CN112577447B - Three-dimensional full-automatic scanning system and method - Google Patents
Three-dimensional full-automatic scanning system and method Download PDFInfo
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- CN112577447B CN112577447B CN202011431977.0A CN202011431977A CN112577447B CN 112577447 B CN112577447 B CN 112577447B CN 202011431977 A CN202011431977 A CN 202011431977A CN 112577447 B CN112577447 B CN 112577447B
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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
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2504—Calibration devices
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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
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2518—Projection by scanning of the object
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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
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/25—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object
- G01B11/2545—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. one or more lines, moiré fringes on the object with one projection direction and several detection directions, e.g. stereo
Abstract
The invention discloses a three-dimensional full-automatic scanning system and a method, the system comprises a scanning module, a communication module and a basic device module, the basic device module comprises a scanning platform, a computer, a turntable assembly, a mechanical arm and a calibration plate, the turntable assembly, the calibration plate and the mechanical arm are respectively arranged on the scanning platform, the communication module is used for establishing communication connection between the computer and the turntable assembly, the mechanical arm and the scanning module, the calibration plate is provided with coding mark points and non-coding mark points, the turntable assembly is used for fixing an object to be detected, and the scanning module is fixedly connected to the tail end of the mechanical arm and used for scanning the object to be detected. The three-dimensional full-automatic scanning system and the method provided by the invention are simple and convenient to operate, high in operation efficiency, high in measurement precision, good in repeatability and highly automatic, and can be used for batch detection.
Description
Technical Field
The invention relates to the technical field of three-dimensional scanning, in particular to a three-dimensional full-automatic scanning system and a three-dimensional full-automatic scanning method.
Background
With the development of manufacturing technology and measuring technology, the detection requirements of complex curved surface parts become more. The geometric information of the complex curved surface can be obtained by: contact measurement, such as three-dimensional coordinate machines; non-contact measurements, such as three-dimensional structured light scanning systems. The contact type measurement scanning speed is low, and the degree of freedom is low; in non-contact measurement, three-dimensional structured light measurement is taken as a representative, and is realized based on a triangulation method, and the optical triangulation method calculates depth information of a point to be measured through angle change generated by deviation of the point relative to an optical reference line. The three-dimensional structured light measurement has the advantages of simple structure, high measurement speed, strong real-time processing capability, flexible and convenient use and the like, and is widely applied to length, distance and three-dimensional shape measurement.
Although the three-dimensional structured light scanning has many advantages, there are still some limitations in specific scenes, such as inconvenient operation of moving a probe, time and labor waste, and a large amount of data redundancy generated in the scanning process. Aiming at the problems that when the same workpiece is detected in batch, the repeatability of a manual scanning path is poor, the scanning results obtained in different batches are different, the requirements on high detection speed, high efficiency and manpower and material resource saving of the batch detection field cannot be met, and the problem of batch detection is solved.
The above background disclosure is only for the purpose of assisting understanding of the concept and technical solution of the present invention and does not necessarily belong to the prior art of the present patent application, and should not be used for evaluating the novelty and inventive step of the present application in the case that there is no clear evidence that the above content is disclosed at the filing date of the present patent application.
Disclosure of Invention
In order to solve the technical problems, the invention provides a three-dimensional full-automatic scanning system and a method, which are simple and convenient to operate, high in operation efficiency, high in measurement precision, good in repeatability and high in automation degree, and can be used for batch detection.
In order to achieve the purpose, the invention adopts the following technical scheme:
the invention discloses a three-dimensional full-automatic scanning system which comprises a scanning module, a communication module and a basic device module, wherein the basic device module comprises a scanning platform, a computer, a turntable assembly, a mechanical arm and a calibration plate, the turntable assembly, the calibration plate and the mechanical arm are respectively arranged on the scanning platform, the communication module is used for enabling the computer to be respectively communicated with the turntable assembly, the mechanical arm and the scanning module, the calibration plate is provided with coding mark points and non-coding mark points, the turntable assembly is used for fixing an object to be detected, and the scanning module is fixedly connected to the tail end of the mechanical arm and used for scanning the object to be detected.
Preferably, the scanning module includes projecting apparatus and binocular camera, the projecting apparatus with the binocular camera respectively with communication connection between the computer, the projecting apparatus be used for projecting grating stripe to on the measured object, the binocular camera is used for gathering the projection at grating stripe image on the measured object.
The invention also discloses a three-dimensional full-automatic scanning method, which adopts the three-dimensional full-automatic scanning system to automatically scan a measured object and comprises the following steps:
a1: fixedly connecting a measured object to the turntable assembly, and arranging a plurality of mark points on the turntable assembly;
a2: the computer establishes communication connection with the turntable assembly, the mechanical arm and the scanning module through the communication module;
a3: calibrating the scanning module, and calibrating the hand and the eye of the mechanical arm;
a4: controlling the mechanical arm and the turntable assembly to scan the plurality of marking points through the scanning module to obtain information of the plurality of marking points;
a5: according to the information of the plurality of mark points, the computer controls the turntable assembly and the mechanical arm so that the scanning module performs preliminary scanning on the object to be measured, and primary scanning point clouds are encapsulated to obtain a preliminary scanning triangular mesh model of the object to be measured;
a6: aligning the preliminary scanning triangular mesh model with the CAD model of the measured object, and automatically generating an automatic scanning path of the measured object according to an automatic path planning algorithm;
a7: and B, the scanning module scans the measured object according to the automatic scanning path obtained in the step A6, and point cloud data are obtained after scanning is completed.
