CN113641155A - High-temperature forging detection control system - Google Patents
High-temperature forging detection control system Download PDFInfo
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- G05B19/00—Programme-control systems
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- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by quality surveillance of production
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Abstract
The invention discloses a high-temperature forging detection control system, which comprises an information acquisition module, a control module and an auxiliary function module, wherein the control module is based on an embedded industrial personal computer and comprises a Halcon image processing module, a position detection module, a temperature detection module, a size detection module, a defect detection module and a quality evaluation module, and the quality evaluation module evaluates the quality of a forging and forms a detection report according to detection data of the position detection module, the temperature detection module, the size detection module and the defect detection module; the information acquisition module comprises a camera and an infrared temperature sensor, acquires image information and sends the image information to the control module; the auxiliary function module comprises a camera control module, a point cloud analysis module, a motion control module and a detection data and detection report query module. The invention realizes the real-time accurate detection of various parameters of the forging piece to be detected in a high-temperature environment, and improves the quality and the production efficiency of the metal processing and forming product.
Description
Technical Field
The invention belongs to the technical field of forging automation, and particularly relates to a high-temperature forge piece detection control system.
Background
In the long-term operation process of a forging production line, the robot finger blocks are abraded, the paw is subjected to high-temperature thermal deformation for a long time, and the like, so that the deviation of the placement position of the robot when the robot carries a high-temperature forged piece at a high speed is caused, the qualification rate of the forged piece product is greatly reduced, even the damage of a die or a press is caused, and the long-term stable operation of the production line is seriously influenced. In addition, in the forging production process, still can often meet the forging and glue the condition of mould, after the punching a hole of forging line, the side cut process, generally carry out the selective examination by the manual work, unqualified condition appears in the product, need the manual work to stop the production line and carry out work such as inspection, repair the mould, influence metal machining fashioned product quality and production efficiency, this stable operation that all can influence automatic production line moreover, and increase manual work volume and manufacturing cost.
Disclosure of Invention
The invention aims to provide a high-temperature forge piece detection control system, which realizes real-time and accurate detection of various parameters of a forge piece to be detected in a high-temperature environment, improves the quality and the production efficiency of metal processing formed products, and ensures ordered and stable operation of a high-temperature forge piece production line in a forging environment.
The technical solution for realizing the purpose of the invention is as follows: the utility model provides a high temperature forging detects control system, includes information acquisition module, control module and auxiliary function module, wherein:
the control module is based on an embedded industrial personal computer and comprises a Halcon image processing module, a position detection module, a temperature detection module, a size detection module, a defect detection module and a quality evaluation module, wherein the Halcon image processing module is used for processing images acquired by a camera to obtain a three-dimensional point cloud picture; the position detection module is used for detecting the position of taking and placing the forge piece, judging whether the position of the forge piece has deviation or not and feeding the deviation value back to the production line in real time to finish position correction; the temperature detection module detects the temperature of each station through an infrared temperature sensor and judges whether the temperature meets the process requirement of forging or not, and if not, the temperature of the production line is adjusted; the size detection module is used for detecting the sizes of the trimming and punching of the forge piece; the defect detection module is used for detecting the defects of the forged piece and classifying the defects; the quality evaluation module evaluates the quality of the forge piece according to the detection data of the position detection module, the temperature detection module, the size detection module and the defect detection module and forms a detection report;
the information acquisition module comprises a camera and an infrared temperature sensor, and acquires data and sends the data to the control module;
the auxiliary function module is used for assisting the control module to complete detection of the forge piece, and comprises a camera control module, a point cloud analysis module, a motion control module and a detection data and detection report query module, wherein the camera control module is used for controlling the opening of the camera, setting parameters of the control camera and displaying the collected point cloud data; the point cloud analysis module is used for displaying and analyzing three-dimensional point cloud pictures at different angles, the motion control module controls the execution action of equipment in the workshop according to the information of the control module, and the detection data and detection report query module is used for storing and checking the detection data and the detection report.
