CN113978756A - Large component barrel section butt joint experiment table and butt joint method based on trial assembly simulation - Google Patents
Large component barrel section butt joint experiment table and butt joint method based on trial assembly simulation Download PDFInfo
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- CN113978756A CN113978756A CN202111176427.3A CN202111176427A CN113978756A CN 113978756 A CN113978756 A CN 113978756A CN 202111176427 A CN202111176427 A CN 202111176427A CN 113978756 A CN113978756 A CN 113978756A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
- B64F5/60—Testing or inspecting aircraft components or systems
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
- B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor
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Abstract
The invention discloses a large-component barrel section butt joint experiment table and a butt joint method based on trial assembly simulation, wherein the experiment table obtains barrel section surface appearance data through a handheld 3D scanner, obtains position information of key feature points on a barrel section end face through an M20 high-precision real-time measurement camera, controls a moving part through a six-freedom-degree motion platform, and simultaneously performs secondary verification on butt joint accuracy through a Gocator 3D laser profile sensor, so that dynamic and real-time process model trial assembly simulation verification can be realized, and deviation measurement under actual measurement data can be realized, so that the function of verifying assembly deviation analysis software can be realized. Meanwhile, the method can also be used for providing research foundation and technical verification for the prediction of the assembly deviation of the general assembly butt joint of the large components in actual engineering.
Description
Technical Field
The invention belongs to the technical field of airplane assembly, and particularly relates to a butt joint experiment table and a butt joint method for a large part cylinder section of an airplane.
Background
The airplane is a product with complex appearance, huge number of parts and complex coordination relationship. In the process of airplane assembly, the quality of butt joint assembly directly influences the assembly accuracy of the whole airplane. The fuselage comprises frame, truss, covering, crossbeam isotructure, but receives self structural feature, part rigidity is low, manufacturing error and the influence of factors such as the frock clamping locate mode of taking during the assembly make actual part appearance and theoretical manufacturing model between have certain deviation, this deviation is along with assembly process production, transmission and accumulation, receive the influence of terminal surface depth of parallelism and straightness tolerance that hangs down in the butt joint process, the coordination is complicated, there are problems such as butt joint jump and butt joint clearance, need trial assembly repeatedly and inefficiency, it is difficult to accurate prediction assembly deviation.
With the proposition of a digital twinning concept and the development of a modern advanced measurement technology, high-precision part surface data can be obtained through three-dimensional digital measurement equipment, a digital twinning model capable of mapping real state information of parts one by one is constructed, the precision of key feature points after the parts are assembled under actual working conditions is predicted by a mathematical analysis method, the cost and the time are saved to a certain extent, and the method has important significance for improving the assembly accuracy of an airplane and guiding subsequent assembly work. However, the application of the technology based on the digital twinning still stays at the description level of the concept, and no technical method for realizing the digital twinning in the aspect of predicting the deviation of the actual assembly body is researched in the literature.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a large-component cylinder section butt joint experiment table and a butt joint method based on trial assembly simulation, the experiment table obtains the surface appearance data of a cylinder section through a handheld 3D scanner, obtains the position information of key characteristic points on the end surface of the cylinder section through an M20 high-precision real-time measurement camera, performs six-freedom-degree motion control on a moving part through a six-freedom-degree motion platform, and simultaneously performs secondary verification on the butt joint accuracy through a Gocator 3D laser profile sensor, so that the dynamic and real-time process model trial assembly simulation verification can be realized, and the deviation measurement under the actual measurement data can be realized, so that the function of verifying assembly deviation analysis software is realized. Meanwhile, the method can also be used for providing research foundation and technical verification for the prediction of the assembly deviation of the general assembly butt joint of the large components in actual engineering.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a large component barrel section butt joint experiment table based on trial assembly simulation comprises: the device comprises a camera calibration module, a camera measurement module, a laser measurement module, a cylinder section supporting and posture adjusting module and a control and display module; the large component cylinder section comprises a movable end cylinder section and a fixed end cylinder section;