Preferably, the scanning module includes a projector and a binocular camera, and the step a3 specifically includes: and combining the depth of field and the angle required by the calibration of the binocular camera and the angle change test required by the calibration of the hand and the eye to obtain a plurality of calibration positions, driving the mechanical arm to operate according to the plurality of calibration positions by the computer, and completing the calibration of the binocular camera and the calibration of the hand and the eye of the mechanical arm by matching the projector and the binocular camera.
Preferably, calibrating the binocular camera specifically includes: calculating the coordinates of any point P in the camera coordinate system of the reference camera in the binocular camera and the coordinates in the world coordinate system, and calibrating a projection matrix M:
wherein Z iscIs the depth coordinate of the point P in the camera coordinate system, (u, v) is the coordinate of the point P on the pixel plane, (u0,v0) Is the central coordinate of the pixel plane, dx and dy represent the real transverse size and longitudinal size of the pixel on the camera photosensitive chip, and f is the focal length of the camera; r is a rotation matrix, t is a translation vector, (X)w,Yw,Zw) Is the coordinate of the point P in the world coordinate system, Px＝f/dx，pyF/dy; m is a3 × 4 projection matrix; m1From camera internal parameter ax，ay，u0，v0Determining; m2Is an external reference of the camera.
Preferably, the performing hand-eye calibration on the mechanical arm specifically includes: calculating a coordinate transformation relation from a reference camera in the binocular camera to a terminal tool coordinate system of the mechanical arm:
GX＝XH
wherein, X is a hand-eye calibration matrix, and G ═ EF-1And E is the reference camera in the coordinate system Cc1Relative to a coordinate system CwIs the orientation of the reference camera in the coordinate system Cc2Relative to a coordinate system CwH is the mechanical arm in the coordinate system Cc1And a coordinate system Cc2Relative orientation of each other, Cc1As a camera coordinate system before movement of the reference camera, Ct1As a coordinate system of the platform before movement of the reference camera, Cc2As a reference camera coordinate system after movement, Ct2As a coordinate system of the platform after movement of the reference camera, CwIs a world coordinate system.
Preferably, the step a6 of automatically generating the automatic scanning path of the object to be measured according to an automatic path planning algorithm includes: triangularization is carried out on the CAD model of the object to be detected so as to subdivide the CAD model of the object to be detected into grid CAD models, patches on the grid CAD models are automatically sampled and corresponding viewpoints are calculated, the viewpoints are classified and then combined, the poses of the viewpoints are adjusted according to shielding detection and a long and narrow patch overturning algorithm, the viewpoints after pose adjustment are sequenced through a sequencing algorithm, then limit detection and collision detection are respectively carried out on the viewpoints, corresponding viewpoints are deleted according to the results of the limit detection and the collision detection, and the automatic scanning path of the object to be detected is obtained.
Preferably, automatically sampling the patches on the grid CAD model and calculating corresponding viewpoints, and classifying and combining the viewpoints specifically includes: classifying the patches into large patches and small patches according to the area of each patch, respectively calculating the viewpoints corresponding to the large patches and the small patches, defining the narrow long side of each patch after being approximately rectangular as the main direction of each patch, and performing equidistant sampling in the main direction of each patch to obtain sampling points corresponding to one patch; extending the distance of the sampling point along the normal direction of the surface patch to the depth of field of the camera to obtain a viewpoint position; and merging the viewpoints corresponding to the large surface patches, and deleting redundant viewpoints smaller than a preset distance threshold.
Preferably, the adjusting the pose of the viewpoint according to the occlusion detection and the long and narrow patch inversion algorithm, and the ranking of the pose-adjusted viewpoint by the ranking algorithm specifically comprises: after redundant viewpoints are deleted, turning and adjusting the long and narrow patches, judging whether the poses of the viewpoints corresponding to the long and narrow patches meet the condition that the connecting line direction of the binocular cameras in the scanning module is consistent with the main direction, and if not, adjusting the poses to be parallel to the main direction; carrying out occlusion judgment on the viewpoint after the pose is adjusted, connecting the viewpoint with the corresponding sampling point on the panel, if the viewpoint and the CAD model have an intersection, representing that the occlusion problem exists, and deleting the viewpoint; and then sorting the viewpoints of merging simplification, pose adjustment and shielding position deletion according to the distance between the viewpoints.
Preferably, the respectively performing the limit detection on the viewpoints includes: judging whether the coordinates of the viewpoint are in the working space range of the mechanical arm, if not, judging the corresponding viewpoint as an unreachable point of the mechanical arm, and deleting the unreachable point; and after the unreachable points are deleted, calculating the angle value of the joint angle of the mechanical arm according to the rest of the viewpoints, judging whether the angle value of the joint angle of the mechanical arm is in the angle movement range of the joint shaft of the mechanical arm, if not, judging the corresponding viewpoint as a limit point, and deleting the limit point.
Preferably, the judging whether the coordinates of the viewpoint are within the working space range of the robot arm includes: calculating the position point of the tail end of the mechanical arm according to a positive kinematic equation to construct a point cloud and obtain the working space range of the mechanical arm, wherein the positive kinematic equation is as follows:
wherein the content of the first and second substances,
representing transformed coordinates from a base of the robot arm to an end tool coordinate system of the robot arm,
a coordinate conversion matrix from the connecting rod i-1 to the connecting rod i is shown, and the connecting rod i-1 represents a base of the mechanical arm when i is 1;
in the above formula, c represents cos (), s represents sin (), and αi-1Showing the connecting rod i-1 being wound around xi-1Will zi-1Rotate to ziThe angle of rotation; a isi-1Showing connecting rod i-1 along xi-1Will zi-1Is translated to and ziThe distance of translation; thetaiShowing the connecting rod i-1 being wound around ziX is to bei-1Rotate to xiThe angle of rotation; diShowing connecting rod i-1 along ziX is to bei-1Is translated to xiThe distance of translation; x is the number ofi-1、zi-1Is the x-axis and z-axis of the coordinate system of the connecting rod i-1, xi、ziIs the x-axis and z-axis of the coordinate system of link i;
θi＝θimin+(θimax-θimin)×rand(N，1)
where N is the number of randomly generated points in the workspace, θiminDenotes thetaiMinimum value of, thetaimaxDenotes thetaiIs measured.
