CN113074664A - Rapid RV reducer cycloid wheel manufacturing error detection system based on imaging technology - Google Patents
Rapid RV reducer cycloid wheel manufacturing error detection system based on imaging technology Download PDFInfo
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Abstract
The invention discloses an imaging technology-based system for rapidly detecting manufacturing errors of a cycloidal gear of an RV reducer, which comprises an imaging module, an image processing module, an error solving module, a result display module and a data storage module, wherein the imaging module is used for acquiring an image of the cycloidal gear of the RV reducer; the imaging module comprises a light source, a zoom lens, a CMOS imaging sensor, a data transmission unit and a communication unit, and the image processing module comprises a camera calibration unit, an image preprocessing unit, an edge detection and feature extraction unit and a pixel-level coordinate extraction unit; the error solving module comprises a pixel coordinate conversion unit, a tooth profile comparison unit and an error calculation unit; the result display module comprises data, tables and graphic displays; the data storage module comprises a local database unit and a cloud database unit. The invention realizes the non-contact high-precision rapid detection of the cycloid wheel of the RV reducer, automatically stores the full-flow data into the local database and the uploading cloud database, and has important significance for the research and development of the manufacturing and assembling process of the RV reducer.
Description
Technical Field
The invention belongs to the technical field of detection, and particularly relates to a quick detection system for manufacturing errors of a cycloidal gear of an RV reducer based on an imaging technology.
Background
The RV reducer is one of three major core parts of a robot, the market of the RV reducer is almost monopolized by Nipponbottsk at present, and the manufacturing, assembling, performance detection and other production processes of the RV reducer are completely mastered in the last 80 th century; in recent years, under the support of national policies, many domestic companies also invest a lot of manpower and financial resources to develop the production process of the RV reducer and obtain some achievements, but the performance of the produced RV reducer has a great gap with the product of Japanese Nabo Tesky. The RV reducer is complex in production process, comprises a part manufacturing process, a detection process, a product assembling process and the like, wherein the detection process is a key for determining the performance of the RV reducer, and the machining precision of parts is ensured through the detection process, so that the performance of the RV reducer can be ensured. Among the components of the RV reducer, the cycloid wheel is one of the key components, and the manufacturing precision of the cycloid wheel greatly affects the transmission precision and the meshing force of the RV reducer, so that the quick and accurate measurement of the manufacturing error of the cycloid wheel has important significance on the manufacturing process and the assembling process of the RV reducer.
At present, universal equipment such as a three-coordinate measuring instrument, a contourgraph, a gear measuring center and the like are mainly adopted for detecting the cycloid gear of the RV reducer, and partial self-grinding special equipment is also adopted, such as a cycloid gear tooth groove comparison detection method and a positioning and fixing device for detecting the cycloid gear. The detection devices can not realize the rapid and accurate measurement of the manufacturing precision of the cycloid wheel, the general equipment is complex to operate, the detection flow is complex, and the self-grinding special equipment can improve the detection speed or the detection precision of the cycloid wheel in a certain link but can not detect all errors of the cycloid wheel at one time.
Disclosure of Invention
The purpose of the invention is as follows: aiming at the problems in the prior art, the invention discloses a system for rapidly detecting the manufacturing error of a cycloidal gear of an RV reducer based on an imaging technology, which has the advantages of simple structure, convenience in operation, high detection precision, comprehensive error detection items and high detection speed, greatly improves the detection efficiency of a production field, and is suitable for the mass production condition.
The technical scheme is as follows: the invention adopts the following technical scheme: a rapid detection system for manufacturing errors of a cycloidal gear of an RV reducer based on an imaging technology is characterized by comprising an imaging module, an image processing module, an error solving module, a result display module and a data storage module; the output of the imaging module is respectively connected with the input of the image processing module, the input of the result display module and the input of the data storage module, the output of the image processing module is respectively connected with the input of the error solving module, the input of the result display module and the input of the data storage module, and the output of the error solving module is respectively connected with the input of the result display module and the input of the data storage module;
the imaging module is used for acquiring image data of the cycloidal gear to be detected;
the image processing module is used for processing the image data of the cycloidal gear to be detected to obtain the outline edge and the outline edge pixel coordinate matrix of the cycloidal gear to be detected, and the outline edge comprises a tooth profile and a central hole outline;
the error solving module is used for solving the error between the outline edges of the cycloidal gear to be tested and the standard cycloidal gear;
the result display module is used for displaying data generated by the imaging module, the image processing module and the error solving module;
the data storage module is used for storing the data generated by the imaging module, the image processing module and the error solving module.
