CN113503811B - Calibration method for offset matrix of iScan in five-axis cutting machine tool coordinate system - Google Patents

Calibration method for offset matrix of iScan in five-axis cutting machine tool coordinate system Download PDF

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CN113503811B
CN113503811B CN202110506470.5A CN202110506470A CN113503811B CN 113503811 B CN113503811 B CN 113503811B CN 202110506470 A CN202110506470 A CN 202110506470A CN 113503811 B CN113503811 B CN 113503811B
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CN113503811A (en
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刘锦潮
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Aipeiyi Intelligent Equipment Co ltd
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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
    • G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/80—Analysis of captured images to determine intrinsic or extrinsic camera parameters, i.e. camera calibration
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/10—Image acquisition modality
    • G06T2207/10028—Range image; Depth image; 3D point clouds
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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Abstract

The invention relates to the field of model calculation, and particularly discloses a calibration method of an offset matrix of an iScan in a tool coordinate system of a five-axis cutting machine, which comprises the following specific steps: step one, acquiring original point cloud data by using an iScan; step two, data are arranged and filtered; step three, roughly calculating a bias matrix and calibrating spherical center coordinates; and fourthly, fitting calculation and accurate solving. The invention provides a calibration method of an iScan offset matrix in a tool coordinate system of a five-axis cutting machine, which can reduce errors, further improve the precision of acquiring the terminal pose, improve the splicing precision of scanning data, improve the working accuracy of a scanner and compensate an optimized five-axis cutting machine kinematic model.

Description

Calibration method for offset matrix of iScan in five-axis cutting machine tool coordinate system
Technical Field
The invention relates to the field of model calculation, in particular to a calibration method of an offset matrix of an iScan in a tool coordinate system of a five-axis cutting machine.
Background
The iScan is a line scanning product of an API company, a light source adopts two blue line lasers which are mutually crossed at 90 degrees, laser projection diffuse reflection and a triangulation method of single-phase machine imaging, projection of a scanning line on the surface of a measured object is measured, and point cloud data is formed in a discretization mode. If the continuous scanning data of the object surface is required to be obtained, the line scanner needs to be moved to enable the laser line to continuously sweep the object surface, and the six-degree-of-freedom information between the object and the scanner, the position and the posture at the moment of shooting each frame of image are known, so that all the point cloud data can be spliced under the same coordinate system.
The method has the advantages that more comprehensive data of the five-axis cutting machine can be obtained by using the iScan, an optimized kinematics model of the five-axis cutting machine can be compensated, and in order to further improve the accuracy of obtaining the terminal pose and improve the splicing accuracy of the scanning data, the method for calibrating the offset matrix of the iScan in the tool coordinate system of the five-axis cutting machine is provided.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a calibration method of an offset matrix of an iScan in a tool coordinate system of a five-axis cutting machine, which can effectively solve the problems in the prior art and provides the following technical scheme:
the method for calibrating the offset matrix of the iScan in the coordinate system of the five-axis cutting machine tool comprises the following specific steps:
step one, acquiring original point cloud data by using an iScan;
step two, data are arranged and filtered;
step three, roughly calculating a bias matrix and calibrating spherical center coordinates;
and fourthly, fitting calculation and accurate solving.
Preferably, the iScan in step one is a typical laser line scanner, where all measurement data points lie in a plane through which the line laser sweeps, and the data for calibration must be widely distributed in this plane to cover the depth of field and the various intervals of the entire scan line, regardless of the optimal use of the local area.
Preferably, the processing is performed on the scanning data obtained from the six-dimensional measurement system according to the original point cloud data obtained from the isccan under the local coordinate system of the scanner:
wherein: />-a measurement point coordinate vector in the scanner coordinate system;
the transformation from a tool coordinate system to a machine tool coordinate system when measuring the point, wherein the tool coordinate system is equivalent to an F3 coordinate system of I360, and for a robot, the pose of the end flange is selected as T 0 When the terminal pose is displayed under the base coordinate system;
-measuring point coordinate values in the machine tool coordinate system;
-a transformation matrix from the scanner coordinate system to the end tool coordinate system.