Preferably, the calculating the angle value of the joint angle of the robot arm from the remaining viewpoints and the determining whether the angle value of the joint angle of the robot arm is within the angular movement range of the joint axis of the robot arm specifically includes: calculating a pose matrix T of the mechanical arm according to the position coordinates (X, Y, Z) and Euler angles (A, B, C) of the remaining viewpoints:
in the above formula, c represents cos (), s represents sin (), the angle values of the six joint angles of the mechanical arm are calculated according to the pose matrix T, whether the angle values of the six joint angles of the mechanical arm are within the angle motion ranges of the six joint axes of the mechanical arm is judged, and if not, the corresponding viewpoint is judged as the limiting point.
Preferably, the collision detection of the viewpoints respectively includes: and calculating the bounding boxes of the mechanical arm and the scanning module, judging whether the bounding boxes of the mechanical arm and the scanning module generate an intersection in the motion process, and if so, judging the viewpoint in the intersection as a collision point.
Preferably, after the limiting detection and the collision detection are respectively performed on the viewpoints and the corresponding viewpoints are deleted according to the results of the limiting detection and the collision detection, the method further includes: and reordering the viewpoints according to the joint angle corresponding to each viewpoint so that the change of the joint angle corresponding to the viewpoint is minimum.
Compared with the prior art, the invention has the beneficial effects that: the three-dimensional full-automatic scanning system and the method provided by the invention have the advantages of simple operation, high operation efficiency, high measurement precision, good repeatability and high automation, can be used for batch detection, can be analyzed through a CAD model of a detected object, automatically calculates the scanning direction, position and path, can complete full-automatic three-dimensional scanning of different detected objects by the mechanical arm only by executing a fixed program, replaces complicated manual programming and operation which are easy to make mistakes, and ensures the operation efficiency, scanning precision and safety of equipment.
Drawings
FIG. 1 is a block diagram of the structural modules of a three-dimensional fully automatic scanning system in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic view of a three-dimensional fully automatic scanning system according to a preferred embodiment of the present invention;
FIG. 3 is a flow chart of a three-dimensional fully automatic scanning method of a preferred embodiment of the present invention;
FIG. 4 is a graph illustrating the effect of coarse scanning of a crankshaft according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of an automatic path planning for a crankshaft in accordance with an embodiment of the present invention;
FIG. 6 is a graph illustrating the effect of the fine scanning of the crankshaft according to the exemplary embodiment of the present invention;
FIG. 7a is a crankshaft offset chromatogram of an embodiment of the present invention;
FIG. 7b is a graph of crankshaft deflection with labels showing the results of an embodiment of the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects to be solved by the embodiments of the present invention more clearly apparent, the present invention is further described in detail below with reference to the accompanying drawings and the embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element. In addition, the connection may be for either a fixing function or a circuit connection function.
The above-described difficulties in the background art are solved by installing an optical scanner at the end of a programmable industrial robot and driving the robot to perform automated scanning by programming. However, the online teaching programming of the mechanical arm also brings many problems, such as long programming time and short running water detection time; there is no good optimal adjustment for the measurement path; programming quality cannot be guaranteed, and repeated paths or undetected areas are easy to occur; operational errors can result in equipment crash damage, resulting in economic losses. Aiming at the problem, the invention provides a three-dimensional structured light full-automatic scanning system and a method which are simple and convenient to operate, high in operation efficiency, high in measurement precision, good in repeatability and highly automatic and can be used for batch detection. The method is used for programming the mechanical arm off line based on a CAD model. Through the analysis to the measured object CAD model, automatic calculation scanning direction, position and route, the arm only need execute fixed procedure can accomplish the full-automatic three-dimensional scanning to different measured objects, replaced complicated and easy manual programming and the operation of makeing mistakes, guaranteed the efficiency of equipment operation, the precision and the security of scanning.
Referring to fig. 1, a preferred embodiment of the present invention discloses a three-dimensional full-automatic scanning system, which includes a scanning module 10, a communication module 20 and a basic device module 30, wherein the basic device module includes a scanning platform, a computer, a turntable assembly, a mechanical arm and a calibration plate, the turntable assembly, the calibration plate and the mechanical arm are respectively disposed on the scanning platform, the communication module is used to establish communication connection between the computer and the turntable assembly, the mechanical arm and the scanning module, the calibration plate is provided with a coding mark point and a non-coding mark point, the turntable assembly is used to fix an object to be measured, and the scanning module is fixedly connected to the end of the mechanical arm for scanning the object to be measured.
Specifically, the scanning module 10 includes a scanning probe 11, the scanning probe 11 includes a blue light projector 111 and two industrial cameras 112, the blue light projector 111 and the two industrial cameras 112 are respectively in communication connection with a computer, the computer is provided with automatic measurement software to control the blue light projector 111 and the two industrial cameras 112 through the software, the blue light projector 111 projects grating stripes to the surface of the object to be measured after receiving instructions from the computer, and the two industrial cameras 112 constitute a binocular camera to collect grating stripe images projected on the surface of the object to be measured.
