CN111928776A - Multi-sensor-based non-contact online measurement system and method for numerical control machine tool - Google Patents
Multi-sensor-based non-contact online measurement system and method for numerical control machine tool Download PDFInfo
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- CN111928776A CN111928776A CN202010755834.9A CN202010755834A CN111928776A CN 111928776 A CN111928776 A CN 111928776A CN 202010755834 A CN202010755834 A CN 202010755834A CN 111928776 A CN111928776 A CN 111928776A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
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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
- B23Q17/2414—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for indicating desired positions guiding the positioning 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
- 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
- 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
- B23Q17/2452—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces
- B23Q17/2471—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces of workpieces
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
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- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Machine Tool Sensing Apparatuses (AREA)
- Numerical Control (AREA)
- Length Measuring Devices By Optical Means (AREA)
Abstract
The invention provides a non-contact on-line measuring system and a non-contact on-line measuring method of a numerical control machine tool based on multiple sensors, wherein the system comprises a measuring module, a calibration module, a communication module and a data processing module; the measurement module comprises measurement module hardware and measurement module software; the measurement module software is used for completing measurement work and acquiring information of a measured part on a machine tool workbench; the calibration module comprises calibration module hardware and calibration module software; the communication module realizes the communication between the industrial camera, the linear laser displacement sensor and the measurement module software, and the data processing module communicates with the machine tool numerical control system; the data processing module judges actual clamping information of the measured part in a machine tool coordinate system, generates corresponding processing information and realizes data interaction with a machine tool numerical control system through the communication module. The invention can effectively solve the problem of limited measurement range of the traditional detection method and has the advantages of high precision, high efficiency, non-contact nondestructive detection and the like.
Description
Technical Field
The invention relates to the technical field of numerical control machine tool measurement, in particular to a numerical control machine tool non-contact on-line measurement system and method based on multiple sensors.
Background
In order to improve the production efficiency, the on-machine measurement technology is increasingly applied to the processing process of high-precision parts such as aerospace and the like. On-machine measurement can be divided into two modes of contact measurement and non-contact measurement. The contact measurement generally requires complex measurement route planning and design and repeated touch of the measurement point by using a contact measurement head, which is inefficient. For some large and complex parts to be measured, the traditional vision non-contact measurement method has lower measurement accuracy, and is limited by a view field, a depth of field and the like, so that the measurement requirements cannot be met. In the existing method of combining vision with laser measurement, a laser is mainly used as a projection light source, and the surface information of a measured part is obtained by the optical triangulation principle that a camera receives reflected light. On one hand, the measuring method needs to adjust the position relation between the laser and the camera to obtain the best measuring effect, and is inconvenient to operate; on the other hand, the measurement precision is lower than that of a linear laser integrated sensor, the point cloud processing is more complex, the programming calculation amount is larger, and the efficiency is lower.
In the existing aerospace high-precision part measuring process, the problems of low efficiency, low measuring precision and the like exist in the existing measuring process, and the measuring requirements cannot be met. The invention provides a multi-sensor-based non-contact online measurement system and method for a numerical control machine tool, which can effectively solve the problem of limited measurement range of the traditional detection method and have the advantages of high precision, high efficiency, non-contact nondestructive detection and the like.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to solve the problems in the prior art, provides a numerical control machine tool non-contact on-line measurement system and method based on multiple sensors, can effectively solve the problem that the traditional detection method is limited in measurement range, and has the advantages of high precision, high efficiency, non-contact nondestructive detection and the like.