the camera calibration module is arranged at the periphery of the large component cylinder section and is used for calibrating the camera measurement module; the camera measurement module is arranged on the periphery of the large component cylinder section and used for acquiring the position information of key characteristic points on the large component cylinder section; the laser measurement module is arranged in the large component cylinder section and used for acquiring external shape data of the inner surface of the butt joint part of the large component cylinder section; the cylinder section supporting and posture adjusting module is arranged below the large component cylinder section and used for controlling the position and the posture of the large component cylinder section; the control and display module is arranged on the periphery of the large part cylinder section and is used for processing data of each module of the experiment table, realizing data communication among the modules of the experiment table, performing simulation verification on the butt joint process of the large part cylinder section and displaying the data in real time through a visualization technology;
the camera measurement module acquires position information of key feature points of the large part cylinder section, generates control information after comparing the position information with preset large part cylinder section assembly primary butt joint design deviation in the control and display module, and controls the cylinder section support posture adjusting module to adjust the posture of the movable end cylinder section until the requirement of large part cylinder section assembly primary butt joint design deviation is met; then, the laser measurement module is used for obtaining the shape data of the inner surface of the butt joint part of the large component cylinder section, after the control and display module is compared with the preset assembly secondary butt joint design deviation of the large component cylinder section, control information is generated, and the control cylinder section support posture adjusting module is used for adjusting the posture of the movable end cylinder section until the requirement of the assembly secondary butt joint design deviation of the large component cylinder section is met; the control and display module acquires end surface point cloud data of the large part cylinder section, simulation verification is carried out by combining the point cloud data of the side surface of the large part cylinder section acquired by the photographic measurement module, and the butt joint process of the movable end cylinder section and the static end cylinder section is displayed in real time through a visualization technology.
Further, the photographing calibration module comprises a calibration scale, a calibration scale supporting device, a calibration camera and a calibration camera supporting device; the calibration camera supporting device comprises a camera holder, a telescopic rod and a movable support;
the calibration ruler is placed on the calibration ruler supporting device; the calibration camera is arranged on the camera cloud deck, and the camera cloud deck is used for controlling the pitching and the deflection motion of the calibration camera; the camera cloud platform is arranged at the upper end of the telescopic rod, and the lower end of the telescopic rod is fixed on the movable support; the telescopic rod is used for adjusting the height of the calibration camera, and the movable support enables the calibration camera to move on a horizontal plane; the calibration scale and the photographing measurement module are photographed at a plurality of positions by moving the calibration camera, the photographed image information is transmitted to the control and display module in a wireless mode, and the control and display module automatically calibrates the phase measurement module.
Further, the photogrammetry module comprises two high-precision real-time measurement cameras and two camera support frames; the camera support frame comprises a camera pan-tilt head, an expansion rod and a base, wherein the camera pan-tilt head and the expansion rod are the same as those in the calibration camera support device;
the two high-precision real-time measuring cameras are respectively arranged on the camera cloud platforms on the two camera supporting frames; the camera holder in the camera support frame is used for controlling the functions of high-precision real-time measurement of pitching and deflection of the camera, and can realize measurement at different angles; the camera holder in the camera support frame is arranged at the upper end of a telescopic rod in the camera support frame, and the lower end of the telescopic rod is fixed on the base; the telescopic rod in the camera support frame is used for adjusting the height of the high-precision real-time measurement camera; the two high-precision real-time measuring cameras are arranged at a distance of A meters, the two cameras are both at a distance of B meters from the large component barrel section, and the high-precision real-time measuring cameras are at a distance of C meters from the base; the camera calibration module calibrates the position relation between the two high-precision real-time measurement cameras.
Furthermore, the laser measuring module comprises two supporting devices, a horizontal plate, a stepping motor, a coupler, a rotating shaft, a connecting rod, a sensor support and a laser profile sensor;
the horizontal plate is arranged inside the static end cylinder section, and the two supporting devices are both arranged on the horizontal plate and are separated by a certain distance; a stepping motor is arranged at the top end of one supporting device and used for providing power for rotary motion; the rotating shaft is connected with a rotating shaft of the stepping motor through the coupler; a through hole is processed on the other supporting device, and the rotating shaft penetrates through the through hole to support the rotating shaft; the rotating shaft is positioned in the central axis of the static end cylinder section, the rotating shaft is connected with a connecting rod perpendicular to the rotating shaft, and the connecting rod rotates along with the rotating shaft on the circular section of the butt joint part of the movable end cylinder section and the static end cylinder section; a sensor support is arranged at the other end of the connecting rod, and the laser profile sensor is arranged on the sensor support; the connecting rod rotates, and the laser profile sensor can scan the butt joint part of the movable end cylinder section and the static end cylinder section by 360 degrees.