The communication module 20 includes a robot arm control cabinet 21 and a turntable control cabinet 22, the robot arm control cabinet 21 is used for establishing a communication connection between a computer and a robot arm, the turntable control cabinet 22 is used for establishing a communication connection between a computer and a turntable, the communication module 20 may further include communication units in the blue light projector 111 and the two industrial cameras 112, and the blue light projector 111 and the two industrial cameras 112 are respectively connected with the computer through the communication units in the blue light projector 111 and the two industrial cameras 112.
The basic device module 30 specifically comprises a computer 31, a tool 32, a turntable 33, six-axis mechanical arms 34, a plane calibration plate 35 and a scanning platform 36, wherein the computer 31 is used for data communication and man-machine interaction and controls the whole scanning process, the tool 32 is connected to the turntable 33 to form the turntable assembly, the tool 32 is used for supporting and clamping a measured object, the turntable 33 bears the measured object to rotate, the six-axis mechanical arms 34 have six degrees of freedom, the scanning measuring head 11 is installed on a tail end tool platform of the six-axis mechanical arms 34, the plane calibration plate 35 comprises 12-bit coding mark points and non-coding mark points, the plane calibration plate 35 can be arranged at a position near the turntable 33, and the scanning platform 36 is used for positioning and supporting all devices of the full-automatic scanning system.
The specific construction schematic diagram of the three-dimensional full-automatic scanning system is shown in fig. 2, the scanning probe 11 is mounted on a six-axis mechanical arm 34, and is fixed on a terminal tool platform (TCP) of the six-axis mechanical arm 34 through screws, signals for driving the six-axis mechanical arm 34 are input by a mechanical arm control cabinet 21, and the mechanical arm control cabinet 21 is connected to a power supply; the object to be measured 40 is placed on the tool 32, and the tool 32 is fixed on the turntable 33 through the hexagon socket head cap screw; the signal input and control of the rotary table 33 are realized by a rotary table control cabinet 22, and the rotary table control cabinet 22 is also connected to a power supply; the turntable control cabinet 22 and the mechanical arm control cabinet 21 are respectively connected with a host of the computer 31 through USB data lines, and communication signals are sent to serial ports through computer software to realize the control of the control cabinet by the computer 31, so that the six-axis mechanical arm 34 is controlled by the computer 21 to drive the scanning measuring head 11 to be matched with the turntable 33 to realize full-automatic three-dimensional scanning.
As shown in fig. 3, the preferred embodiment of the present invention discloses a three-dimensional full-automatic scanning method, which adopts the three-dimensional full-automatic scanning system, and specifically includes the following steps:
s1: hardware preparation of fully automatic scanning system: and starting a system main switch, starting a camera and a projector, starting a mechanical arm and a turntable switch, mounting a tool on the turntable, placing the object to be measured on the tool, clamping, and pasting a mark point on the tool.
S2: software preparation of fully automatic scanning system: and opening automatic measurement software, establishing communication connection between a computer and the mechanical arm and the turntable, and connecting the camera and the projector.
S3: calibrating a full-automatic scanning system: and calibrating the camera and calibrating the hand and the eye of the mechanical arm.
And comprehensively considering the depth of field and the angle required by the camera and the angle change required by the calibration of the hands and the eyes, and testing to obtain 15 calibration positions. And the teaching mechanical arm is driven by a computer to operate according to a teaching path and is matched with the scanning measuring head to simultaneously complete the calibration of the binocular camera and the hand-eye calibration of the mechanical arm.
Calibrating the binocular cameras, namely calibrating the internal parameters of the two cameras respectively, and calibrating R, t transformation of the two cameras, wherein the camera calibration considers a pixel coordinate system, a camera coordinate system and a world coordinate system. Finding out the conversion relation among three coordinate systems according to a computer vision monocular camera model to calculate the coordinate of any point P in a reference camera coordinate system and the coordinate in a world coordinate system, and calibrating a projection matrix M:
wherein Z iscIs the depth coordinate of the point P in the camera coordinate system, (u, v) is the coordinate of the point P on the pixel plane, (u0,v0) Is the central coordinate of the pixel plane, dx and dy represent the real transverse size and longitudinal size of the pixel on the camera photosensitive chip, and f is the focal length of the camera; r is a rotation matrix, t is a translation vector, (X)w,Yw,Zw) Is the coordinate of the point P in the world coordinate system, Px＝f/dx，pyF/dy; m is a3 × 4 projection matrix; m1From camera internal parameter ax，ay，u0，v0Determining, only in relation to the internal structure of the camera; m2The method is a camera external reference and only relates to the translation and rotation conversion relation of the camera to world coordinates. (u)0,v0) And (u, v) are pixel coordinates which can be transformed to the camera coordinate system through the focal length f transformation.
The hand-eye calibration is to solve the coordinate transformation relation from the reference camera to the coordinate system of the tool at the tail end of the mechanical arm. Cc1、Ct1For the camera coordinate system and platform coordinate system before camera movement, Cc2、Ct2The camera coordinate system and the platform coordinate system after the camera moves. Calibrating the cameras to obtain internal and external parameters, wherein the cameras are respectively arranged at Cc1And Cc2Relative to C in the coordinate systemwIs represented by the matrix E, F, then G ═ EF-1. Reading C on a robot arm demonstratort1And Ct2The relative orientation between them is represented by the matrix H. The camera is fixed on the platform before and after moving, and the visible angle is Cc1And Ct1Relative orientation and Cc2And Ct2The relative orientation is the same, namely X is a matrix formed by the calibration parameters of the hand and the eye. The hand-eye relation equation is as follows:
GX＝XH
the matrix G is obtained by external parameters calibrated by a camera, the matrix H is read by a mechanical arm demonstrator, and the hand-eye calibration matrix X can be solved by solving an equation.