The technical scheme is as follows:
the invention provides a non-contact on-line measuring system of a numerical control machine tool based on multiple sensors, which comprises a measuring module, a calibration module, a communication module and a data processing module, wherein the measuring module is used for measuring the non-contact on-line measuring system of the numerical control machine tool based on the multiple sensors;
the measurement module comprises measurement module hardware and measurement module software; the measuring module hardware comprises an industrial camera, a linear laser displacement sensor and a sensor bracket; the measurement module software is used for completing measurement work and acquiring position information, surface information and geometric characteristics of a measured part on a machine tool workbench;
the calibration module comprises calibration module hardware and calibration module software; the hardware of the calibration module is a calibration board; the calibration module software is used for completing calibration of the industrial camera and calibration of the linear laser displacement sensor, acquiring imaging parameters of the industrial camera and a pose relation relative to a machine tool coordinate system, and compensating installation errors of the linear laser displacement sensor;
the communication module is mainly used for realizing the communication between the industrial camera, the linear laser displacement sensor and the measurement module software, and the data processing module is used for communicating with the machine tool numerical control system;
the data processing module controls the calibration module and the measurement module to realize the calibration work and the measurement work of the measurement system, judges the actual clamping information of the measured part in the machine tool coordinate system through the data analysis of the calibration result and the measurement result, generates corresponding processing information, and realizes the data interaction with the machine tool numerical control system through the communication module.
The improved sensor support is characterized in that the upper portion of the sensor support is of a cylindrical structure and is installed in a tool holder of a machine tool to be connected with a main shaft of the machine tool, the lower portion of the sensor support is a fixing plate, an industrial camera and a linear laser displacement sensor are fixed on the fixing plate, and a plurality of sensors are integrated to the main shaft of the machine tool.
The calibration plate is fixed on the side of the non-processing area of the working table of the machine tool through a mounting positioning hole, and a cylindrical hole for high-precision calibration is processed on the horizontal upper surface.
In a further improvement, the measuring distance of the line laser displacement sensor is preferably 60-85mm, and the measuring range is preferably 27-32 mm.
The invention also provides a non-contact on-machine measuring method of the numerical control machine based on the multi-sensor, which comprises the following steps:
1) the measured part is fixed in the machining area of the machine tool workbench through a machine tool clamp, the calibration plate is fixed on the side of the non-machining area of the machine tool workbench, and the position relation between the calibration plate and the machine tool coordinate system is determined through manual positioning before measurement;
2) the non-contact on-line measuring system controls the numerical control machine tool to drive the measuring module sensor to measure the calibration plate through data interaction with the numerical control system of the machine tool, so that the sensor calibration of the measuring system is realized; a measuring sensor in the measuring module is positioned above the calibration plate and ensures that the calibration plate is positioned in a measuring range, and measuring module software executes a camera calibration program to obtain the position relation among camera parameters, a camera coordinate system and a calibration plate coordinate system, so as to solve the position relation between the camera coordinate system and a machine tool coordinate system; the measurement module software executes a linear laser displacement sensor calibration program according to the calibration result of the camera, and finishes the installation error compensation work of the linear laser displacement sensor by taking the calibration plate plane as a calibration target;
3) the numerical control machine tool drives the measuring module to move to a measuring position, so that the measured part is positioned in a camera view field;
4) the non-contact on-line measuring system is operated by triggering the measuring module, firstly, an industrial camera collects and processes images of a measured part, position information and size information of the measured part on a workbench are obtained, a measuring route of a laser displacement sensor is ruled, and the laser displacement sensor is guided to scan and measure the measured part;
5) the data processing module processes the point cloud data of the measured part, extracts geometric features and generates a numerical control machining program matched with the actual clamping position of the measured part, the communication module transmits the numerical control machining program to the numerical control system of the machine tool, and the numerical control machine tool realizes self-adaptive machining according to the received numerical control machining program.
The invention has the beneficial effects that:
1. according to the invention, a plurality of sensors are fixed at the tail end of the machine tool spindle, and the sensors can move rapidly and precisely by means of a numerical control machine tool movement mechanism and a numerical control system, so that the measurement efficiency and the measurement precision can be improved, and the automation can be realized;
2. according to the invention, the sensor support is simple in structure and convenient to disassemble, the connection between the sensor and the machine tool spindle is realized, the switching between the sensor and a machining tool can be realized through the automatic tool changing mechanism, the on-machine measurement can be carried out after the parts are machined, the parts are not required to be transferred to a measuring chamber, the error caused by multiple clamping is avoided, and the rapid measurement is realized;
3. according to the invention, the calibration plate is fixed on the left side or the right side of the non-processing area of the machine tool, so that the on-site quick calibration of the sensor can be realized on the basis of the known relative position relationship between the calibration plate and the coordinate system of the machine tool, repeated calibration is not needed, and the method is convenient and quick. In addition, the requirements of measurement ranges of parts with different sizes can be met by replacing the specification of the calibration plate;
4. the invention realizes a non-contact on-machine measuring method for the laser detection of the visual positioning guide line by multiple sensors, namely an industrial camera combined with a line laser displacement sensor, and compared with a single visual measuring mode, the precision is obviously improved.