Compared with the prior art, the invention has the following remarkable advantages:
(1) according to the high-temperature forging detection control system, various parameters such as defects, temperature, position and size of the high-temperature forging are detected on line through the camera and the infrared temperature sensor, so that the machining precision and the forging efficiency can be effectively improved;
(2) according to the high-temperature forging detection control system, the collected data such as the position, the temperature, the appearance size and the like are stored in the SQL database, a detection report is generated according to manual selection, and a query time period can be selected to query relevant data of a product in the current time period; supporting the query of position detection data, temperature monitoring data, size detection data and defect detection data; supporting inputting the forging name to be inquired in a text box, and carrying out fuzzy matching;
(3) according to the high-temperature forge piece detection control system, the detection result can be fed back to the main control unit or the robot of the production line through the IO point and is in signal butt joint with each device of the production line, so that the safe and stable operation of the production line is guaranteed, in addition, the detection data can be fed back to the main control unit of the production line and the forging production line management and control system through the industrial Ethernet or the serial port, and the state monitoring and management and control functions of the whole production line are realized.
Drawings
FIG. 1 is a schematic diagram of the overall structure of a high-temperature forging detection control system.
Fig. 2 is a schematic diagram of the communication connection module.
Fig. 3 is a schematic diagram of the core function module.
Fig. 4 is a schematic diagram of the auxiliary function module.
Fig. 5 is a camera connection interface diagram.
Fig. 6 is a production line PLC connection interface diagram.
Fig. 7 is a diagram of an infrared temperature sensor connection interface.
FIG. 8 is a block diagram of a location detection function.
FIG. 9 is an interface diagram of a temperature sensing function module.
FIG. 10 is a size detection function block interface diagram.
FIG. 11 is a functional module interface diagram for defect detection.
FIG. 12 is a quality assessment function block interface diagram.
Fig. 13 is a test chart of a camera control module.
FIG. 14 is a test chart of a point cloud analysis module.
FIG. 15 is a motion control function block interface diagram.
FIG. 16 is a report and print function interface diagram.
Detailed Description
The invention is further described with reference to the following figures and embodiments.
As shown in fig. 1, the high-temperature forging detection control system in this embodiment includes a communication connection module, a core function module, and an auxiliary function module. The communication connection module consists of a camera, a production line PLC and an infrared temperature sensor; the core function module consists of a Halcon image processing module, a position detection module, a temperature detection module, a size detection module, a defect detection module and a quality evaluation module; the auxiliary function module consists of a camera control module, a point cloud analysis module, a motion control module and a detection data and detection report query module.
As shown in fig. 2, the communication connection module is divided into three parts, namely camera communication connection, production line PLC connection and infrared temperature sensor connection. The camera communication connection part realizes the setting of camera IP and port and the setting of exposure time, and supports the connection and disconnection operation; the production line PLC connecting part realizes IP setting and port setting of the production line PLC and supports connection and disconnection operations; the infrared temperature sensor connecting part realizes IP setting and port setting of the infrared temperature sensor and supports connection and disconnection operations.
As shown in fig. 5, the camera connection interface includes an IP input box, a port input box, and an exposure time setting box, and supports a connection operation, a disconnection operation, and a reconnection operation. After the connection is successful, the connection success characters exist on the interface.
As shown in fig. 6, the PLC connection interface of the production line includes an IP input box, a port input box, and supports a connection operation, a disconnection operation, and a reconnection operation. After the connection is successful, the connection success characters exist on the interface.
As shown in fig. 7, the infrared temperature sensor interface includes an IP input box, a port input box, and supports a connection operation, a disconnection operation, and a reconnection operation. After the connection is successful, the connection success characters exist on the interface.