S4: global point scanning: and operating the mechanical arm to cooperate with the turntable, scanning the mark points on the tool, exporting the mark point information, and storing the mark point information into a file to obtain global points (namely a series of stored scanned mark points), wherein the global points are used for assisting the point cloud registration in the automatic scanning process.
S5: coarse scanning: and importing the global points, setting parameters, carrying out rough scanning on the measured object by the automatic control mechanical arm of the computer, and packaging the rough-scanning point cloud to obtain a rough-scanning triangular mesh model. The parameter setting is to set the exposure time of the camera and adjust the exposure time to a proper value, so that the brightness of the picture displayed in real time on the software interface is moderate, and the mark point on the tool can be seen. After the exposure time is set, selecting a proper angle for scanning the measured object, keeping the mechanical arm stationary after reaching the position, and sending an instruction to the turntable for rotation through the serial port by the operation software. And selecting a plurality of proper rotating intervals of the rotating disc, recording the rotating angle of the rotating disc, and arranging the rotating angle into a coarse scanning path. And then, the computer controls the mechanical arm to run the path to carry out rough scanning on the measured object, and the rough scanning point cloud is packaged in automatic measurement software to obtain a rough scanning triangular mesh model of the measured object.
S6: automatic path planning: and automatically aligning the rough-scanning triangular mesh model and the CAD model of the measured object in automatic measurement software, and automatically generating a scanning path corresponding to the measured object according to an automatic path planning algorithm.
The automatic alignment of the rough-scanning triangular mesh model and the CAD model of the measured object in the automatic measurement software specifically comprises the following steps: three points are selected on the CAD model of the object to be measured, three points at corresponding positions are also selected on the obtained rough-scanning triangular mesh model, and the rough-scanning triangular mesh model and the CAD model of the object to be measured can be aligned after the confirmation button is clicked, so that the automatic scanning platform, the turntable and the rough-scanning triangular mesh model are aligned to the coordinate system of the CAD model of the object to be measured.
The step of automatically generating the scanning path corresponding to the measured object according to the automatic path planning algorithm specifically includes:
the automatic path planning algorithm triangulates the CAD model of the measured object input into the software, and subdivides the CAD model into a grid CAD model. The patches are classified into large patches and small patches according to the area of each patch. Calculating a viewpoint corresponding to a large patch, specifying that the narrow length side of the patch is the main direction of the patch after the patch is approximately rectangular, and sampling at equal intervals in the main direction of the patch to obtain a sampling point corresponding to the patch; the same operation is performed for the dough pieces. And extending the sampling point along the normal direction of the surface patch by the distance of the depth d of the camera to obtain the viewpoint position. And combining the viewpoints corresponding to the large pictures, taking a certain threshold value, and deleting the redundant viewpoints with a short distance to simplify the number of the viewpoints.
And simplifying a number of viewpoints, turning and adjusting the long and narrow patches, judging whether the poses of the viewpoints corresponding to the long and narrow patches meet the condition that the connecting line direction of two cameras in the scanning measuring head is consistent with the main direction, and if not, adjusting the directions to be parallel to the main direction. And (4) carrying out occlusion judgment on the viewpoint with the adjusted pose, connecting the viewpoint with the corresponding sampling point on the surface, and deleting the viewpoint if the viewpoint is intersected with the CAD model and the occlusion problem exists. Merging is simplified, pose is adjusted, and the viewpoints of the shielding positions are deleted and sorted according to the distance between the viewpoints.
And after sorting, carrying out limit detection and collision detection on the viewpoint, firstly judging whether the viewpoint coordinate is in the working space range of the mechanical arm, and deleting the viewpoint coordinate, namely the unreachable point, outside the working space. The working space of the mechanical arm can be obtained by setting the angle range of each joint angle and using a Monte Carlo method to obtain the uniform random value of each joint of the mechanical arm in the variation range:
θi＝θimin+(θimax-θimin)×rand(N，1)
the obtained angle random value is introduced into a positive kinematic equation
Wherein
In the above formula, c represents cos (), s represents sin (), and a, d and alpha are parameters obtained in the establishment of the mechanical arm model. The meaning of each specific parameter is: n is the number of randomly generated points in the working space and can be set by self, and the larger N is, the more points in the space are, the denser the space is; n in a matrix of positive kinematic equationsx、ny、nz、ox、oy、oz、ax、ay、az、px、py、pzThe total 12 variables are respectively simplified parameters; the mechanical arm adopted in the embodiment is a six-axis mechanical arm, i is 1-6, and 0 represents a base of the mechanical arm, wherein
Representing a coordinate transformation matrix from the base of the robot arm to the first link,
representing a transformation matrix from the base of the robot arm to the end tool coordinate system,
a coordinate conversion matrix from the connecting rod i-1 to the connecting rod i is shown, and when i is 1, the connecting rod i-1 represents a base of the mechanical arm; a isi-1、di、αi-1And thetaiIs a parameter, alpha, established by the end-of-arm tool coordinate systemi-1Representing the connecting rod i-1 wound around xi-1Will zi-1Rotate to ziThe angle of rotation; a isi-1Representing connecting rod i-1 along xi-1Will zi-1Is translated to and ziThe distance of translation; thetaiRepresenting the connecting rod i-1 wound around ziX is to bei-1Rotate to xiThe angle of rotation, that is, the angle value of each joint angle; diRepresenting connecting rod i-1 along ziX is to bei-1Is translated to xiThe distance of translation; x is the number ofi-1，zi-1Is the x-axis and z-axis of the link i-1 coordinate system, xi，ziAre the x-axis and z-axis of the link i-coordinate system.
And finally, calculating a position point corresponding to the tail end of the mechanical arm to construct a point cloud consisting of random points, and obtaining the working space of the mechanical arm.