Is deformed according to the above formula to obtainWherein->For the coordinate values of the data points in the tool coordinate system, it can be known that in order to solve the coordinate transformation T, a set of typical data needs to be acquired, the coordinate values of the set of data in the tool coordinate system are known +.>And coordinate values in the scanner coordinate system +.>The matrix T can solve the computation, as is known.
Preferably, the sorting and filtering of the data in the second step includes: and searching arc data on each scanning line by using a sliding window, marking and recording the positions of a starting point and a termination point of a data segment with a fitting roundness error of not more than 0.25mm and a fitting radius of not more than 25mm of the maximum allowable sphere according to the point distance of 0.2mm on the iScan scanning line, adopting an observation window with a width of 75 effective data, namely about 15mm long, and after the searching of each scanning line is finished, fully selecting and fitting all points conforming to the arc characteristics on the scanning line to calculate a 3D circle, and recording and storing the position of the circle center and the radius for standby.
Preferably, the step three of roughly calculating the bias matrix and calibrating the coordinates of the sphere center includes:
a) Selecting the scan line with the largest fitting radius from each group of scan data, considering the scan line to pass through the sphere center, wherein the fitting circle center is approximate to the real sphere center position, and the circle/sphere center position si of each key scan line meets the following conditionsWherein->For calibrating the coordinate value of the sphere center under the coordinate system of each scanning line tool, c is the coordinate value of the standard sphere under the coordinate system of the machine, and is unknown in the method;
b) In order to solve the coordinates of the sphere center, an estimated position of the sphere center is used as an initial value of iterative calculation, and the method adopts the tool coordinate system origins corresponding to key scanning lines to fit and calculate the sphere center c 0 As an initial value, c 0 Substituting the above formula to obtain a system of equations, wherein the number of equations is the number of key scanning lines, and at least three key scanning line equations can be solved:
solving for the initial value T of T 0 By application T 0 Calculating a new spherical center coordinate c':
c) Repeating the iterative calculation, wherein the residual error formula is as follows, the convergence condition is set, and the iteration number of 5 times can be converged to 0.000001mm in practice:
d) Discussion of singular conditions: the theory of the equation set can be solved, but there is a risk of overlarge solving error in practice and actually occurs in experimental data, in order to avoid the problem, we need to ensure that calibration data are uniformly scattered in the depth of field and the width direction, for calibration data approaching to a singular state, the method adopts a method of adding an auxiliary point pair, namely adding the central point of a handle of a scanner to participate in fitting calculation, selecting the spherical center point of a first key scanning line, and enabling the lower x and y coordinate values of the spherical center point under the coordinate system of the scanner to be zero Fitting a target to the tool coordinate system
The root should be used in front when the tool coordinate system is Z-axis pointing to the scanner handleThe point pair is added into a solving equation, so that the Z axis of a scanner in solving can be ensured to be perpendicular to the Z axis of a tool coordinate system;
the coarse alignment matrix is obtained below, noting that coarse alignment does not take into account sphere radius optimization, but instead directly uses the center of the key scan line to fit to a common calibration sphere center point.
Preferably, the fitting calculation in the fourth step includes:
a) Converting the arc part data point of each scanning line from the scanner coordinate system to the tool coordinate system by using a rough calculated offset matrix, and passing the spherical center coordinateConverting into a tool coordinate system, normalizing vectors from the sphere center to each scanning point in the tool coordinate system, and multiplying the normalized vectors by a sphere radius value to obtain a theoretical point on the sphere as a target point for fitting calculation:
wherein r is the radius of the calibration sphere, and the initial value is the average value of the radius of the fitting circle of the key scanning lineSubstitution, T 0 Substituting a result matrix of coarse alignment;
b) For data points s on all effective arcs according to the above formula i A set of fitting target values (t) 0 ，t 1 ，t 2 ……t n ) According to the system of equationsSolving for new->。
c) Will beSubstitution formula->Obtaining (m) 0 ，m 1 ，m 2 ……m n ) Re-fitting and calculating a standard sphere, and repeating the step a) and the step b) after updating the sphere radius and the sphere center coordinates to perform iterative operation;
d) The mean square error of the fitting sphere is used as a residual error of iterative calculation convergence, the RMS can be converged to about 0.000001mm about 100 times, and the corresponding spherical center coordinate variation is smaller than 0.001mm;
e) And (5) finishing iterative calculation and outputting a matrix T.