5. The whole set of non-contact on-machine measurement method and system is convenient to install, can be suitable for different types of numerical control machines, and has wide application range and strong universality and transportability.
Drawings
FIG. 1 is a schematic diagram of the overall structure of a non-contact on-machine measurement method and system,
figure 2 is an enlarged view of portion a of figure 1,
FIG. 3 is a front view of a sensor holder of the non-contact on-machine measurement method and system,
FIG. 4 is a schematic flow chart of the non-contact on-machine measurement method and system for part inspection,
FIG. 5 is a schematic diagram of the overall structure of a measuring module of the non-contact on-machine measuring method and system,
the method comprises the following steps of 1-a numerical control machine tool, 2-a machine tool spindle, 3-a machine tool workbench, 4-a machine tool clamp, 5-a part to be measured, 6-a sensor support, 7-an industrial camera, 8-a line laser displacement sensor, 9-a calibration plate, 10-a machine tool handle, 11-a connecting plate, 12-a fixing plate and 13-an upper computer platform.
Detailed Description
The invention is further described with reference to the following figures and detailed description.
The specific embodiment of the numerical control machine tool non-contact on-line measuring system based on the multiple sensors, which is provided by the invention, is shown in fig. 1 and fig. 2, and comprises a sensor bracket 6, an industrial camera 7, a linear laser displacement sensor 8, a calibration plate 9 and an upper computer platform 13.
The machine tool fixture 4 is fixed on the machine tool workbench 3, and the part 5 to be measured is clamped in the machine tool fixture 4; the calibration plate 9 is fixed on the left side or the right side of a non-processing area on the machine tool workbench 3 through a mounting positioning hole, and before measurement, the relative position relation between the numerical control machine 1 and the calibration plate 9 is determined in a manual positioning mode; during the process of switching to the process of processing the measured part 5 during and after the measurement is finished, the measured part 5 and the calibration plate 9 do not need to be repeatedly clamped.
As shown in fig. 3, the sensor bracket 6 is mounted at the end of the machine tool spindle 2 by means of a machine tool shank 10 and is used for fixing the industrial camera 7 and the line laser displacement sensor 8; the numerical control system of the machine tool 1 can control the machine tool spindle 2 to drive the industrial camera 7 and the linear laser displacement sensor 8 to move in the Z-axis direction, and control the machine tool workbench 3 to move in the X-axis and Y-axis directions, so that the relative positions of the measured part 5 or the calibration plate 9 and the industrial camera 7 and the linear laser displacement sensor 8 can be adjusted, and the measured part 5 or the calibration plate 9 is ensured to be in the measuring range of the industrial camera 7 and the linear laser displacement sensor 8.
As shown in fig. 4, the sensor bracket 6 comprises a connecting plate 11 and a fixing plate 12, wherein the connecting plate 11 comprises a cylindrical structure and a steel plate and can be installed in a machine tool shank 10 like a cutter so as to be connected with the machine tool spindle 2; four countersunk holes and four through holes are processed on the fixing plate 12, the countersunk holes are used for installing the industrial camera 7, and the through holes are used for installing the line laser displacement sensor 8.