Further, the cylinder section supporting and posture adjusting module comprises a static supporting platform, a six-degree-of-freedom motion platform and two shape-preserving tool brackets; the six-degree-of-freedom motion platform comprises an upper platform, a lower platform, 6 electric cylinders, 6 servo motors and a central integrated system;
the static support platform and the six-degree-of-freedom motion platform are aligned to be placed on the ground, the distance between the static support platform and the six-degree-of-freedom motion platform is set to be between D meters and E meters, and a shape-preserving tool bracket is respectively arranged on the static support platform and the six-degree-of-freedom motion platform; the static end cylinder section is arranged on a shape-retaining tool bracket on the static support platform, and the movable end cylinder section is arranged on a shape-retaining tool bracket on the six-degree-of-freedom motion platform; the upper platform is used for mounting a movable end shape-preserving tool bracket, the lower platform is placed on the ground, and the 6 electric cylinders, the 6 servo motors and the central integrated system are mounted between the upper platform and the lower platform;
each electric cylinder is provided with a servo motor for providing power, and the servo motor drives the electric cylinder to stretch and retract so as to realize the motion of the six-freedom-degree motion platform in six-freedom-degree directions; the six-degree-of-freedom motion platform is in data communication with the control and display module through the central integrated system, the control and display module sends an instruction to the central integrated system 33, and the central integrated system controls the servo motor to drive the electric cylinder to stretch.
Further, the control and display module comprises a PC, a network data line and a handheld 3D scanner;
the PC is connected with the central integrated system through a network data line, the position information of key characteristic points of the large component cylinder section measured by the camera measurement module is wirelessly transmitted to the PC, then the data is processed through data processing software in the PC, the next data parameter for adjusting the posture of the cylinder section at the moving end is obtained, and the next data parameter is transmitted to the six-degree-of-freedom motion platform; the handheld 3D scanner obtains end face point cloud data of the large component cylinder section before the camera measurement module starts to measure, carries out simulation verification by combining the point cloud data of the side face of the large component cylinder section obtained by the camera measurement module, and displays the butt joint process of the movable end cylinder section and the static end cylinder section in real time through a visualization technology.
A large component cylinder section butt joint method based on trial assembly simulation comprises the following steps:
step 1: building a test bed;
the method comprises the following steps of (1) aligning a static supporting platform and a six-degree-of-freedom motion platform on the ground, setting the distance between the static supporting platform and the six-degree-of-freedom motion platform to be D-meter to E-meter, and respectively placing two shape-preserving tool brackets, a static end cylinder section and a dynamic end cylinder section on the static supporting platform and the six-degree-of-freedom motion platform; placing a calibration ruler, a photographic measuring module and a PC machine at a specified position, wherein the calibration ruler is placed right in front of the butt joint end surfaces of the cylinder sections of the static end cylinder section and the movable end cylinder section from F meters to G meters; the camera measurement module is placed at the position B meters right in front of the butt joint platform, the distance between the two high-precision real-time measurement cameras is A meters, and the height is C meters;
step 2: arranging the mark points of the photographic codes;
photographic code mark points are uniformly distributed on the butt joint end face and the appearance profile face of the movable end cylinder section and the butt joint end face and the appearance profile face of the static end cylinder section, so that the position posture relation of the static end cylinder section and the movable end cylinder section is conveniently monitored in the butt joint and measurement processes;
and step 3: collecting surface profile information by a handheld 3D scanner;
pasting a certain number of circular mark points on the butt joint end faces of a static end cylinder section and a movable end cylinder section to be scanned, measuring by adopting a laser triangulation method, and forming a triangle by a laser transmitter, a camera lens and the butt joint end faces of a handheld 3D scanner; in the measuring process, the handheld 3D scanner keeps a certain distance and moves at a constant speed, point cloud data collection is carried out on the butt joint end face, and a collected butt joint end face point cloud data model is displayed in real time;
and 4, step 4: calibrating a camera calibration photogrammetry module;