And calculating a mechanical arm pose matrix T according to the remaining viewpoint position coordinates (X, Y, Z) and Euler angles (A, B, C).
In the above formula, c represents cos (), s represents sin (), the angle values of the 6 mechanical arm joint angles are solved according to the obtained T matrix, whether the obtained angle values of the 6 mechanical arm joint angles are within the angle motion range of 6 axes is judged, the beyond viewpoint is the limiting point, and the limiting point is deleted. And collision detection is carried out on the surrounding boxes of the mechanical arm and the scanning measuring head, whether an intersection is generated in the motion process is judged, and if the intersection is generated, the viewpoint in the intersection is judged as a collision point. And after the limit detection and the collision detection are finished, the viewpoints are reordered according to the angle values of the 6 joint angles corresponding to each viewpoint, so that the change of the joint angles corresponding to the viewpoints is minimum, namely the condition of minimum motion cost of the mechanical arm is met, and then the automatic measurement software outputs a finally planned full-automatic scanning path.
S7: full-automatic scanning: and (4) running the full-automatic scanning path generated in the step (S6) on the basis of the rough scanning engineering, and automatically controlling the mechanical arm by the computer to complete the whole scanning process.
S8: detection and analysis: and after scanning is finished, point cloud data is obtained, and after the point cloud data is packaged into a triangular mesh model, detection on the aspects of contour, size, appearance, defects and the like is carried out.
The three-dimensional full-automatic scanning method provided by the preferred embodiment of the invention provides a scheme with simple and convenient operation, high operation efficiency, high measurement precision, good repeatability and high automation for batch detection of complex curved surface parts, and has the following advantages:
(1) in the method, step S3 is carried out to complete the calibration of the binocular structured light camera and the hand-eye calibration of the reference camera and the mechanical arm at the same time, and the camera internal parameter, external parameter and hand-eye relation matrix are obtained in one calibration process. And the pose of the mechanical arm for automatic calibration replaces the pose of the traditional calibration plate, the same effect is realized, and the method has the characteristics of rapidness and stability.
(2) In the method, step S6, a CAD model of the object to be measured is given, and the corresponding viewpoint and path are automatically generated, and for different objects to be measured, the CAD models are different, and the optimal scanning path automatically calculated by software is also different, so that the method has the characteristic of strong adaptability; the path planning considers the conditions of shielding, collision and minimum mechanical arm movement cost at the same time, so that the method has the characteristics of high stability and accessibility, and the three-dimensional detection efficiency is greatly improved.
(3) The full-automatic scanning result of the step S7 of the method is established on the coarse scanning result, so the method has the characteristics of high measurement precision and complete measurement data.
In a specific example, the method for performing three-dimensional full-automatic scanning on a crankshaft workpiece by using the structured light-based three-dimensional full-automatic scanning method comprises the following specific steps:
step S1, hardware preparation of the full-automatic scanning system: and starting a system main switch, starting a camera and a projector, starting a mechanical arm and a turntable switch, mounting a tool on the turntable, placing the crankshaft on the tool, clamping the crankshaft tightly, and labeling points on the tool.
Step S2, software preparation of the full-automatic scanning system: and opening automatic measurement software, establishing communication between a computer and the mechanical arm and the turntable, and connecting the camera and the projector.
Step S3, calibrating the full-automatic scanning system: the mechanical arm is operated to move 15 positions, the pose of the mechanical arm is recorded in the mechanical arm demonstrator respectively, pose information is exported in mechanical arm software, and the pose information is arranged into a path file to be used as input to be transmitted to automatic measurement software. And the software sends a signal after reading the path, drives the mechanical arm to operate according to a teaching path, and completes calibration of the binocular camera and hand-eye calibration of the mechanical arm simultaneously by matching with the scanning probe projection grating to shoot and calculate coordinates of the coding mark point and the non-coding mark point on the calibration plate, so as to obtain internal parameters of the two cameras, a conversion relation between the cameras and a conversion relation between the reference camera and a tool coordinate system (TCP) at the tail end of the mechanical arm.
Step S4, global point scan: and moving the mechanical arm to enable the scanning measuring head to align to the mark point on the tool, acquiring an image in the automatic measurement software, reconstructing the mark point, and moving the turntable to acquire the mark point image at the next position. And adjusting the position of the mechanical arm and the angle of the turntable until most of the mark points on the tool are identified, and exporting the scanned global points for the next use.
Step S5, crankshaft rough scan: after the system is calibrated, the global points obtained in the step S4 are imported, the exposure time of the camera is set, a coarse scanning path is generated by using the rotation of the turntable, the mechanical arm is automatically controlled by the computer to perform coarse scanning on the crankshaft, the coarse scanning point cloud is encapsulated to obtain a coarse scanning triangular mesh model, and the coarse scanning effect graph of the crankshaft is shown in fig. 4.
Step S6, automatic path planning: and (4) importing the automatic scanning platform, the turntable, the rough-scanning triangular mesh model obtained in the step (S5) and the crankshaft CAD nominal model into automatic measurement software for automatic alignment, so that the automatic scanning platform, the turntable and the rough-scanning triangular mesh model are aligned to a crankshaft CAD coordinate system. And automatically generating a full-automatic scanning path of the crankshaft according to an automatic path planning algorithm. The automatic path planning algorithm automatically samples the patches on the crankshaft CAD and calculates corresponding viewpoints, the viewpoints are classified and combined, the poses of the viewpoints are adjusted according to shielding detection and a long and narrow patch turning algorithm, the viewpoints after pose adjustment are sequenced through a sequencing algorithm and then limit detection and collision detection of path points are carried out, the algorithm automatically deletes part of inaccessible points and collision points of the mechanical arm in automatic measurement software, and finally obtains a planned full-automatic scanning path, the automatic path planning schematic diagram of the crankshaft is shown in FIG. 5, 100 represents a crankshaft workpiece, and 200 represents the positions of the viewpoints.