As shown in fig. 5, the upper computer software system of the multi-sensor based non-contact on-machine measurement method and system for the numerical control machine tool provided by the invention comprises a calibration module, a measurement module, a data processing module and a communication module. The communication module mainly realizes the communication between the industrial camera 7 and the linear laser displacement sensor 8 and the upper computer platform 13 and the communication between the upper computer platform 13 and the machine tool numerical control system, wherein the machine tool numerical control system is connected with the upper computer platform 13 through a serial port, and the industrial camera 7 and the linear laser displacement sensor 8 are connected with the upper computer through Ethernet. The calibration module is used for completing calibration of the industrial camera and calibration of the linear laser displacement sensor. The measuring module is used for controlling the industrial camera 7 to carry out calibration and image acquisition processing work of the measured part 5, and obtaining the position and size information of the measured part 5, so that the guide line laser measuring module carries out measurement path planning and scanning measurement work of the measured part 5 according to the information obtained by the industrial camera 7; the data processing module receives the data acquired by the line laser module, performs point cloud processing, geometric feature detection and adaptive numerical control machining program generation of the part 5 to be detected, and transmits the generated numerical control machining program to the numerical control system of the machine tool.
The invention provides a non-contact on-machine measuring method and a non-contact on-machine measuring system of a numerical control machine tool based on multiple sensors, which have the following steps:
before machining, a part 5 to be measured is clamped on a machine tool workbench 3 through a machine tool clamp 4, and a machine tool automatic tool changing mechanism is adopted to change to a machine tool shank 10 provided with a measuring module;
a numerical control system of the numerical control machine 1 controls a machine tool spindle 2 and a machine tool workbench 3 to move, so that a calibration plate 9 is positioned in a measurement range of an industrial camera 7 and a linear laser displacement sensor 8, upper computer software triggers the industrial camera 7 to execute a calibration program, parameters of the industrial camera 7 are obtained, and a position relation between a coordinate system of the industrial camera 7 and a machine tool coordinate system is calculated; the upper computer platform 13 triggers the line laser displacement sensor 8 to execute a calibration program, and completes the installation error compensation of the line laser displacement sensor 8.
After calibration is finished, the numerical control system of the machine tool 1 controls the machine tool spindle 2 and the machine tool workbench 3 to move, so that the part 5 to be measured is in the measuring range of the industrial camera 7; firstly, the upper computer software triggers the industrial camera 7 to acquire and process the image of the measured part 5, the position information and the surface dimension information of the measured part 5 on the machine tool workbench 3 are acquired, and then according to the acquired information, the upper computer platform 13 prescribes the measuring path of the line laser displacement sensor 8 and guides the line laser displacement sensor 8 to scan and measure the surface of the measured part 5.
And the upper computer platform 13 processes the point cloud data of the measured part 5, extracts geometric features, generates a self-adaptive numerical control machining program matched with the actual clamping position of the measured part 5, and transmits the self-adaptive numerical control machining program to the numerical control system.
And the automatic tool changing mechanism is changed to a tool for machining.
In the numerical control machine tool non-contact on-machine measurement method and system based on the multiple sensors, the line laser displacement sensor 8 is different from the point laser displacement sensor, can project a series of laser points to the area of a line segment on the surface of an object and receive laser lines reflected by the surface of the object, thereby obtaining the contour information of the line segment area on the surface of the object. Therefore, the three-dimensional appearance of the measured part 5 can be obtained by combining the motion mechanism of the numerical control machine 1.
In the numerical control machine tool non-contact type on-machine measuring method and system based on the multiple sensors, the measuring distance of the linear laser displacement sensor 8 is preferably 60-85mm, and the measuring range is preferably 27-32 mm.
While the invention has been described in terms of its preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
Claims (8)
1. Numerical control machine tool non-contact on-line measuring system based on multisensor, its characterized in that: the device comprises a measuring module, a calibration module, a communication module and a data processing module;
the measurement module comprises measurement module hardware and measurement module software; the measuring module hardware comprises an industrial camera, a linear laser displacement sensor and a sensor bracket; the measurement module software is used for completing measurement work and acquiring position information, surface information and geometric characteristics of a measured part on a machine tool workbench;
the calibration module comprises calibration module hardware and calibration module software; the hardware of the calibration module is a calibration board; the calibration module software is used for completing calibration of the industrial camera and calibration of the linear laser displacement sensor, acquiring imaging parameters of the industrial camera and a pose relation relative to a machine tool coordinate system, and compensating installation errors of the linear laser displacement sensor;
the communication module is mainly used for realizing the communication between the industrial camera, the linear laser displacement sensor and the measurement module software, and the data processing module is used for communicating with the machine tool numerical control system;
the data processing module controls the calibration module and the measurement module to realize the calibration work and the measurement work of the measurement system, judges the actual clamping information of the measured part in the machine tool coordinate system through the data analysis of the calibration result and the measurement result, generates corresponding processing information, and realizes the data interaction with the machine tool numerical control system through the communication module.