Preferably, the imaging module comprises a light source, and a zoom lens, a CMOS image sensor, a data transmission unit and a communication unit which are connected in sequence;
the light source is used for irradiating the cycloid wheel to be tested;
the zoom lens is used for shooting the cycloid wheel to be tested;
the CMOS image sensor is used for carrying out image recognition to obtain image data of the cycloidal gear to be detected;
the data transmission unit is used for transmitting the image data of the cycloidal gear to be detected;
the communication unit is used for transmitting the acquired image data to the image processing module.
Preferably, the cycloid wheel to be measured is horizontally placed in the center of a workpiece table, the surface of the workpiece table is a horizontal and smooth plane, and the flatness requirement is 1 micrometer;
the zoom lens has an automatic focusing function and is arranged right above the workpiece table, the axis of the zoom lens is positioned in the center of the workpiece table and is vertical to the surface of the workpiece table, the verticality requirement is 1 mu m, and the focal length of the zoom lens is adjusted to ensure that the cycloidal gear to be measured occupies more than 50% of the picture of the zoom lens.
Preferably, the image processing module comprises a camera calibration unit, an image preprocessing unit, an image edge detection and feature extraction unit and a pixel-level coordinate extraction unit which are connected in sequence;
the camera calibration unit is used for calibrating the relation between the pixel coordinates and the actual coordinates in the image data;
the image preprocessing unit is used for preprocessing the image data of the cycloidal gear to be detected;
the image edge detection and feature extraction unit is used for extracting the outline edge of the cycloidal gear to be detected from the preprocessed image data;
the pixel-level coordinate extraction unit is used for extracting pixel-level coordinates of the contour edge of the cycloidal gear to be detected to obtain a contour edge pixel coordinate matrix.
Preferably, the error solving module comprises a pixel coordinate conversion unit, a tooth profile comparison unit and an error calculation unit which are connected in sequence;
the pixel coordinate conversion unit is used for converting the profile edge of the cycloidal gear to be tested into a standard tooth profile coordinate system, so that the profile edge of the cycloidal gear to be tested and the profile edge of the standard cycloidal gear have the same coordinate origin and coordinate axis;
the tooth profile comparison unit is used for solving the point coordinate values and the distances on the profile edges of the cycloidal gear to be tested and the standard cycloidal gear under the same pin wheel rotation angle;
the error calculation unit is used for solving and separating the tooth pitch error, the tooth profile error and the center hole error of the cycloidal gear to be measured.
Preferably, the contour edge of the standard cycloidal gear is guided into an error solving module by a CAD drawing, a standard tooth profile coordinate system is established by taking the center of a center hole of the standard cycloidal gear as a coordinate origin, and a contour edge actual coordinate matrix of the standard cycloidal gear is obtained.
Preferably, the line widths of the contour edges of the standard cycloidal gear and the cycloidal gear to be tested are both 1 pixel.
Preferably, the display contents of the result display module include: the error solved by the error solving module, the contour edge of the standard cycloid wheel, the image data of the cycloid wheel to be tested collected by the imaging module and the (contour edge of the) cycloid wheel to be tested output by the image processing module;
the display forms include data display, table display and graphic display.
Preferably, the data storage module includes a local database unit and a cloud database unit.