Compared with the prior art, the invention provides a calibration method of an offset matrix of an iScan in a tool coordinate system of a five-axis cutting machine, which has the following beneficial effects:
the calibration method can reduce errors, further improve the precision of acquiring the terminal pose, improve the splicing precision of the scanning data, improve the working accuracy of the scanner, and compensate the optimized five-axis cutting machine kinematic model.
Drawings
FIG. 1 is a flow chart of a method for calibrating an offset matrix of an iScan in a five-axis cutter tool coordinate system.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the calibration method of the offset matrix of the iscan in the coordinate system of the five-axis cutting machine tool comprises the following specific steps:
step one, acquiring original point cloud data by using an iScan;
step two, data are arranged and filtered;
step three, roughly calculating a bias matrix and calibrating spherical center coordinates;
and fourthly, fitting calculation and accurate solving.
In a further embodiment of the present invention, the iScan is a typical laser line scanner, and all measurement data points are located in a plane through which the line laser is scanned, and in order to ensure reliable coordinate transformation without considering the optimal use of local areas, the data for calibration must be widely distributed in the plane, covering the depth of field and each section of the whole scan line.
In the embodiment of the invention, further, the scanning data obtained from the six-dimensional measurement system is processed according to the original point cloud data obtained from the isccan under the local coordinate system of the scanner:
wherein: />-a measurement point coordinate vector in the scanner coordinate system;
transformation from tool coordinate system to machine tool coordinate system when measuring the point, wherein the toolThe F3 coordinate system with the coordinate system equivalent to I360 is the pose of the end flange, namely the selected T, for the robot 0 When the terminal pose is displayed under the base coordinate system;
-measuring point coordinate values in the machine tool coordinate system;
-a transformation matrix from the scanner coordinate system to the end tool coordinate system.
Is deformed according to the above formula to obtainWherein->For the coordinate values of the data points in the tool coordinate system, it can be known that in order to solve the coordinate transformation T, a set of typical data needs to be acquired, the coordinate values of the set of data in the tool coordinate system are known +.>And coordinate values in the scanner coordinate system +.>The matrix T can solve the computation, as is known.
In a further embodiment of the present invention, the sorting and filtering the data in the second step includes: and searching arc data on each scanning line by using a sliding window, marking and recording the positions of a starting point and a termination point of a data segment with a fitting roundness error of not more than 0.25mm and a fitting radius of not more than 25mm of the maximum allowable sphere according to the point distance of 0.2mm on the iScan scanning line, adopting an observation window with a width of 75 effective data, namely about 15mm long, and after the searching of each scanning line is finished, fully selecting and fitting all points conforming to the arc characteristics on the scanning line to calculate a 3D circle, and recording and storing the position of the circle center and the radius for standby.
