylindrical surface of the pneumatic plunger and is subjected to resistance formed by internal positive pressure gas flow, oil mist, cutting fluid and chips in the machining environment of a machine tool are rejected outside and cannot enter the light path to pollute the window mirror and various optical elements, and thus positive pressure protection is formed on the light path between the window mirror and the pneumatic plunger. The backlight source is used for providing uniform background illumination during imaging to form a cutter image with good light and shade contrast. The optical fiber sensor is used for ensuring the safety of the cutter setting process, a connecting line of the transmitting end and the receiving end of the optical fiber sensor is perpendicular to the axis of the cutter, the rough position of the end of the cutter is detected in the cutter descending process, and the cutter is prevented from colliding with a detector in the cutter descending process under the condition that the clamping length of the cutter is unknown. The cleaning nozzle is used for cleaning the cutter before imaging, and removing residual cuttings and cutting fluid on the cutter. The shell is used for installing and protecting all components, and the concave area of the shell provides a measuring space for the cutter.
The data processing controller is installed in an electric cabinet of the numerical control machine tool and comprises a computing module, a light source control module and a gas circuit control module, wherein the computing module is used for controlling the camera module to collect images, processing the acquired cutter images, computing the length and the diameter of the cutter and controlling the on-off of the backlight source and the gas circuit through the light source controller and the gas circuit control module. And the calculation module communicates with a CNC controller of the numerical control machine tool by using a network port or a serial port through a communication protocol, and updates the calculated length and diameter of the tool into a tool compensation register of the CNC controller of the numerical control machine tool. The calculation module can also be accessed to a workshop local area network to carry out remote communication with the cutter data server.
As a variation of the above structure, the computing module of the data processing controller may also adopt embedded hardware, so as to be integrated into the detector. The concave area part of the shell can also be added with a pneumatic protective door which is only opened during the measurement, thereby providing further protection for the vision machine tool setting gauge operating under the severe working conditions.
The data processing controller includes a kernel program and a measurement macro program.
The kernel program is an executable file generated by compiling a high-level language, runs in a calculation module of the data processing controller, and an operating system can be a Windows system or a Linux system, and has the main functions of realizing the control of a tool setting flow, the setting of image acquisition and exposure parameters, the processing of a tool image, the calculation of the length and the diameter of the tool and the communication with a CNC controller; the kernel program also comprises a database module which can store and query the measured data and the images and support remote backup of the data in the local database to the tool data server through a workshop local area network.
The measuring macro program is an NC subprogram consisting of numerical control programming instructions, can be called by a processing NC main program and runs in a numerical control machine controller, and has the main function of matching with a kernel program to control the movement of a main shaft and a cutter so as to complete a cutter setting process, and the measuring macro program and the kernel program carry out data exchange by utilizing network port or serial port communication through a communication protocol.
As shown in fig. 2, the working principle of the on-machine tool setting gauge is as follows:
firstly, after the vision on-machine tool setting instrument is electrified, a kernel program in a computing module is automatically started and is in a waiting measuring state, a pneumatic plunger is in a normally closed state, and positive air pressure protection is always started;
and secondly, before machining, running a measurement macro program in a numerical control machining NC main program in a subprogram calling mode, wherein parameters can be transmitted when the measurement macro program is called, and the parameters are used for appointing the specific section position of diameter measurement on the cutter.
And thirdly, controlling the cutter to move to a tool setting starting point by the measurement macro program, wherein the tool setting starting point is a fixed position designated by a user and is usually positioned above the detector. Under the control of the measurement macro program, the cutter is continuously lowered from the cutter setting starting point to the concave measurement area in the middle of the shell. As the clamping length of the cutter is unknown, in order to ensure safety, in the descending process of the cutter, the end part of the cutter can shield a laser beam emitted by an emitting end of an optical fiber sensor, so that a step triggering signal is generated at a receiving end of the optical fiber sensor, the signal is sent to a CNC controller of a numerical control machine tool, a G31 jump instruction is triggered to run by a measuring macro program, the cutter stops descending according to the step triggering signal, and the macro program sets the value of a first macro variable (macro variable 1) to be 1.