Has the advantages that: the invention has the following beneficial effects:
1. the method realizes non-contact high-precision rapid detection of the cycloid wheel of the RV reducer, and the detected full-flow data can be stored locally and can also be directly stored in a cloud database, so that the detection is convenient for people in different regions to look up, the detected full-flow data can be used for subsequent big data analysis, and the method has important significance for research and development of manufacturing and assembly processes of the RV reducer;
2. the invention can control the detection precision according to the size of the imaging module CMOS image sensor pixel, and the measurement precision is high;
3. according to the invention, all error items of the cycloid gear can be measured through one-time imaging measurement;
4. the measurement result can be displayed in a tabular mode or in a graphical mode, and reading is convenient.
Drawings
FIG. 1 is a block diagram schematically illustrating the construction of a detection system according to the present invention;
FIG. 2 is a schematic structural diagram of a workpiece table and a cycloid wheel to be detected of the detection system of the present invention;
FIG. 3 is a schematic block diagram of an imaging module of the detection system of the present invention;
FIG. 4 is a schematic block diagram of an image processing module of the detection system of the present invention;
FIG. 5 is a schematic block diagram of a data storage module of the detection system of the present invention;
FIG. 6 is a schematic view of the pitch error separation of the detection system of the present invention;
FIG. 7 is a schematic view of tooth profile error separation for the detection system of the present invention.
Detailed Description
The present invention will be further described with reference to the accompanying drawings.
The invention discloses a rapid detection system for manufacturing errors of a cycloidal gear of an RV reducer based on an imaging technology, which comprises the following components as shown in figure 1: the imaging module 101, the image processing module 102, the error solving module 103, the result display module 104 and the data storage module 105, wherein the output of the imaging module 101 is respectively connected with the input of the image processing module 102, the input of the result display module 104 and the data storage module 105, the output of the image processing module 102 is respectively connected with the input of the error solving module 103, the input of the result display module 104 and the data storage module 105, and the output of the error solving module 103 is respectively connected with the input of the result display module 104 and the data storage module 105.
As shown in fig. 3, the imaging module 101 includes a light source 301, and a zoom lens 302, a CMOS image sensor 303, a data transmission unit 304, and a communication unit 305, which are connected in this order. The light source 301 irradiates the cycloidal gear 201 to be tested placed on the workpiece table 202, the zoom lens 302 shoots the cycloidal gear 201 to be tested and sends the shot content to the CMOS image sensor 303 for image recognition, the CMOS image sensor 303 sends the recognized image to the communication unit 305 through the data transmission unit 304, and the imaging module 101 sends the collected image of the cycloidal gear 201 to be tested to the image processing module 102 through the communication unit 305. As shown in fig. 2, the surface of the workpiece table 202 is a horizontal smooth plane, the flatness requirement is 1 μm, and the cycloid wheel 201 to be measured is horizontally placed at the center of the workpiece table 202; the zoom lens 302 has an automatic focusing function and is arranged right above the workpiece table 202, the axis of the zoom lens 302 is positioned in the center of the workpiece table 202 and is vertical to the surface of the workpiece table 202, the verticality requirement is 1 mu m, and the adjustment of the focal length of the zoom lens 302 ensures that the cycloidal gear 201 to be measured occupies more than 50% of the picture of the zoom lens 302.