As shown in fig. 3, the core function module is divided into a Halcon image processing module, a position detection module, a temperature detection module, a size detection module, a defect detection module and a quality evaluation module. The Halcon image processing module is used for processing the image acquired by the camera by adopting a mature image processing algorithm to obtain a three-dimensional point cloud picture, and the position detection module displays the deviation of the position x and the position y under different station conditions and adjusts the position of the deviation, so that the automation level of the production line can be effectively improved; the temperature detection module measures the temperature under different station conditions, sets the optimal temperature, and then clicks a temperature adjusting button to adjust the temperature; when the dimension detection module is used for punching and trimming edges, the maximum length of a forged and forged piece can be measured and displayed, the minimum width can be measured and displayed, the dimension deviation of the trimmed edges can be detected, whether the trimming effect is qualified or not can be displayed, the position x, the position y and the diameter of a punched hole in the forging and stamping process can be respectively displayed, and whether the detection result is qualified or not can be prompted; the defect detection module can display the defect types of the forged forgings through vision, and count indexes such as the number of products on the day, the number of defective products on the day, the defect rate of the products on the day, the accumulated defect rate and the like; the quality evaluation module mainly comprises three parts of an evaluation method, evaluation weight and an evaluation result, can analyze the correlation between the defects of the product and each index parameter, and provides a plurality of quality evaluation methods including a neural network classification method, a Bayesian network classification method, a support vector machine classification method and a gray evaluation and fuzzy evaluation method.
As shown in fig. 8, the position detection function interface is mainly directed to detection and correction of the position after placing the forging and before placing the forging. The system comprises an x position deviation display frame, a y position deviation display frame, a position detection button, a position correction button, a correction result display frame and the like. And in the position detection part, the position of the forge piece taken and placed by the robot is detected, and whether the position of the forge piece has deviation or not is judged. The method mainly comprises two steps:
(1) the position detection is carried out after the forge piece is placed on the robot, in the long-term operation process of a forging production line, the finger block of the robot is abraded, the paw is deformed when being heated at high temperature for a long time, the placing position deviation is caused when the robot carries the high-temperature forge piece at high speed due to the factors, so that the product is unqualified, and a press or a die is seriously damaged;
(2) the robot carries out position detection before taking the forging, and after the press is pushed down, the ejector rod is ejected out, and position deviation sometimes appears, and the robot can be guided to correct the grabbing position through the position matching function of the vision system, so that the outage rate is reduced, and the stability of the whole production line is enhanced. In addition, the detection device can also judge whether the press is stuck after forging is finished, and the system can give information prompts such as early warning and die repairing of the equipment. The positions of the forgings are detected by a vision detection algorithm through the connection of sensors such as a vision sensor, the position deviation of the forgings is judged, the deviation value is fed back to a production line in real time, and the functions of detecting and correcting the positions are completed through correction.
The temperature detection module comprises a temperature detection unit, a temperature display unit, an optimal temperature setting unit and a temperature adjusting unit, wherein the temperature detection unit is used for detecting the temperature of the station, the temperature display unit is used for displaying the detected temperature, the optimal temperature setting unit is used for setting an expected temperature value, and the temperature adjusting unit is used for adjusting the temperature of the station to reach the expected value; as shown in fig. 9, the temperature detection function interface can display the temperature value of each station in real time, and the accurate control of the current station process parameters can be realized through temperature detection. In order to deal with the measurement of the forged piece in a high-temperature environment, according to the radiation spectral characteristics of a high-temperature object and the spectral response characteristics of a CCD camera, a high-interference-resistance LED blue light source is adopted and matched with a low-pass filter, so that the influence of high-temperature radiation on the image quality is reduced. When the temperature is collected, the infrared temperature sensor collects temperature data of any specified axial section of the forge piece to be measured, the highest value is obtained, and the influence of oxide skin on temperature measurement is reduced. The temperature detection interface comprises a temperature detection function button, a station measurement temperature display numerical value, an optimal temperature setting frame and a temperature adjusting button. The left side is a temperature imaging graph, and the closer the color is to red, the higher the temperature is; conversely, the closer the temperature is to blue, the lower the temperature.