And fourthly, the kernel program inquires the state of the first macro variable, and if the value of the first macro variable is 1, the gas circuit control module opens the cleaning nozzle through the cleaning gas pipe and cleans the cutter through jetting high-pressure gas flow. Otherwise, the waiting is continued.
And fifthly, the measuring macro program safely moves the cutter to a focusing position in front of the field of view of the telecentric lens, namely a cutter setting point, and meanwhile, the macro program sets the value of a second macro variable (macro variable 2) to be 1.
And sixthly, the kernel program inquires the value of the second macro variable, if the variable is 1, the kernel program opens the camera module, and simultaneously opens the backlight light source through the light source control module. Otherwise, the cutter is continuously cleaned.
And seventhly, the gas circuit control module closes the cleaning nozzle through the cleaning gas pipe, opens the pneumatic plunger through the plunger gas pipe, and performs parallel projection on the camera module through the telecentric lens in the rotation process of the cutter to obtain a cutter image sequence.
And eighthly, after shooting is finished, the kernel program closes the camera module, the light source control module closes the backlight light source, the pneumatic control module closes the pneumatic plunger through the plunger air pipe, and the kernel program sets the value of the third macro variable (macro variable 3) to be 1. And if the measuring macro program detects that the third macro variable is 1, controlling the cutter to return to the cutter setting starting point to complete the cutter setting action.
Ninthly, processing the cutter image sequence acquired by the camera module and the telecentric lens by the kernel program, wherein the image processing flow is shown in fig. 3: (1) firstly, the cutter image sequence is superposed and synthesized, namely, the area containing the cutter on the image is merged, so that the influence of the spiral groove of the cutter is eliminated, and the image of the maximum swept body of the cutter is obtained. (2) And carrying out binarization on the image by adopting an Otsu algorithm to obtain a binary image, carrying out edge detection on the binary image by adopting a Canny edge detection operator to obtain the maximum profile of the cutter, and carrying out sub-pixel edge extraction by adopting a Zernike moment method on the basis of a pixel-level profile in order to improve the measurement precision. (3) And analyzing the intersection point of the central axis of the tool contour and the tool contour, and calculating the length of the tool according to the distance from the point to the image first line. (4) According to the parameters transmitted by the measuring macro program, the diameter of the tool can be obtained by calculating the distance between two sides of the tool outline at the specified section position of the tool, for example, a plurality of section positions are specified by the measuring macro program, and the diameters of the positions can be calculated simultaneously.
And step ten, after the calculation is finished, on one hand, the kernel program transmits the length and the diameter of the cutter to a cutter compensation register of a Computer Numerical Control (CNC) controller through a communication interface of the controller, so that the cutter setting function is realized. On the other hand, the measurement data is stored in a database of a kernel program, for example, the vision on-machine tool setting instrument is accessed to a workshop local area network, and the measurement data can also be pushed to a tool data server for remote backup of the data.
The invention provides a visual on-machine tool setting gauge consisting of hardware and software, which is based on a telecentric optical parallel projection imaging principle, adopts a 45-degree reflector, can efficiently and highly accurately detect the length and the diameter of a revolving body tool on-machine only by using a single camera, communicates with a CNC (computer numerical control) controller of a numerical control machine in real time and automatically updates data in a tool compensation register of the CNC controller. The method supports local storage and remote backup of the measurement data and the images, and realizes tracing of historical measurement data. The vision on-machine tool setting gauge has a dual-protection design of positive air pressure and a pneumatic plunger, and ensures that an optical element is not polluted and runs reliably in a severe machining environment with cutting fluid, oil mist and cutting chips.