As shown in fig. 4, the image processing module 102 includes a camera calibration unit 401, an image preprocessing unit 402, an image edge detection and feature extraction unit 403, and a pixel-level coordinate extraction unit 404, which are connected in sequence, and the image processing module 102 is configured to receive an image of the cycloidal gear 201 to be detected transmitted by the imaging module 101, process the image by using an image processing algorithm, and extract a pixel-level coordinate of the processed contour edge of the cycloidal gear 201 to be detected. The camera calibration unit 401 is configured to obtain a relationship between a pixel coordinate in an image and an actual coordinate, calibrate an actual distance size corresponding to a pixel in the image of the cycloidal gear 201 to be measured, and only need to calibrate once after adjusting a focal length of the zoom lens 302 for the cycloidal gear 201 to be measured with the same size; specifically, the camera calibration unit 401 adopts a zhangnyou camera calibration method, firstly, a piece of chessboard calibration paper is printed, the chessboard calibration paper is placed at different positions on the workpiece table 202, the imaging module 101 takes a picture, it is ensured that the whole chessboard calibration paper can be taken every time the chessboard calibration paper is taken and the chessboard calibration paper has different positions and angles in different images, the imaging module 101 sends the taken image of the chessboard calibration paper to the camera calibration unit 401, the camera calibration unit 401 performs calculation processing through the zhangnyou camera calibration method, so that the internal reference, the external reference and the distortion parameter of the zoom lens 302 can be obtained, the obtained internal reference, external reference and distortion parameter are transmitted to the image processing module 102, and are subsequently used for compensating the distortion of the image of the cycloid wheel 201 to be measured, so as to obtain the accurate actual coordinate of the cycloid wheel 201 to be measured. The image preprocessing unit 402 is configured to preprocess the image of the cycloidal gear 201 to be detected to obtain a preprocessed image, and remove irrelevant information mainly through image smoothing, noise reduction, binarization and other methods. The image edge detection and feature extraction unit 403 obtains the profile edge of the cycloidal gear 201 to be detected, including the features such as the tooth profile and the central hole profile, in the preprocessed image through an edge detection and feature extraction algorithm. The pixel-level coordinate extraction unit 404 performs pixel-level coordinate extraction on the obtained contour edge of the cycloidal gear 201 to be tested in an image coordinate system, and stores the contour edge in a matrix manner to obtain a contour edge pixel coordinate matrix of the cycloidal gear 201 to be tested; specifically, the pixel-level coordinate extraction unit 404 performs pixel fusion on the image edge detection and the contour edge of the cycloid wheel 201 to be measured extracted by the feature extraction unit 403 based on least square fitting to obtain a contour edge with a line width of 1 pixel, and stores the pixel coordinates of the fused contour edge in a matrix.
As shown in fig. 5, the error solving module 103 includes a pixel coordinate converting unit 501, a tooth profile comparing unit 502, and an error calculating unit 503, which are connected in sequence, the error solving module 103 is configured to solve a pixel-level error between the contour edges of the cycloidal gear 201 to be measured and the standard cycloidal gear, that is, the error solving module 103 performs error solving of the cycloidal gear 201 to be measured at a pixel level, line widths of the contour edge of the standard cycloidal gear and the contour edge of the cycloidal gear 201 to be measured are both 1 pixel, and the error is calculated by using a converted standardized coordinate value of the contour edges of the two. The method comprises the following steps that the outline edge of a standard cycloidal gear is led into an error solving module 103 from a designed CAD drawing in advance, a standard tooth profile coordinate system is established by taking the center of a center hole of the standard cycloidal gear as a coordinate origin, the actual coordinate of the outline edge of the standard cycloidal gear is obtained, and the actual coordinate is stored as an outline edge actual coordinate matrix of the standard cycloidal gear in a matrix mode; the pixel coordinate conversion unit 501 is configured to convert the coordinate system of the contour edge of the cycloidal gear 201 to be measured, which is output by the image processing module 102, into a standard tooth profile coordinate system, so that the coordinate origin and the coordinate axis of the contour edge of the standard cycloidal gear are the same; specifically, the center coordinate of the cycloid wheel 201 to be tested is found out through the center hole profile of the cycloid wheel 201 to be tested, the pixel coordinate of the profile edge extracted by the pixel-level coordinate extraction unit 404 is subjected to translation transformation, the center coordinate of the cycloid