2. The non-contact type on-line measuring system for the numerical control machine based on the multiple sensors according to claim 1, characterized in that: the upper part of the sensor support is of a cylindrical structure and is arranged in a tool shank of a machine tool to be connected with a main shaft of the machine tool, the lower part of the sensor support is a fixing plate, and an industrial camera and a linear laser displacement sensor are fixed on the fixing plate and integrate a plurality of sensors into the main shaft of the machine tool.
3. The non-contact type on-line measuring system for the numerical control machine based on the multiple sensors according to claim 1, characterized in that: the calibration plate is fixed on the side of the non-processing area of the working table of the machine tool through the mounting positioning hole, and a cylindrical hole for high-precision calibration is processed on the horizontal upper surface.
4. The system of claim 2 or 3, which is characterized in that: four counter bores and four through holes are processed on the fixing plate, the counter bores are used for mounting an industrial camera, and the through holes are used for mounting a line laser displacement sensor.
5. The non-contact type on-line measuring system for the numerical control machine based on the multiple sensors according to claim 1, characterized in that: the machine tool numerical control system is connected with the upper computer platform through a serial port.
6. The non-contact type on-line measuring system for the numerical control machine based on the multiple sensors according to claim 1, characterized in that: the industrial camera, the line laser displacement sensor and the upper computer are connected through the Ethernet.
7. The non-contact type on-line measuring system for the numerical control machine based on the multiple sensors according to claim 1, characterized in that: the measuring distance of the line laser displacement sensor is 60-85mm, and the measuring range is 27-32 mm.
8. A non-contact on-machine measuring method of a numerical control machine tool based on multiple sensors is characterized by comprising the following steps:
step S1, fixing the measured part in the processing area of the machine tool workbench through the machine tool clamp, fixing the calibration plate at the side of the non-processing area of the machine tool workbench, and determining the position relation between the calibration plate and the machine tool coordinate system through manual positioning before measurement;
step S2, the non-contact on-line measuring system controls the numerical control machine tool to drive the measuring module sensor to measure the calibration plate through the data interaction with the numerical control machine tool system, so as to realize the sensor calibration of the measuring system; a measuring sensor in the measuring module is positioned above the calibration plate and ensures that the calibration plate is positioned in a measuring range, and measuring module software executes a camera calibration program to obtain the position relation among camera parameters, a camera coordinate system and a calibration plate coordinate system, so as to solve the position relation between the camera coordinate system and a machine tool coordinate system; the measurement module software executes a linear laser displacement sensor calibration program according to the calibration result of the camera, and finishes the installation error compensation work of the linear laser displacement sensor by taking the calibration plate plane as a calibration target;
step S3, the numerical control machine drives the measuring module to move to the measuring position, so that the measured part is in the camera view field;
step S4, the non-contact on-line measuring system triggers the measuring module to work, firstly the industrial camera collects and processes the image of the measured part, obtains the position information and the size information of the measured part on the workbench, and marks the measuring route of the line laser displacement sensor to guide the line laser displacement sensor to scan and measure the measured part;
and step S5, the data processing module processes the point cloud data of the measured part, extracts geometric features and generates a numerical control machining program matched with the actual clamping position of the measured part, the communication module transmits the numerical control machining program to the numerical control system of the machine tool, and the numerical control machine tool realizes self-adaptive machining according to the received numerical control machining program.
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| CN114346410A (en) * | 2021-12-06 | 2022-04-15 | 苏州菲镭泰克激光技术有限公司 | Real-time processing path generation process for three-dimensional scanning and verification |
| CN115307575A (en) * | 2022-06-28 | 2022-11-08 | 北京工业大学 | Columnar part non-contact three-dimensional measuring device and method |
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