On the basis of the embodiment shown in fig. 1, fig. 4 shows another embodiment of the present invention adopting a networking manner, that is, N vision on-machine tool setting gauges are respectively installed on N numerically controlled machine tools, and a controller of each vision on-machine tool setting gauge is in communication with a CNC controller of a corresponding numerically controlled machine tool. The vision on-machine tool setting instruments are all connected into a workshop local area network to form a sensor network. Each vision on-machine tool setting gauge independently operates according to the embodiment of fig. 2, and pushes data measurement to a database of a tool data server through a workshop local area network, so that remote backup of tool measurement data on a plurality of numerically-controlled machine tools in a workshop is realized. A user of the numerical control machine tool can inquire and count historical measurement data generated by the vision on-machine tool setting instrument from a webpage through a terminal computer or a mobile terminal connected with a workshop local area network.
Based on the technical scheme of the invention, the invention can achieve the following effects:
(1) the tool setting efficiency is high. The edge position of the tool outline can be quickly determined by directly analyzing a 2D image sequence of the tool, the measuring principle is simple, and the diameter of a plurality of section positions is supported to be measured simultaneously.
(2) The tool setting precision of the invention is high. The contact type on-machine tool setting gauge is not high in precision due to the fact that the contact type on-machine tool setting gauge needs to contact with a tool and is influenced by the sensitivity of a contact sensor and the abrasion of a contact surface. The laser on-machine tool setting gauge adopts a single-point measurement principle based on laser shielding, and the measurement precision is limited by the motion error of a numerical control machine tool and the focusing size of a laser beam. The invention is based on 2D image processing, parallel projection imaging is carried out on the cutter through the telecentric lens under the illumination of a backlight source, the edge of the cutter is determined through two-dimensional image processing, the measurement precision is irrelevant to the motion error of each axis of a machine tool, the extraction of the edge profile with sub-pixel precision can be realized, and the measurement precision is superior to the prior on-machine cutter setting technology.
(3) The invention adopts the double protection design of positive air pressure and pneumatic plunger, and has reliable light path protection: on one hand, high-pressure gas is introduced into a light path between the window mirror and the pneumatic plunger, the high-pressure gas flows outwards through a matching gap on the outer side of the cylindrical surface of the pneumatic plunger and is subjected to resistance formed by internal positive pressure gas flow, oil mist, cutting fluid and chips in the machining environment of a machine tool are rejected outside and cannot enter the light path to pollute the window mirror and various optical elements, and therefore positive pressure protection is formed on the light path between the window mirror and the pneumatic plunger. On the other hand, the pneumatic plunger is located on the outer side of the light path and has an opening position and a closing position, the pneumatic plunger allows the cutter image to be collected when the pneumatic plunger is opened, and the pneumatic plunger provides protection for the light path when the pneumatic plunger is closed. The design can ensure that the optical element can not be polluted and reliably run in the severe processing environment with cutting fluid, oil mist and cutting chips.