As shown in fig. 10, the size detection functional module is mainly used for detecting the size of the forging, including the detection of trimming and the detection of punching. After clicking a size detection button, detecting the maximum length and the minimum width of the trimming, the deviation of the trimming size and whether the detection result is qualified; the punching detection result comprises a display frame such as a punching x position, a punching y position, a punching diameter, a detection result and the like. The flow of size detection is roughly as follows:
(1) initially aligning a forging to be measured and a digital-analog (a known workpiece three-dimensional model) according to a positioning reference;
(2) presetting 12 point locations, and acquiring the surface of a key area of a forging by a camera to obtain 12 local point clouds;
(3) automatically splicing the 12 measured local point cloud pictures by a Halcon image processing module through mark points which are arranged in advance in the area near the forge piece, thereby obtaining a complete forge piece measurement picture;
(4) in order to further analyze the key size of the measured data, a measured coordinate system (a coordinate system adopted by a Halcon image processing module) and a design coordinate system (a coordinate system adopted by a three-dimensional model of a workpiece) need to be accurately aligned, and a closest point iterative algorithm is adopted to accurately align the measured data (a complete measurement diagram of the forged piece) and a digital analog, so that the accurate alignment of the measured coordinate system of the forged piece and the design coordinate system of the three-dimensional model of the forged piece is finally realized;
(5) and calculating parameters such as the maximum length, the minimum width and the deviation of the cut edge size, the punching position, the punching diameter and the like of the detected cut edge based on the forge piece integrity measurement diagram, and judging whether the forge piece is qualified or not according to the error between the measured value and the true value.
The size detection function is mainly to detect the size of product at side cut, the unit that punches a hole, and detecting system compares three-dimensional point cloud picture and product standard map according to 3D scanning result, judges whether product size satisfies the technology demand, and forging automation line system can sort the product according to the judged result to this improves the qualification rate of product. Based on the 3D point cloud data, the software realizes the communication with the camera, and the purpose of carrying out size detection on the forge piece is achieved by analyzing the 3D point cloud. In order to reduce the influence of vibration on the measurement result, an acceleration sensor is arranged in the measurement equipment, and when the measurement is carried out, if the vibration with larger amplitude (exceeding a certain threshold value) is detected during the measurement, the system gives up the measurement data and carries out the measurement again, so that the influence of the data interfered by the vibration on the accuracy of the whole data is avoided.
As shown in fig. 11, the defect detection function module is mainly used for identifying the forging defects, and after the defect detection button is clicked, displays the current defect type, the current product quantity, the current defect product quantity, the current product defect rate, and the current accumulated defect rate. After the vision system scans and images the high-temperature forge piece, according to the imaging result of the three-dimensional point cloud, the comparison is carried out with the common appearance defect characteristics of insufficient local filling, forging under-pressure, forging dislocation and the like in the forging process, whether the forge piece has defects and defect types is judged, if the defect rate is high, the problem of the production process is indicated, and therefore the function is also beneficial to the improvement and the improvement of the forging and the process. In the defect detection part, through a visual mode, software can automatically identify the defect types of the forge piece, including common defects such as collision damage defects, insufficient filling, forging under-pressure, forging dislocation and the like. Meanwhile, when the defects on the forge piece are found, the defect information can be quickly transmitted to the initial position of the process flow, the corresponding process parameters are modified, and the yield of the forge piece production is improved.
The quality evaluation module comprises an evaluation method selection unit, an evaluation weight setting unit and an evaluation result display unit, wherein the evaluation method selection unit is used for selecting a quality evaluation method, the evaluation weight setting unit is used for setting a weight value, and the evaluation result display unit is used for displaying an evaluation result; as shown in fig. 12, the quality evaluation function module is configured to analyze correlations between defects of the forged product and various index parameters of the product, and provide a plurality of quality evaluation methods, including a neural network classification method, a bayesian network classification method, a support vector machine classification method, and a gray evaluation and fuzzy evaluation method. In the quality evaluation part, the detection of the size of the forge piece is carried out according to a 3D vision system, the judgment of the forging position, the defect detection of the surface of the forge piece and the real-time detection of the temperature of the forge piece by an infrared temperature sensor can detect common local defects in the forging process, such as insufficient filling, undervoltage forging, dislocation forging and the like, and thus a quality evaluation system of the high-temperature forge piece is established.