wheel 201 to be tested is made to be the origin of coordinates of a standard tooth profile coordinate system, then rotation transformation is performed by taking the origin of coordinates as the center, the cycloid wheel 201 to be tested and the standard cycloid wheel have the same coordinate system, then the actual coordinate of the profile edge of the cycloid wheel 201 to be tested is obtained by utilizing the internal reference, the external reference and the distortion parameters of the zoom lens 302 obtained by the camera calibration unit 401, and the actual coordinate of the profile edge is stored as the actual coordinate matrix of the profile edge of the cycloid wheel to be tested in a matrix form; the tooth profile comparison unit 502 and the error calculation unit 503 are used for solving pixel level errors of the profile edges of the cycloidal gear 201 to be tested and the standard cycloidal gear, including a center hole error, a tooth pitch error and a tooth profile error, wherein the tooth profile comparison unit 502 is used for solving the actual coordinate value and distance of the tooth profile of the cycloidal gear 201 to be tested and the tooth profile of the standard cycloidal gear and the actual coordinate value and distance of the center hole profile under the same pin wheel rotation angle, and can be obtained by emitting a ray through a coordinate origin to intersect with the two tooth profiles and the two center hole profiles respectively; the error calculation unit 503 solves the error of the center hole of the cycloidal gear 201 to be measured compared with the standard cycloidal gear, and solves and separates the tooth pitch error and the tooth profile error of the cycloidal gear 201 to be measured compared with the standard cycloidal gear by an error separation algorithm, wherein the center hole error is the difference value between the circle radius of the center hole of the cycloidal gear to be measured and the circle radius of the center hole of the standard cycloidal gear, and is obtained by calculating the actual coordinate value and the distance of the outline of the center hole of the cycloidal gear 201 to be measured and the standard cyclo; the error separation is to separate the tooth pitch error of each tooth on the tooth profile, then compensate the tooth pitch error to the actual tooth profile, and then separate the tooth profile error, wherein the tooth profile error is mainly the distance of the actual tooth profile deviating from the theoretical tooth profile in the normal direction, and the specific method is as follows:
1) drawing the actual tooth profile of the cycloidal gear to be measured in a standard tooth profile coordinate system according to the actual coordinate matrix of the profile edge of the cycloidal gear to be measured, comparing the actual tooth profile with a theoretical tooth profile, namely the tooth profile of a standard cycloidal gear, and respectively calculating the tooth profile of each of the cycloidal gear to be measured and the standard cycloidal gear and the tooth profile (R)p-Rrp) Coordinates (x) of intersection point of reference circle with radius and origin of coordinates as center of circlei,yi)、(xi′,yi') wherein RpIndicating the pin wheel radius, R, of a standard cycloidal gearrpRepresents the pin tooth radius of a standard cycloidal gear, as shown in fig. 6; since the pitch error is very small, the pitch error can be expressed in terms of the distance between the intersection coordinates, so the pitch error of each tooth can be expressed as:
wherein, the theoretical tooth profile is taken as the reference, and the counterclockwise deviation f of the actual tooth profile of the cycloidal gear to be measuredpt,iTake positive value, clockwise bias fpt,iTaking a negative value; the pitch error of each tooth corresponds to an included angle that can be expressed as: thetap,i＝fpt,i/(Rp-Rrp)。
2) According to the tooth pitch error and the corresponding included angle of each tooth, the corresponding included angle theta is carried out on each tooth in the actual coordinate matrix of the outline edge of the cycloidal gear to be testedp,iThe actual tooth profile coordinate matrix of the cycloidal gear to be measured, which does not contain the tooth pitch error, can be obtained through the rotation transformation. As shown in fig. 7, a solid black line
Is the theoretical tooth profile, blue scatter
Is the tooth profile and the theoretical tooth profile of the cycloidal gear to be measured without tooth pitch error and with tooth profile error
Tooth profile of cycloidal gear to be measured
In the direction n normal to the theoretical tooth profilecThere is an error dr, which is the tooth profile error, so the tooth profile equation of the cycloidal gear to be measured containing the tooth profile error can be expressed as:
in the formula
The method is characterized in that a unit normal vector of a theoretical tooth profile corresponding to the ith point on the tooth profile of the cycloidal gear to be measured is obtained, a tooth profile error coordinate can be obtained by subtracting a tooth profile actual coordinate matrix of the cycloidal gear to be measured, which does not contain a tooth pitch error, from a tooth profile actual coordinate matrix of a standard cycloidal gear, and the coordinate length is the tooth profile error.