Step S7, full auto scan: the path generated in the step S6 is run on the basis of the rough scanning project, the mechanical arm is automatically controlled by the computer to drive the scanning probe to complete the whole scanning process, the point cloud data of the crankshaft is obtained, and the point cloud data can be packaged into a triangular mesh model, and the crankshaft fine scanning effect diagram is shown in fig. 6.
Step S8, detection analysis: and (3) introducing the crankshaft triangular grid model and the crankshaft CAD model into automatic measurement software for automatic alignment, analyzing the integral deviation of the grid model and the CAD model, obtaining a crankshaft deviation chromatogram shown in figure 7a and a crankshaft deviation schematic diagram shown in figure 7b, and finally obtaining the detection result of the scanning result which is qualified.
The three-dimensional full-automatic scanning method provided by the embodiment of the invention is simple and convenient to operate, high in operation efficiency, high in measurement precision, good in repeatability, highly automatic and applicable to batch detection.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.
Claims (13)
1. A three-dimensional full-automatic scanning method is characterized in that a three-dimensional full-automatic scanning system is adopted to automatically scan a measured object, the three-dimensional full-automatic scanning system comprises a scanning module, a communication module and a basic device module, the basic device module comprises a scanning platform, a computer, a turntable assembly, a mechanical arm and a calibration plate, the turntable assembly, the calibration plate and the mechanical arm are respectively arranged on the scanning platform, the communication module is used for enabling the computer to respectively establish communication connection with the turntable assembly, the mechanical arm and the scanning module, a coding mark point and a non-coding mark point are arranged on the calibration plate, the turntable assembly is used for fixing the measured object, and the scanning module is fixedly connected to the tail end of the mechanical arm and used for scanning the measured object;
the three-dimensional full-automatic scanning method comprises the following steps:
a1: fixedly connecting a measured object to the turntable assembly, and arranging a plurality of mark points on the turntable assembly;
a2: the computer establishes communication connection with the turntable assembly, the mechanical arm and the scanning module through the communication module;
a3: calibrating the scanning module, and calibrating the hand and the eye of the mechanical arm;
a4: controlling the mechanical arm and the turntable assembly to scan the plurality of marking points through the scanning module to obtain information of the plurality of marking points;
a5: according to the information of the plurality of mark points, the computer controls the turntable assembly and the mechanical arm so that the scanning module performs preliminary scanning on the object to be measured, and primary scanning point clouds are encapsulated to obtain a preliminary scanning triangular mesh model of the object to be measured;
a6: aligning the preliminary scanning triangular mesh model with the CAD model of the measured object, and automatically generating an automatic scanning path of the measured object according to an automatic path planning algorithm;
a7: and B, the scanning module scans the measured object according to the automatic scanning path obtained in the step A6, and point cloud data are obtained after scanning is completed.
2. The three-dimensional full-automatic scanning method according to claim 1, wherein the scanning module comprises a projector and a binocular camera, the projector and the binocular camera are respectively in communication connection with the computer, the projector is used for projecting grating stripes onto the object to be measured, and the binocular camera is used for collecting grating stripe images projected onto the object to be measured.
3. The three-dimensional full-automatic scanning method according to claim 1, wherein the scanning module comprises a projector and a binocular camera, and the step a3 specifically comprises: and combining the depth of field and the angle required by the calibration of the binocular camera and the angle change test required by the calibration of the hand and the eye to obtain a plurality of calibration positions, driving the mechanical arm to operate according to the plurality of calibration positions by the computer, and completing the calibration of the binocular camera and the calibration of the hand and the eye of the mechanical arm by matching the projector and the binocular camera.
4. The three-dimensional full-automatic scanning method according to claim 3, wherein calibrating the binocular camera specifically comprises: calculating the coordinates of any point P in the camera coordinate system of the reference camera in the binocular camera and the coordinates in the world coordinate system, and calibrating a projection matrix M:
wherein Z iscIs the depth coordinate of the point P in the camera coordinate system, (u, v) is the coordinate of the point P on the pixel plane, (u0,v0) Is the central coordinate of the pixel plane, dx and dy represent the real transverse size and longitudinal size of the pixel on the camera photosensitive chip, and f is the focal length of the camera; r is a rotation matrix, t is a translation vector, (X)w,Yw,Zw) Is the coordinate of the point P in the world coordinate system, PxF/dx, py f/dy; m is a3 × 4 projection matrix; m1From camera internal parameter ax，ay，u0，v0Determining; m2Is an external reference of the camera.
5. The three-dimensional full-automatic scanning method according to claim 3, wherein the hand-eye calibration of the mechanical arm specifically comprises: calculating a coordinate transformation relation from a reference camera in the binocular camera to a terminal tool coordinate system of the mechanical arm:
GX＝XH
wherein, X is a hand-eye calibration matrix, and G ═ EF-1And E is the reference camera in the coordinate system Cc1Relative to a coordinate system CwIs the orientation of the reference camera in the coordinate system Cc2Relative to a coordinate system CwH is the mechanical arm in the coordinate system Cc1And a coordinate system Cc2Relative orientation of each other, Cc1As a camera coordinate system before movement of the reference camera, Ct1As a coordinate system of the platform before movement of the reference camera, Cc2As a reference camera coordinate system after movement, Ct2As a coordinate system of the platform after movement of the reference camera, CwIs a world coordinate system.