(4) The invention supports the tracing of historical measurement data. The existing on-machine tool setting gauge only updates the current measurement result to a tool compensation register, but can not store and trace the historical data detected by the tool. If the vision on-machine tool setting instrument is accessed to a workshop local area network, the measurement data can be pushed to a database of a tool data server, and remote backup of the data is realized.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (5)
1. The utility model provides a vision is at quick-witted tool setting appearance which characterized in that includes: the device comprises a detector, a data processing controller and a cutter data server;
the detector is connected with the data processing controller through a signal cable; the data processing controller is also respectively connected with the CNC controller and the cutter data server; a telecentric lens and a backlight source are arranged in the detector, the telecentric lens and the backlight source are utilized to perform parallel projection imaging on the cutter, a cutter image sequence is obtained in the rotation process of the cutter, the cutter image sequence is analyzed by the data processing controller, the length and the diameter of the cutter are calculated and transmitted to a tool compensation register of the CNC controller, and the tool setting is completed;
the detector specifically includes: the device comprises a protective shell, a camera module, a telecentric lens, a 45-degree reflector, a window mirror, a pneumatic plunger and an optical fiber sensor;
the optical fiber sensor comprises an optical fiber sensor transmitting end and an optical fiber sensor receiving end; the protective shell is a concave protective shell; a camera module, a telecentric lens, a 45-degree reflector, a window mirror, a pneumatic plunger and an emitting end of the optical fiber sensor are arranged in the first side cavity of the concave protective shell; the optical fiber sensor receiving end is arranged in the second side cavity of the protection shell; the transmitting end of the optical fiber sensor and the receiving end of the optical fiber sensor are symmetrically arranged by taking the cutter as a center; the backlight source is arranged in the second side cavity and used for providing uniform background illumination during imaging to form a cutter image with good light and shade contrast;
the telecentric lens is arranged on a lens interface of the camera module, and the axis of the telecentric lens is parallel to the axis of the cutter; the camera module and the telecentric lens are used for acquiring parallel projection images of the rotary cutter; the 45-degree reflector is arranged at the upper part of the telecentric lens; the 45-degree reflector is used for performing 90-degree steering on an imaging light path; the window mirror is arranged at the reflecting end of the 45-degree reflector; the window mirror is used for sealing the camera module, the telecentric lens and the 45-degree reflector; the pneumatic plunger and the window mirror are on the same imaging light path, the axis of the pneumatic plunger is perpendicular to the normal direction of the plane of the window mirror, and the pneumatic plunger is used for controlling the camera module to collect a cutter image and protecting the imaging light path;
the detector further comprises: cleaning the nozzle;
the cleaning nozzle is arranged on the surface of the groove area of the concave protective shell; the cutter corresponds to the cleaning nozzle; the cleaning nozzle is used for cleaning the cutter before imaging to remove residual cuttings and cutting fluid on the cutter;
the data processing controller specifically comprises: the device comprises a calculation module, a light source control module, a gas path control module, a cleaning gas pipe, a plunger gas pipe and a positive pressure protection gas pipe;
the computing module, the light source control module and the gas circuit control module are sequentially connected through the signal cable; the calculation module is also connected with the CNC controller; the computing module and the light source control module are also respectively connected with the signal cable; the calculation module is connected with the cutter data server through a workshop local area network;
the cleaning air pipe is used for connecting the cleaning nozzle and the air path control module;
the plunger air pipe is used for connecting the pneumatic plunger and the air path control module;
the positive pressure protective air pipe is used for connecting high-pressure air in the imaging light path and the air path control module;
the vision on-machine tool setting gauge is used for realizing a tool setting method of the vision on-machine tool setting gauge, and the tool setting method comprises the following steps:
firstly, after the vision on-machine tool setting instrument is electrified, a kernel program in a computing module is automatically started and is in a waiting measuring state, a pneumatic plunger is in a normally closed state, and positive air pressure protection is always started;
secondly, before machining, running a measurement macro program in a numerical control machining NC main program in a subprogram calling mode, and transmitting parameters when calling the measurement macro program for specifying the specific section position of diameter measurement on the cutter;