placing a calibration scale in front of a butt joint experiment table, and calibrating a phase measurement module through a calibration camera after finishing the arrangement work of the photographic code mark points; moving the calibration cameras, respectively carrying out photographing calibration at a plurality of positions, and automatically calibrating the position relation of two high-precision real-time measurement cameras in the photographing measurement module;
and 5: taking a picture, measuring and acquiring initial pose information;
starting a photographing measurement module to perform photographing measurement, acquiring pose information of the static end cylinder section and the moving end cylinder section, and transmitting the pose information to a PC (personal computer);
step 6: adjusting the posture of the large component cylinder section;
processing the pose information acquired in the step 5 through data processing software matched in a PC, comparing the pose information with the preset assembly primary butt joint design deviation of the large component cylinder section, obtaining data parameters of pose adjusting movement, generating control information and transmitting the control information to a six-degree-of-freedom movement platform; the six-degree-of-freedom motion platform controls the movable end cylinder section to adjust the posture;
and 7: repeating the photographic measurements;
repeating the step 5 and the step 6 until the preset primary butt joint design deviation of the large component cylinder section assembly is met;
and 8: line laser scanning measurement verification
After meeting the preset primary butt joint design deviation of the large component barrel section, starting a stepping motor to enable a laser profile sensor to obtain the external shape data of the internal surface of the butt joint part and transmit the external shape data to a PC (personal computer) for data processing, and after comparing the external shape data with the preset secondary butt joint design deviation of the large component barrel section, generating control information and transmitting the control information to a six-freedom-degree motion platform; the six-degree-of-freedom motion platform controls the movable end cylinder section to adjust the posture; until the preset secondary butt joint design deviation of the large component cylinder section assembly is met;
and step 9: verifying the docking accuracy;
performing simulation verification on the actual measurement point cloud data acquired by the camera measuring module each time through the large component barrel section butt joint end surface point cloud data model acquired in the step 3, and visualizing the assembly state on a PC in real time; before each actual butt joint, performing one-time trial assembly on a PC (personal computer) to verify whether the posture adjustment meets the butt joint requirement;
step 10: completing butt joint;
and when the verification of the step 9 is passed, performing final plug-in docking to finish docking.
Further, a is 3, B is 2, C is 1.7, D is 0.6, E is 0.8, F is 0.2, and G is 0.3.
Further, the high-precision real-time measurement camera is an M20 high-precision real-time measurement camera.
Further, the stepping motor is a 57BYGH301 stepping motor.
Further, the laser profile sensor is a Gocator 3D laser profile sensor.
The invention has the following beneficial effects:
the invention can realize the dynamic and real-time process model trial assembly simulation verification and also can realize the deviation measurement under the actual measurement data so as to realize the function of verifying the assembly deviation analysis software. Meanwhile, the method can also be used for providing research foundation and technical verification for the prediction of the assembly deviation of the general assembly butt joint of the large components in actual engineering.
Drawings
Fig. 1 is a schematic view of the overall structure of the present invention.
Fig. 2 is a schematic structural diagram of the camera calibration module of the present invention.
FIG. 3 is a schematic diagram of the structure of the photogrammetric module of the present invention.
FIG. 4 is a schematic diagram of a laser measuring module according to the present invention.
FIG. 5 is a schematic structural view of a barrel section supporting posture adjustment module according to the present invention.
FIG. 6 is a schematic structural diagram of a six-DOF motion platform according to the present invention.
FIG. 7 is a schematic diagram of a control and display module according to the present invention.
In the figure: 1-a photographic calibration module, 2-a photographic measurement module, 3-a laser measurement module, 4-a barrel section support posture adjustment module, 5-a control and display module, 6-a calibration ruler, 7-a calibration ruler support device, 8-a calibration camera, 9-a camera holder, 10-a telescopic rod, 11-a movable support, 13-a high-precision real-time measurement camera, 14-a base, 15-a support device, 16-a horizontal plate, 17-a stepping motor, 18-a coupler, 19-a rotating shaft, 20-a connecting rod, 21-a sensor support, 22-a laser profile sensor, 23-a barrel section butt joint end face, 24-a static end barrel section, 25-a dynamic end barrel section, 26-a static support table and 27-a six-freedom-degree motion platform, 28-shape-preserving tool bracket, 29-upper platform, 30-lower platform, 31-electric cylinder, 32-servo motor, 33-central integrated system, 34-PC, 35-data transmission line, 36-hand-held 3D scanner, and 37-wooden table.