The result display module 104 may be used to display the error solved by the error solving module 103, and the display forms include data display, table display and graphic display. The result display module 104 further includes: the method comprises the following steps of accurately displaying the pixel level of the outline edge of a standard cycloid wheel, accurately displaying the pixel level of an image of a cycloid wheel 201 to be tested, acquired by an imaging module 101, and accurately displaying the pixel level of the outline edge of the cycloid wheel 201 to be tested, output by an image processing module 102, wherein the display line width is 1 pixel, and the display proportion is scalable; the tooth profile of the cycloidal gear 201 to be tested and the tooth profile of the standard cycloidal gear are displayed by discrete point coordinates under the condition of the same equal division of the same coordinate system, and the tooth pitch error, the tooth profile error and other errors of the cycloidal gear 201 to be tested are displayed by a data table and an error curve graph.
The data storage module 105 comprises a local database unit and a cloud database unit, and is used for storing full-flow data generated by the imaging module 101, the image processing module 102 and the error solving module 103, setting a unique ID number for the cycloidal gear 201 to be detected, respectively storing different types of data into corresponding databases, and associating through the unique ID number, so that search and query are facilitated. The data storage module 105 adopts a scheme that a local database and a cloud database are stored simultaneously, and uploads data of each flow in the measurement process to the cloud database through a network by using a cloud data platform interface, so that the data can be used without being limited by regions, and big data analysis can be performed when the data volume is accumulated to a certain degree.
The invention will be further illustrated with reference to the following specific examples:
when the invention is used, firstly, the high-speed Ethernet port of the imaging module 101 is connected with the high-speed Ethernet port of the local computer by using a network cable, and an IP address is set to ensure that the two can normally communicate in the same network segment; the system comprises a local computer, an image processing module 102, an error solving module 103, a result display module 104 and a data storage module 105, wherein the local computer is provided with developed upper computer software;
then, the cycloidal gear 201 to be detected is placed at the center of the workpiece table 202, the imaging module 101 is started to collect images through upper computer software, and an instruction is sent to the imaging module 101, so that the imaging module 101 automatically adjusts the zoom lens 302 to a proper focal length, the collected images of the cycloidal gear 201 to be detected occupy more than 50% of frames, and the focal length of the lens is locked;
taking down the cycloidal gear 201 to be tested from the workpiece table 202, placing a calibration template, namely chessboard calibration paper, below the zoom lens 302, sending an image acquisition instruction to the imaging module 101 through the camera calibration unit 401, continuously acquiring 14 images by the imaging module 101 and naming the images in sequence, wherein the orientation of the chessboard calibration paper is changed to ensure that the chessboard calibration paper acquired each time has different positions and angles in the images, and then solving internal reference, external reference, radial distortion parameters and tangential distortion parameters of the zoom lens 302 through a Zhangyingyou calibration method integrated in the camera calibration unit 401, thereby obtaining the corresponding relation between actual coordinates and pixel coordinates; then, if the cycloidal gears with the same model are measured, the cycloidal gears with the same model are directly and horizontally placed at the center of the workpiece table 202 without refocusing and calibration;
after the camera calibration is finished, the error measurement of the cycloid wheel to be measured can be carried out: the method comprises the steps of placing a cycloid wheel 201 to be detected at the center of a workpiece platform 202, sending an acquisition instruction to an imaging module 101 through an image processing module 102 to obtain an image of the cycloid wheel 201 to be detected, transmitting the image of the cycloid wheel 201 to be detected to an image preprocessing unit 402 through a communication unit 305 in the imaging module 101 to be preprocessed, wherein the preprocessing method can be selected according to image acquisition quality, the image preprocessing unit 402 integrates algorithms such as image filtering, image enhancement, image binarization, image morphological operation and the like, an ideal preprocessed image is obtained through selection of the appropriate preprocessing method, then image edge detection and feature extraction are carried out on the preprocessed image through an edge detection and feature extraction algorithm integrated by an image edge detection and feature extraction unit 403, and the image edge detection and feature extraction unit 403 integrates Roberts, Sobel, Prewitt, Laplan, Log/Marr, Canny, Kirsch and feature extraction, An edge detection