As shown in fig. 4, the auxiliary function module is divided into a camera control module, a point cloud analysis module, a motion control module, and a detection data and detection report query module. The modules mainly realize the control of peripheral equipment and additional functions, and the control capability of a user on a production line and corollary equipment can be greatly improved through the modules, so that the production efficiency is improved.
As shown in fig. 13, the camera control module is mainly used for operating the camera, and is an auxiliary function module unit. The function module mainly comprises a camera opening button, an exposure time setting module, a minimum light intensity setting module, a collection starting button, a collection mode function selecting button and a collection finishing button. An image display module is arranged below the laser scanning area, can display the image in the current camera view field in real time, and displays the point cloud data of the laser scanning area.
As shown in fig. 14, the point cloud analysis module may be configured to open point cloud data, display point cloud in real time, realize fast switching of different angles of the point cloud, and operate a camera. In the point cloud analysis part, a plurality of point cloud data can be placed in the same interface for comparison, and the point cloud analysis part has the characteristics of strong contrast, intuition and obvious.
As shown in fig. 15, the motion control function module is mainly used to control the forward rotation and the reverse rotation of the servo driver, and the software includes a device function searching button, a device function turning button, a relay function turning button, and the like. All relays connected with the computer can be found by clicking the searching equipment, the equipment is turned on to realize communication with the relays, and the relay is turned on to be a direct function button for controlling the relays.
As shown in fig. 16, in the production process, the core function module stores the detected related data in the database, and the report and print function module can query the historical data. The inquiry modes are divided into various modes, including screening through time periods, selecting data (position detection data, size detection data, temperature detection data, defect detection data and the like) to be displayed, inquiring according to product numbers, and simultaneously supporting fuzzy inquiry of the product numbers. And displaying the query result in a form of a table, and storing the query result in the csv file for subsequent query. According to the data, a detection report of the forge piece can be generated through the analysis and judgment of the quality evaluation module.
During application, a 3D camera is erected on a blanking assembly line on a forging site, three-dimensional point cloud collection is carried out in the moving process of a connecting rod roller line, and the anti-interference performance of the 3D camera under the thermal state condition of a forge piece is verified.
The detection data of the position detection module, the temperature detection module and the size detection module can be fed back to a main control unit of a production line and a forging production line management and control system through an industrial Ethernet or a serial port, and the state monitoring and management and control functions of the whole production line are achieved.
The system was developed based on HALCON and C # co-programming.
In light of the foregoing description of the preferred embodiments of the present invention, it is to be understood that various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (10)
1. The utility model provides a high temperature forging detects control system which characterized in that, includes information acquisition module, control module and auxiliary function module, wherein:
the information acquisition module comprises a camera and an infrared temperature sensor, and acquires data and sends the data to the control module;
the control module is based on an embedded industrial personal computer and comprises a Halcon image processing module, a position detection module, a temperature detection module, a size detection module, a defect detection module and a quality evaluation module, wherein the Halcon image processing module is used for processing images acquired by a camera to obtain a three-dimensional point cloud picture; the position detection module is used for detecting the position of taking and placing the forge piece, judging whether the position of the forge piece has deviation or not and feeding the deviation value back to the production line in real time to finish position correction; the temperature detection module detects the temperature of each station through an infrared temperature sensor and judges whether the temperature meets the process requirement of forging or not, and if not, the temperature of the production line is adjusted; the size detection module is used for detecting the sizes of the trimming and punching of the forge piece; the defect detection module is used for detecting the defects of the forged piece and classifying the defects; the quality evaluation module evaluates the quality of the forge piece according to the detection data of the position detection module, the temperature detection module, the size detection module and the defect detection module and forms a detection report;
the auxiliary function module is used for assisting the control module to complete detection of the forge piece, and comprises a camera control module, a point cloud analysis module, a motion control module and a detection data and detection report query module, wherein the camera control module is used for controlling the opening of the camera, setting parameters of the control camera and displaying acquired data; the point cloud analysis module is used for displaying and analyzing three-dimensional point cloud pictures at different angles, the motion control module controls the execution action of equipment in the workshop according to the information of the control module, and the detection data and detection report query module is used for storing and querying the detection data and the detection report in a database.