Detailed Description
The invention is further illustrated with reference to the following figures and examples.
The invention designs a large-part barrel section butt joint experiment table based on dynamic process model trial assembly simulation, which simulates actual airplane body butt joint assembly by using two barrel section sample pieces which are reduced in equal proportion to each other, and is used for providing research foundation and technical verification for prediction of assembly butt joint assembly deviation of large parts of the type in actual engineering.
As shown in fig. 1, a large component barrel section butt joint experiment table based on trial assembly simulation includes: the device comprises a camera calibration module 1, a camera measurement module 2, a laser measurement module 3, a cylinder section supporting and posture adjusting module 4 and a control and display module 5; the large component cylinder section comprises a movable end cylinder section 25 and a static end cylinder section 24;
the camera calibration module 1 is arranged at the periphery of the large component cylinder section and is used for calibrating the camera measurement module 2; the photogrammetric module 2 is placed on the periphery of the large component cylinder section and is used for acquiring the position information of key characteristic points on the large component cylinder section; the laser measuring module 3 is arranged in the large component cylinder section and is used for acquiring external shape data of the inner surface of the butt joint part of the large component cylinder section; the cylinder section supporting and posture adjusting module 4 is arranged below the large component cylinder section and used for controlling the position and the posture of the large component cylinder section; the control and display module 5 is placed on the periphery of the large part cylinder section and used for processing data of each module of the experiment table, realizing data communication among the modules of the experiment table, performing simulation verification on the butt joint process of the large part cylinder section and displaying the data in real time through a visualization technology;
the camera measurement module 2 acquires position information of key feature points of the large component cylinder section, generates control information after comparing the position information with preset large component cylinder section assembly primary butt joint design deviation in the control and display module 5, and controls the cylinder section support posture adjusting module 4 to adjust the posture of the movable end cylinder section 25 until the requirement of large component cylinder section assembly primary butt joint design deviation is met; then, the laser measuring module 3 is used for obtaining the shape data of the inner surface of the butt joint part of the cylinder section of the large component, after the control and display module 5 is compared with the preset assembling secondary butt joint design deviation of the cylinder section of the large component, control information is generated, and the cylinder section supporting and posture adjusting module 4 is controlled to adjust the posture of the cylinder section 25 of the movable end until the requirement of the assembling secondary butt joint design deviation of the cylinder section of the large component is met; the control and display module 5 acquires end surface point cloud data of the large component cylinder section, performs simulation verification by combining the large component cylinder section side surface point cloud data acquired by the photographic measurement module 2, and displays the butt joint process of the movable end cylinder section 25 and the static end cylinder section 24 in real time through a visualization technology.
Further, as shown in fig. 2, the camera calibration module 1 includes a calibration scale 6, a calibration scale supporting device 7, a calibration camera 8 and a calibration camera supporting device; the calibration camera supporting device comprises a camera cloud deck 9, a telescopic rod 10 and a movable support 11; when taking a photo measurement, parameters such as brightness, contrast, acquisition control and the like of the M20 high-precision real-time measurement camera need to be set firstly. The photogrammetry module adopts two cameras to carry out photogrammetry, and carries out calibration and correction on the two M20 high-precision real-time measurement cameras according to conversion theories such as projection transformation and the like.
The calibration ruler 6 is placed on the calibration ruler supporting device 7; the calibration camera 8 is mounted on the camera holder 9, and the camera holder 9 is used for controlling the pitching and yawing motions of the calibration camera 8; the camera cloud deck 9 is arranged at the upper end of the telescopic rod 10, and the lower end of the telescopic rod 10 is fixed on the movable support 11; the telescopic rod 10 is used for adjusting the height of the calibration camera 8, and the movable support 11 enables the calibration camera 8 to move on a horizontal plane; the calibration scale 6 and the photogrammetric module 2 are shot at a plurality of positions by moving the calibration camera 8, the shot image information is transmitted to the control and display module 5 in a wireless mode, and the control and display module 5 automatically calibrates the photogrammetric module 2.