algorithm such as Nevitia obtains the outline edge of the cycloidal gear 201 to be detected by selecting a proper edge detection algorithm, deletes the outline irrelevant to error detection, then a pixel-level coordinate extraction unit 404 in upper computer software performs pixel fusion on the outline edge of the cycloidal gear to be detected based on a least square algorithm, extracts the characteristics such as the tooth profile and the central hole outline of the cycloidal gear to be detected, stores the characteristics in a matrix manner, checks the characteristics through a result display module 104, leads in a CAD drawing of a standard cycloidal gear through an error solving module 103, obtains the actual coordinate value of the outline edge of the standard cycloidal gear, stores the actual coordinate value in the matrix manner, obtains the actual coordinate value of the outline edge of the cycloidal gear 201 to be detected through a pixel coordinate conversion unit 501, stores the actual coordinate value in the matrix manner, quantizes the actual coordinate value of the outline edge corresponding to the cycloidal gear to be detected and the standard cycloidal gear under, and stored in a matrix manner; various error items (central hole error, tooth pitch error and tooth profile error) between the contour edge of the cycloidal gear 201 to be tested and the contour edge of the standard cycloidal gear are solved through an error calculation unit 503 and displayed through a result display module 104; the data storage module 105 can perform local data storage and cloud uploading simultaneously, and the result display module 104 has multiple display modes and display results, and can select corresponding data to display according to needs.
The imaging technology-based rapid detection system for the manufacturing errors of the cycloidal gear of the RV reducer is convenient and rapid to operate, does not need too much manual operation in the measurement process, has high measurement speed and high precision, and is very suitable for mass production detection; the invention can also control the detection precision according to the size of the pixel of the imaging module CMOS image sensor, and the pixel is assumed to be 10M, and the imaging frame is 1: 1 square, after focusing, a plane with the actual size of 100 × 100mm is exactly collected, the cycloidal gear occupies 50% of the frame, and the size of each pixel point is 1 μm, so that the measurement accuracy of the detection system is 1 μm, and the measurement accuracy is high.
The above description is only of the preferred embodiments of the present invention, and it should be noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the invention and these are intended to be within the scope of the invention.
Claims (9)
1. A quick detection system for manufacturing errors of a cycloidal gear of an RV reducer based on an imaging technology is characterized by comprising an imaging module (101), an image processing module (102), an error solving module (103), a result display module (104) and a data storage module (105); the output of the imaging module (101) is respectively connected with the input of the image processing module (102), the input of the result display module (104) and the input of the data storage module (105), the output of the image processing module (102) is respectively connected with the input of the error solving module (103), the input of the result display module (104) and the input of the data storage module (105), and the output of the error solving module (103) is respectively connected with the input of the result display module (104) and the input of the data storage module (105);
the imaging module (101) is used for acquiring image data of the cycloidal gear (201) to be tested;
the image processing module (102) is used for processing image data of the cycloidal gear (201) to be tested to obtain a profile edge and a profile edge pixel coordinate matrix of the cycloidal gear (201) to be tested, and the profile edge comprises a tooth profile and a central hole profile;
the error solving module (103) is used for solving the error between the outline edges of the cycloidal gear (201) to be tested and the standard cycloidal gear;
the result display module (104) is used for displaying data generated by the imaging module (101), the image processing module (102) and the error solving module (103);
the data storage module (105) is used for storing data generated by the imaging module (101), the image processing module (102) and the error solving module (103).
2. The imaging technology-based system for rapidly detecting the manufacturing error of the cycloidal gear of the RV reducer is characterized in that an imaging module (101) comprises a light source (301), and a zoom lens (302), a CMOS image sensor (303), a data transmission unit (304) and a communication unit (305) which are connected in sequence;
the light source (301) is used for irradiating the cycloidal gear (201) to be tested;
the zoom lens (302) is used for shooting the cycloidal gear (201) to be tested;
the CMOS image sensor (303) is used for carrying out image recognition to obtain image data of the cycloidal gear (201) to be detected;
the data transmission unit (304) is used for transmitting the image data of the cycloidal gear (201) to be tested;
the communication unit (305) is used for transmitting the acquired image data to the image processing module (102).