6. The method according to any one of claims 2 to 5, wherein the step A6 of automatically generating the automatic scanning path of the object to be measured according to an automatic path planning algorithm includes: triangularization is carried out on the CAD model of the object to be detected so as to subdivide the CAD model of the object to be detected into grid CAD models, patches on the grid CAD models are automatically sampled and corresponding viewpoints are calculated, the viewpoints are classified and then combined, the poses of the viewpoints are adjusted according to shielding detection and a long and narrow patch overturning algorithm, the viewpoints after pose adjustment are sequenced through a sequencing algorithm, then limit detection and collision detection are respectively carried out on the viewpoints, corresponding viewpoints are deleted according to the results of the limit detection and the collision detection, and the automatic scanning path of the object to be detected is obtained.
7. The method according to claim 6, wherein automatically sampling patches on the mesh CAD model and calculating corresponding viewpoints, and classifying and combining the viewpoints specifically comprises: classifying the patches into large patches and small patches according to the area of each patch, respectively calculating the viewpoints corresponding to the large patches and the small patches, defining the narrow long side of each patch after being approximately rectangular as the main direction of each patch, and performing equidistant sampling in the main direction of each patch to obtain sampling points corresponding to one patch; extending the distance of the sampling point along the normal direction of the surface patch to the depth of field of the camera to obtain a viewpoint position; and merging the viewpoints corresponding to the large surface patches, and deleting redundant viewpoints smaller than a preset distance threshold.
8. The three-dimensional full-automatic scanning method according to claim 7, wherein the pose of the viewpoint is adjusted according to occlusion detection and a long and narrow patch inversion algorithm, and the ranking of the viewpoint after pose adjustment through a ranking algorithm specifically comprises: after redundant viewpoints are deleted, turning and adjusting the long and narrow patches, judging whether the poses of the viewpoints corresponding to the long and narrow patches meet the condition that the connecting line direction of the binocular cameras in the scanning module is consistent with the main direction, and if not, adjusting the poses to be parallel to the main direction; carrying out occlusion judgment on the viewpoint after the pose is adjusted, connecting the viewpoint with the corresponding sampling point on the panel, if the viewpoint and the CAD model have an intersection, representing that the occlusion problem exists, and deleting the viewpoint; and then sorting the viewpoints of merging simplification, pose adjustment and shielding position deletion according to the distance between the viewpoints.
9. The method according to claim 6, wherein the performing the limit detection on the viewpoints respectively comprises: judging whether the coordinates of the viewpoint are in the working space range of the mechanical arm, if not, judging the corresponding viewpoint as an unreachable point of the mechanical arm, and deleting the unreachable point; and after the unreachable points are deleted, calculating the angle value of the joint angle of the mechanical arm according to the rest of the viewpoints, judging whether the angle value of the joint angle of the mechanical arm is in the angle movement range of the joint shaft of the mechanical arm, if not, judging the corresponding viewpoint as a limit point, and deleting the limit point.
10. The method of claim 9, wherein determining whether the coordinates of the viewpoint are within the working space of the robotic arm comprises: calculating the position point of the tail end of the mechanical arm according to a positive kinematic equation to construct a point cloud and obtain the working space range of the mechanical arm, wherein the positive kinematic equation is as follows:
wherein the content of the first and second substances,
representing transformed coordinates from a base of the robot arm to an end tool coordinate system of the robot arm,
a coordinate conversion matrix from the connecting rod i-1 to the connecting rod i is shown, and the connecting rod i-1 represents a base of the mechanical arm when i is 1;
in the above formula, c represents cos (), s represents sin (), and αi-1Showing the connecting rod i-1 being wound around xi-1Will zi-1Rotate to ziThe angle of rotation; a isi-1Showing connecting rod i-1 along xi-1Will zi-1Is translated to and ziThe distance of translation; thetaiShowing the connecting rod i-1 being wound around ziX is to bei-1Rotate to xiThe angle of rotation; diShowing connecting rod i-1 along ziX is to bei-1Is translated to xiThe distance of translation; x is the number ofi-1、zi-1Is the x-axis and z-axis of the coordinate system of the connecting rod i-1, xi、ziIs the x-axis and z-axis of the coordinate system of link i;
θi＝θimin+(θimax-θimin)×rand(N,1)
where N is the number of randomly generated points in the workspace, θiminDenotes thetaiMinimum value of, thetaimaxDenotes thetaiIs measured.
11. The three-dimensional full-automatic scanning method according to claim 9, wherein calculating an angle value of a joint angle of the robot arm from the remaining viewpoints, and determining whether the angle value of the joint angle of the robot arm is within an angular movement range of a joint axis of the robot arm specifically comprises: calculating a pose matrix T of the mechanical arm according to the position coordinates (X, Y, Z) and Euler angles (A, B, C) of the remaining viewpoints:
in the above formula, c represents cos (), s represents sin (), the angle values of the six joint angles of the mechanical arm are calculated according to the pose matrix T, whether the angle values of the six joint angles of the mechanical arm are within the angle motion ranges of the six joint axes of the mechanical arm is judged, and if not, the corresponding viewpoint is judged as the limiting point.
12. The method according to claim 6, wherein the collision detection of the viewpoints comprises: and calculating the bounding boxes of the mechanical arm and the scanning module, judging whether the bounding boxes of the mechanical arm and the scanning module generate an intersection in the motion process, and if so, judging the viewpoint in the intersection as a collision point.
13. The three-dimensional full-automatic scanning method according to claim 6, wherein the performing limit detection and collision detection on the viewpoints respectively, and deleting the corresponding viewpoints according to the results of the limit detection and collision detection further comprises: and reordering the viewpoints according to the joint angle corresponding to each viewpoint so that the change of the joint angle corresponding to the viewpoint is minimum.
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