2. The high-temperature forging detection control system according to claim 1, wherein the position detection module obtains the position of the forging through a visual detection algorithm on a three-dimensional point cloud picture of the Halcon image processing module.
3. The high-temperature forging detection control system of claim 2, wherein the position detection module comprises an x position deviation calculation unit, a y position deviation calculation unit and a position correction unit, the x position deviation calculation unit is used for calculating the deviation of the x position, the y position deviation calculation unit is used for calculating the y position deviation, and the position correction unit is used for correcting the pick-and-place position of the robot.
4. The high-temperature forging detection control system according to claim 1, wherein the temperature detection module comprises a temperature detection unit, a temperature display unit, an optimal temperature setting unit and a temperature adjusting unit, the temperature detection unit is used for detecting the temperature of the station, the temperature display unit is used for displaying the detected temperature, the optimal temperature setting unit is used for setting a desired temperature value, and the temperature adjusting unit is used for adjusting the temperature of the station to the desired value.
5. The system for detecting and controlling the high-temperature forged piece according to claim 1, wherein the camera adopts an LED blue light source and is matched with a low-pass filter to collect images, parameters of the camera include exposure time, minimum light intensity and collection mode, and an acceleration sensor is arranged in the camera.
6. The high-temperature forging detection control system according to claim 1, wherein the size detection module comprises a trimming detection unit and a punching detection unit, the trimming detection unit is used for displaying trimming data, and the punching detection unit is used for displaying punching data.
7. The high-temperature forging detection control system of claim 6, wherein the detection method of the size detection module is as follows:
initially aligning the forge piece to be detected and the three-dimensional model of the forge piece according to the positioning reference;
presetting 12 point locations, collecting the surface of a forging to obtain 12 local point cloud pictures;
based on preset installation mark points, automatically splicing the 12 local point cloud pictures through a Halcon image processing module, thereby obtaining a forge piece integrity measurement picture;
precisely aligning the forge piece complete measurement diagram with the forge piece three-dimensional model by adopting a closest point iterative algorithm, and further precisely aligning a measurement coordinate system of the forge piece with a design coordinate system of the forge piece three-dimensional model;
and calculating the maximum length and the minimum width of the trimming, the deviation of the trimming size, the punching position and the punching diameter based on the forge piece integrity measurement diagram, and judging whether the forge piece is qualified or not according to the error between the measured value and the true value.
8. The system of claim 1, wherein the defect detection module identifies the type of the defect by comparing the three-dimensional point cloud image with a standard forging image, and obtains the number of products, the number of defective products, the defect rate of products and the accumulated defect rate of the products on the same day.
9. The high-temperature forging detection control system of claim 1, wherein the quality evaluation module comprises an evaluation method selection unit, an evaluation weight setting unit and an evaluation result display unit, the evaluation method selection unit is used for selecting a quality evaluation method, the evaluation weight setting unit is used for setting a weight value, and the evaluation result display unit is used for displaying the evaluation result; the quality evaluation method comprises a neural network classification method, a Bayesian network classification method, a support vector machine classification method and a gray evaluation and fuzzy evaluation method.
10. The system of claim 1, wherein the detection data and detection report query module performs fuzzy matching query by selecting a time period for query or inputting a forging name.
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