3. The imaging technology-based system for rapidly detecting the manufacturing error of the cycloidal gear of the RV reducer according to claim 2 is characterized in that the cycloidal gear (201) to be detected is horizontally placed at the center of a workpiece table (202), the surface of the workpiece table (202) is a horizontal smooth plane, and the flatness requirement is 1 μm;
the zoom lens (302) has an automatic focusing function and is arranged right above the workpiece table (202), the axis of the zoom lens (302) is positioned in the center of the workpiece table (202) and is vertical to the surface of the workpiece table (202), the verticality requirement is 1 mu m, and the adjustment of the focal length of the zoom lens (302) ensures that the cycloidal gear (201) to be measured occupies more than 50% of the picture width of the zoom lens (302).
4. The imaging technology-based system for rapidly detecting the manufacturing error of the cycloidal gear of the RV reducer is characterized in that an image processing module (102) comprises a camera calibration unit (401), an image preprocessing unit (402), an image edge detection and feature extraction unit (403) and a pixel-level coordinate extraction unit (404) which are connected in sequence;
the camera calibration unit (401) is used for calibrating the relation between the pixel coordinates and the actual coordinates in the image data;
the image preprocessing unit (402) is used for preprocessing the image data of the cycloidal gear (201) to be detected;
the image edge detection and feature extraction unit (403) is used for extracting the outline edge of the cycloidal gear (201) to be detected from the preprocessed image data;
the pixel-level coordinate extraction unit (404) is used for extracting pixel-level coordinates of the contour edge of the cycloidal gear (201) to be detected to obtain a contour edge pixel coordinate matrix.
5. The imaging technology-based rapid detection system for the manufacturing error of the cycloidal gear of the RV reducer is characterized in that an error solving module (103) comprises a pixel coordinate conversion unit (501), a tooth profile comparison unit (502) and an error calculation unit (503) which are connected in sequence;
the pixel coordinate conversion unit (501) is used for converting the outline edge of the cycloidal gear (201) to be tested into a standard tooth profile coordinate system, so that the outline edge of the cycloidal gear (201) to be tested and the outline edge of the standard cycloidal gear have the same coordinate origin and coordinate axis;
the tooth profile comparison unit (502) is used for solving the point coordinate values and the distances between the outline edges of the cycloidal gear (201) to be tested and the standard cycloidal gear under the same pin wheel rotation angle;
the error calculation unit (503) is used for solving the tooth pitch error and the tooth profile error of the cycloidal gear (201) to be measured and the center hole error.
6. The imaging technology-based rapid detection system for the manufacturing errors of the cycloidal gear of the RV reducer is characterized in that a profile edge of a standard cycloidal gear is led into an error solving module (103) from a CAD drawing, a standard tooth profile coordinate system is established by taking the center of a center hole of the standard cycloidal gear as a coordinate origin, and an actual coordinate matrix of the profile edge of the standard cycloidal gear is obtained.
7. The imaging technology-based rapid detection system for the manufacturing errors of the cycloidal gear of the RV reducer is characterized in that the line widths of the contour edges of a standard cycloidal gear and a cycloidal gear (201) to be detected are both 1 pixel.
8. The imaging technology-based rapid detection system for the manufacturing errors of the cycloidal gear of the RV reducer is characterized in that the display content of the result display module (104) comprises the following components: the method comprises the steps that an error solved by an error solving module (103), the outline edge of a standard cycloidal gear, the image data of a cycloidal gear (201) to be detected, which are collected by an imaging module (101), and the outline edge of the cycloidal gear (201) to be detected, which is output by an image processing module (102);
the display forms include data display, table display and graphic display.
9. The imaging technology-based system for rapidly detecting the manufacturing error of the cycloidal gear of the RV reducer is characterized in that a data storage module (105) comprises a local database unit and a cloud database unit.
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