In a further embodiment of the present invention, the step three of roughly calculating the offset matrix and calibrating the coordinates of the sphere center includes:
a) Selecting the scan line with the largest fitting radius from each group of scan data, considering the scan line to pass through the sphere center, wherein the fitting circle center is approximate to the real sphere center position, and the circle/sphere center position si of each key scan line meets the following conditionsWherein->For calibrating the coordinate value of the sphere center under the coordinate system of each scanning line tool, c is the coordinate value of the standard sphere under the coordinate system of the machine, and is unknown in the method;
b) In order to solve the coordinates of the sphere center, an estimated position of the sphere center is used as an initial value of iterative calculation, and the method adopts the tool coordinate system origins corresponding to key scanning lines to fit and calculate the sphere center c 0 As an initial value, c 0 Substituting the above formula to obtain a system of equations, wherein the number of equations is the number of key scanning lines, and at least three key scanning line equations can be solved:
solving for the initial value T of T 0 By application T 0 Calculating a new spherical center coordinate c':
c) Repeating the iterative calculation, wherein the residual error formula is as follows, the convergence condition is set, and the iteration number of 5 times can be converged to 0.000001mm in practice:
d) Discussion of singular conditions: the theory of the equation set can be solved, but there is a risk of overlarge solving error in practice and actually occurs in experimental data, in order to avoid the problem, we need to ensure that calibration data are uniformly scattered in the depth of field and the width direction, for calibration data approaching to a singular state, the method adopts a method of adding an auxiliary point pair, namely adding the central point of a handle of a scanner to participate in fitting calculation, selecting the spherical center point of a first key scanning line, and enabling the lower x and y coordinate values of the spherical center point under the coordinate system of the scanner to be zeroFitting a target to the tool coordinate system
The root should be used in front when the tool coordinate system is Z-axis pointing to the scanner handleThe point pair is added into a solving equation, so that the Z axis of a scanner in solving can be ensured to be perpendicular to the Z axis of a tool coordinate system;
the coarse alignment matrix is obtained below, noting that coarse alignment does not take into account sphere radius optimization, but instead directly uses the center of the key scan line to fit to a common calibration sphere center point.
In a further embodiment of the present invention, the fitting calculation in the fourth step includes:
a) Converting the arc part data point of each scanning line from the scanner coordinate system to the tool coordinate system by using a rough calculated offset matrix, and passing the spherical center coordinateConverting into a tool coordinate system, normalizing the vector from the sphere center to each scanning point in the tool coordinate system, and multiplying the normalized vector byThe theoretical point on the sphere obtained by the sphere radius value is the target point calculated by fitting:
wherein r is the radius of the calibration sphere, and the initial value is the average value of the radius of the fitting circle of the key scanning lineSubstitution, T 0 Substituting a result matrix of coarse alignment;
b) For data points s on all effective arcs according to the above formula i A set of fitting target values (t) 0 ，t 1 ，t 2 ……t n ) According to the system of equationsSolving for new->。
c) Will beSubstitution formula->Obtaining (m) 0 ，m 1 ，m 2 ……m n ) Re-fitting and calculating a standard sphere, and repeating the step a) and the step b) after updating the sphere radius and the sphere center coordinates to perform iterative operation;
d) The mean square error of the fitting sphere is used as a residual error of iterative calculation convergence, the RMS can be converged to about 0.000001mm about 100 times, and the corresponding spherical center coordinate variation is smaller than 0.001mm;
e) And (5) finishing iterative calculation and outputting a matrix T.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims (1)

  1. The method for calibrating the offset matrix of the iScan in the tool coordinate system of the five-axis cutting machine is characterized by comprising the following steps of: the method comprises the following specific steps:
    step one, acquiring original point cloud data by using an iScan, and covering a depth of field and each section of the whole scanning line;
    step two, data are arranged and filtered, wherein the arrangement and the filtration of the data comprise the following steps: searching circular arc data on each scanning line by using a sliding window, marking out data segment starting points and ending point positions with fitting roundness errors not exceeding 0.25mm and fitting radii not exceeding 25mm of the maximum allowable sphere according to the point distance of 0.2mm on the iScan scanning line and adopting an observation window with the width of 75 effective data, namely 15mm length, recording the positions of the starting points and the ending points of all points, which are in line with circular arc characteristics, on each scanning line after the searching of each scanning line is finished, performing full-selection fitting calculation on a 3D circle, and recording and storing the circle center positions and the radii;