thirdly, the measuring macro program controls the cutter to move to a cutter setting starting point, the cutter setting starting point is a fixed position designated by a user, and the cutter setting starting point is positioned above the detector; under the control of a measurement macro program, the cutter descends to a concave measurement area in the middle of the shell from the cutter setting starting point; in the descending process of the cutter, the end part of the cutter can firstly shield a laser beam emitted by the emitting end of the optical fiber sensor, a step triggering signal is generated at the receiving end of the optical fiber sensor, the step triggering signal is sent to a CNC controller of a numerical control machine, a measuring macro program is triggered to run a G31 jump instruction, the cutter stops descending according to the G31 jump instruction, and the macro program sets the value of a first macro variable to be 1;
fourthly, the kernel program inquires the state of the first macro variable, and if the value of the first macro variable is 1, the gas circuit control module opens the cleaning nozzle through the cleaning gas pipe and cleans the cutter through jetting high-pressure gas flow; otherwise, continuing to wait;
fifthly, the macro program is measured to safely move the cutter to a focusing position in front of a field of view of the telecentric lens, namely a cutter setting point, and meanwhile, the macro program sets the value of a second macro variable to be 1;
sixthly, the kernel program inquires the value of a second macro variable, if the value of the second macro variable is 1, the kernel program opens the camera module, and simultaneously opens the backlight light source through the light source control module; otherwise, continuing to clean the cutter;
the seventh step, the gas circuit control module closes the cleaning nozzle through the cleaning gas pipe, opens the pneumatic plunger through the plunger gas pipe, and the camera module performs parallel projection through the telecentric lens in the rotation process of the cutter to obtain a cutter image sequence;
eighthly, after shooting is finished, the kernel program closes the camera module, the light source control module closes the backlight light source, the pneumatic control module closes the pneumatic plunger through the plunger air tube, and the kernel program sets the value of the third macro variable to be 1; and if the measuring macro program detects that the value of the third macro variable is 1, controlling the cutter to return to the cutter setting starting point to complete the cutter setting action.
2. The on-machine tool setting gauge according to claim 1, wherein a high pressure gas is introduced into an imaging optical path between the window mirror and the pneumatic plunger to form a positive pressure protection for the imaging optical path between the window mirror and the pneumatic plunger.
3. The vision on-machine tool setting gauge of claim 1, wherein a line connecting the transmitting end of the optical fiber sensor and the receiving end of the optical fiber sensor is perpendicular to the axis of the tool.
4. The on-machine tool gauge according to claim 1, wherein a pneumatically-actuated guard gate is provided in the groove area.
5. The vision on-machine tool setting gauge of claim 1, further comprising, after the eighth step:
and ninthly, processing the cutter image sequence acquired by the camera module and the telecentric lens by the kernel program, and determining the length and the diameter of the cutter.
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| CN114227377B (en) * | 2022-01-28 | 2022-11-01 | 四川建筑职业技术学院 | Photoelectric installation type tool setting gauge |
| CN114515977B (en) * | 2022-02-23 | 2023-06-06 | 河南航天精工制造有限公司 | Automatic compensation system and method for automatic production line |
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| JPS60222855A (en) * | 1984-04-20 | 1985-11-07 | Canon Inc | Position detection method |
| DE4414784C2 (en) * | 1994-04-28 | 1996-07-18 | Wernicke & Co Gmbh | System for grinding the peripheral edge and / or an optical surface of spectacle lenses |
| US5897275A (en) * | 1996-04-30 | 1999-04-27 | Essetre Di Sella Giovanni | Machine tool for machining panels and plates |
| CN100351039C (en) * | 2004-04-08 | 2007-11-28 | 电子科技大学 | Precisive measurement of static knife profile |
| JP4542046B2 (en) * | 2006-01-30 | 2010-09-08 | セイコープレシジョン株式会社 | Drilling method and drilling device |
| CN101758423A (en) * | 2008-12-23 | 2010-06-30 | 上海诚测电子科技发展有限公司 | Rotational cutting tool state multiple parameter overall assessment method based on image identification |
| JP5725796B2 (en) * | 2010-10-27 | 2015-05-27 | 株式会社牧野フライス製作所 | Tool measuring method and measuring device, and machine tool |
| CN102528562B (en) * | 2012-02-28 | 2014-10-15 | 上海大学 | On-line automatic tool setting and breakage detection device for minitype milling tool |
| CN104942652B (en) * | 2015-06-28 | 2018-06-01 | 长春理工大学 | Laser diffraction examines knife system and method to knife online |
| CN106736849B (en) * | 2017-01-06 | 2018-09-21 | 长春理工大学 | Micro-diameter milling tool active probe formula high-precision tool setting device and method |
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