Further, as shown in fig. 3, the photogrammetry module 2 comprises two high-precision real-time measurement cameras 13 and two camera support frames; the camera support frame comprises a camera pan-tilt 9, an expansion rod 10 and a base 14, wherein the camera pan-tilt 9 and the expansion rod 10 are the same as those of the calibration camera support device; the method is characterized in that two M20 high-precision real-time measuring cameras are used for measuring and are used for acquiring position information of key feature points on a component, the principle is that a human eye three-dimensional imaging process is simulated, the two cameras are arranged at a certain distance, a proper angle is adjusted, so that the two cameras can simultaneously acquire component images of a measuring site, and three-dimensional coordinate data information of a space point on the surface of an object is acquired according to an optical triangle principle.
The two high-precision real-time measuring cameras 13 are respectively arranged on the camera cloud platforms 9 on the two camera support frames; the camera holder 9 in the camera support frame is used for controlling the pitching and deflecting functions of the high-precision real-time measuring camera 13, so that the measurement at different angles can be realized, and the environmental applicability of the measuring system is ensured to the maximum extent; the camera tripod head 9 in the camera support frame is arranged at the upper end of a telescopic rod 10 in the camera support frame, and the lower end of the telescopic rod 10 is fixed on a base 14; the telescopic rod 10 in the camera support frame is used for adjusting the height of the high-precision real-time measuring camera 13; the two high-precision real-time measuring cameras 13 are placed 3 meters away from each other, the two cameras are 2 meters away from the large part cylinder section, and the height of the high-precision real-time measuring cameras 13 from the base 14 is 1.7 meters; the camera calibration module 1 calibrates the position relationship between the two high-precision real-time measurement cameras 13.
Further, as shown in fig. 4, the laser measuring module 3 includes two supporting devices 15, a horizontal plate 16, a stepping motor 17, a coupling 18, a rotating shaft 19, a connecting rod 20, a sensor support 21 and a laser profile sensor 22; the working principle is as follows: firstly, determining the scanning speed in a working state, determining a series of parameters such as a field profile and the like according to the shape size of a cylinder section, carrying out thinning, dispersing and other operations on information captured by a camera in software, and finally filtering and fitting data points in an obtained three-dimensional space to generate a three-dimensional graph.
The horizontal plate 16 is arranged inside the static end cylinder section 24, and the two supporting devices 15 are both arranged on the horizontal plate 16 at a certain distance; a stepping motor 17 is installed at the top end of one supporting device 15 and used for providing power for rotary motion; the rotating shaft 19 is connected with the rotating shaft of the stepping motor 17 through the coupler 18; in order to prevent the rotating shaft 19 from being bent due to overlong, a through hole is processed on the supporting device 15 close to the direction of the butt end surface 23 of the cylinder section for supporting the rotating shaft 19, and the rotating shaft 19 penetrates through the through hole to support the rotating shaft 19; the rotating shaft 19 is positioned on the central axis of the static end cylinder section 24, the connecting rod 20 is connected to the rotating shaft 19 and is perpendicular to the rotating shaft 19, and the connecting rod 20 rotates along with the rotating shaft 19 on the butt joint part circular section of the movable end cylinder section 25 and the static end cylinder section 24; a sensor support 21 is arranged at the other end of the connecting rod 20, and the laser profile sensor 22 is arranged on the sensor support 21; the connecting rod 20 rotates, and the laser profile sensor 22 can scan the butt joint part of the movable end cylinder section 25 and the static end cylinder section 24 by 360 degrees.