    step three, roughly calculating a bias matrix and calibrating spherical center coordinates;
    step four, fitting calculation and accurate solving;
    according to the original point cloud data acquired by the iScan, processing the scanning data in the six-dimensional measurement system under a scanner local coordinate system:
    ，
    wherein:-a measurement point coordinate vector in the scanner's local coordinate system;
    the transformation from the tool coordinate system to the machine tool coordinate system when measuring the point is the pose of the end flange, namely, the selection +.>When the terminal pose is displayed under the base coordinate system;
    -measuring point coordinate values in the machine tool coordinate system;
    t-a transformation matrix from the scanner local coordinate system to the end tool coordinate system;
    is deformed according to the above formula to obtainWherein->For the coordinate values of the data points in the tool coordinate system, it is known that in order to solve the coordinate transformation T, a set of typical data needs to be acquired, and the coordinate values of the set of data in the tool coordinate system are known +.>And coordinate values +.>Knowing, then the matrix T solves the calculation;
    the step three of roughly calculating the bias matrix and calibrating the spherical center coordinates comprises the following steps:
    a) Selecting the scan line with the largest fitting radius from each group of scan data, considering the scan line to pass through the sphere center, wherein the fitting circle center is approximate to the true sphere center position, and the sphere center position of each key scan lineSatisfy->Wherein, the method comprises the steps of, wherein,for calibrating the coordinate value of the sphere center under the coordinate system of each scanning line tool, the unknown quantity is obtained in the step;
    b) Solving the coordinates of the sphere center, taking an estimated position of the sphere center as an initial value of iterative calculation, adopting tool coordinate system origins corresponding to key scanning lines in the step, and fitting and calculating the sphere centerAs an initial value, will +.>Substituting the above formula to obtain a system of equations, wherein the number of equations is the number of key scanning lines, c is the coordinate value of the calibration sphere under the machine coordinate system, and at least three key scanning line equations can be solved:
    ，
    solving for the initial value of TApplication->CalculatingNew sphere center coordinates->：
    ；
    c) Repeating the iterative calculation, setting a convergence condition by a residual formula as follows, and converging the iteration 5 times to 0.000001mm:
    Δ=；
    d) The step adopts the addition of an auxiliary point pair, namely the addition of the central point of the handle of the scanner to participate in fitting calculation, and the spherical center point of the first key scanning line is selected to make the lower x and y coordinate values of the first key scanning line under the local coordinate system of the scanner be zeroFitting a target to the tool coordinate system:
    ，
    adding the point pair into a solving equation to ensure that the Z axis of the scanner in the solving process is perpendicular to the Z axis of the tool coordinate system;
    obtaining a coarse alignment matrix, wherein the coarse alignment does not consider sphere radius optimization, and the circle centers of the key scanning lines are used for fitting to a common calibration sphere center point;
    the fitting calculation accurate solving in the fourth step comprises the following steps:
    a) For the arc part data points of each scanning line, converting the local coordinate system of the scanner into the tool coordinate system by using a rough offset matrix, and then passing the coordinates of the sphere centerConversion to tool coordinate system, vector normalization from sphere center to each scan point under tool coordinate systemMultiplying the normalized value by the sphere radius to obtain a theoretical point on the sphere as a target point for fitting calculation:
    ，
    wherein r is the radius of the calibration sphere, and the initial value is the average value of the radius of the fitting circle of the key scanning lineSubstitution of->Substituting a result matrix of coarse alignment;
    b) According to the formulaData points on all effective arcs +.>Calculating a set of fitting target values +.>According to equation set->Solving for new->；
    c) Will beSubstitution formula->Obtain->Fitting and calculating the calibration sphere again, and updating the sphere radius and sphereRepeating the step a) and the step b) after the heart coordinates, and carrying out iterative operation;
    d) Taking the mean square error of the fitting sphere as a residual error of iterative calculation convergence, wherein 100 times of RMS converges to 0.000001mm, and the corresponding spherical center coordinate variation is smaller than 0.001mm;
    e) And (5) finishing iterative calculation and outputting a matrix T.
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