Further, as shown in fig. 5, the barrel section supporting and posture adjusting module 4 comprises a static supporting platform 26, a six-degree-of-freedom motion platform 27 and two shape-preserving tool brackets 28; as shown in fig. 6, the six-degree-of-freedom motion platform 27 includes an upper platform 29, a lower platform 30, 6 electric cylinders 31, 6 servo motors 32 and a central integrated system 33; the six-degree-of-freedom motion platform 27 is used for controlling six-direction degrees of freedom of the components so as to realize accurate control of the positions and postures of the butt joint components;
the static support platform 26 and the six-degree-of-freedom motion platform 27 are aligned and placed on the ground, the distance between the static support platform and the six-degree-of-freedom motion platform is set to be 0.6-0.8 m, and a shape-preserving tool bracket 28 is respectively arranged on the static support platform and the six-degree-of-freedom motion platform; the static end cylinder section 24 is arranged on a shape-retaining tool bracket 28 on a static support platform 26, and the dynamic end cylinder section 25 is arranged on the shape-retaining tool bracket 28 on a six-degree-of-freedom motion platform 27; the upper platform 29 is used for installing a movable end shape-preserving tool bracket 28, the lower platform 30 is placed on the ground, and 6 electric cylinders 31, 6 servo motors 32 and a central integrated system 33 are installed between the upper platform 29 and the lower platform 30;
each electric cylinder 31 is provided with a servo motor 32 for providing power, and the servo motor 32 drives the electric cylinder 31 to extend and contract to realize the motion of the six-degree-of-freedom motion platform 27 in six-degree-of-freedom directions; the six-degree-of-freedom motion platform 27 is in data communication with the control and display module 5 through the central integrated system 33, the control and display module 5 sends an instruction to the central integrated system 33, and the central integrated system 33 controls the servo motor 32 to drive the electric cylinder 31 to extend and retract.
The central integrated system 33 comprises a servo driver system, a sensor measuring system, a seat pedal connecting rod telescopic mechanism and an electrical control system above the platform, telescopic mechanisms and electrical control systems of channels on the left side and the right side of the platform, an attitude operation system, a control system, a monitoring system and the like;
further, as shown in fig. 7, the control and display module 5 includes a PC 34, a network data line 35, and a handheld 3D scanner 36; 1 wood table 37 is placed at a position 1m away from the left side of the six-degree-of-freedom platform 27, and a PC (personal computer) 34 is placed above the wood table 37 and used for data processing, data communication and simulation visualization of the experiment table;
the PC 34 is connected with the central integrated system 33 through a network data line 35, the position information of key feature points of the large component cylinder section measured by the camera measuring module 2 is wirelessly transmitted to the PC 34, then the data is processed through data processing software in the PC 34, the next attitude-adjusting data parameter of the cylinder section 25 at the moving end is obtained, and the next attitude-adjusting data parameter is transmitted to the six-degree-of-freedom motion platform 27; the handheld 3D scanner 36 acquires end point cloud data of the large cylinder section before the photogrammetric module 2 starts to measure, performs simulation verification by combining the point cloud data of the large cylinder section side acquired by the photogrammetric module 2, and displays the butt joint process of the moving end cylinder section 25 and the static end cylinder section 24 in real time through a visualization technology.
A large component cylinder section butt joint method based on trial assembly simulation comprises the following steps:
step 1: building a test bed;
the static support platform 26 and the six-degree-of-freedom motion platform 27 are placed on the ground in an aligned mode, the distance between the static support platform 26 and the six-degree-of-freedom motion platform 27 is set to be 0.6-0.8 m, and the two shape-preserving tool brackets 28, the static end cylinder section 24 and the dynamic end cylinder section 25 are respectively placed on the static support platform 26 and the six-degree-of-freedom motion platform 27; placing the calibration ruler 6, the photogrammetric module 2 and the PC 34 at specified positions, wherein the calibration ruler 6 is placed at a position (close to a butt joint platform as much as possible) which is 0.2-0.3 meter right in front of the butt joint end surface 23 of the cylinder sections of the static end cylinder section 24 and the movable end cylinder section 25; the photogrammetric module 2 is placed 2 meters in front of the butt joint platform, the distance between the two high-precision real-time measuring cameras 13 is 3 meters (the middle of the two cameras is ensured to face the butt joint end face as far as possible), and the height is 1.7 meters; the PC 34 is placed at a position about 1m to the left of the six-degree-of-freedom motion platform 27.
Step 2: arranging the mark points of the photographic codes;
photographic code mark points are uniformly distributed on the butt joint end face and the appearance profile face of the movable end cylinder section 25 and the butt joint end face and the appearance profile face of the static end cylinder section 24, so that the position posture relation between the static end cylinder section 24 and the movable end cylinder section 25 can be conveniently monitored in the butt joint and measurement processes;
and step 3: the handheld 3D scanner 36 collects surface profile information;
a certain number of circular mark points are stuck on the butt joint end face of the static end cylinder section 24 and the movable end cylinder section 25 to be scanned, a laser triangulation method is adopted for measurement, and a triangle is formed by a laser emitter, a camera lens and the butt joint end face of the handheld 3D scanner 36; in the measurement process, the handheld 3D scanner 36 keeps a certain distance and moves at a constant speed, point cloud data collection is performed on the butt joint end face, and the collected butt joint end face point cloud data model is displayed in real time;
and 4, step 4: calibrating the camera calibration photogrammetry module 2;
the calibration ruler 6 is placed in front of the butt joint experiment table, after the arrangement work of the mark points of the photographic codes is completed, the calibration camera 8 is used for calibrating the phase measurement module 2; the calibration camera 8 is moved to respectively carry out photographing calibration at a plurality of positions, and the position relation of the two high-precision real-time measurement cameras 13 in the photographing measurement module 2 is automatically calibrated;
and 5: taking a picture, measuring and acquiring initial pose information;
starting the camera measuring module 2 to carry out camera measurement, acquiring the pose information of the static end cylinder section 24 and the moving end cylinder section 25, and transmitting the pose information to the PC 34;
step 6: adjusting the posture of the large component cylinder section;
processing the pose information acquired in the step 5 through data processing software matched in the PC 34, comparing the pose information with the preset assembly primary butt joint design deviation of the large component barrel section, obtaining data parameters of pose adjusting movement, generating control information and transmitting the control information to the six-degree-of-freedom movement platform 27; the six-degree-of-freedom motion platform 27 controls the moving end cylinder section 25 to adjust the posture (mainly aligning 5 degrees of freedom except the axial direction of the cylinder section);
and 7: repeating the photographic measurements;
repeating the step 5 and the step 6 until the preset primary butt joint design deviation of the large component cylinder section assembly is met;
and 8: line laser scanning measurement verification
After meeting the preset primary butt joint design deviation of the assembly of the large component cylinder segment, starting the stepping motor 17 to enable the laser contour sensor 22 to obtain the external shape data of the internal surface of the butt joint part and transmit the external shape data to the PC 34 for data processing, and after comparing the external shape data with the preset secondary butt joint design deviation of the assembly of the large component cylinder segment, generating control information and transmitting the control information to the six-freedom-degree motion platform 27; the six-degree-of-freedom motion platform 27 controls the moving end cylinder section 25 to adjust the posture; until the preset secondary butt joint design deviation of the large component cylinder section assembly is met;
and step 9: verifying the docking accuracy;
performing simulation verification on the basis of actually-measured point cloud data acquired by the photogrammetric module 2 each time through the large component barrel section butt joint end surface point cloud data model acquired in the step 3, and visualizing the assembly state on the PC 34 in real time; before each actual docking, one trial assembly is carried out on the PC 34 to verify whether the posture adjustment meets the docking requirement;
step 10: completing butt joint;
and when the verification of the step 9 is passed, performing final plug-in docking to finish docking.
Further, the high-precision real-time measuring camera 13 is an M20 high-precision real-time measuring camera.
Further, the stepping motor 17 is a 57BYGH301 stepping motor.
Further, the laser profile sensor 22 is a Gocator 3D laser profile sensor.
Claims (9)
1. The utility model provides a big component section of thick bamboo section butt joint laboratory bench based on trial assembly emulation which characterized in that includes: the device comprises a camera calibration module, a camera measurement module, a laser measurement module, a cylinder section supporting and posture adjusting module and a control and display module; the large component cylinder section comprises a movable end cylinder section and a fixed end cylinder section;
the camera calibration module is arranged at the periphery of the large component cylinder section and is used for calibrating the camera measurement module; the camera measurement module is arranged on the periphery of the large component cylinder section and used for acquiring the position information of key characteristic points on the large component cylinder section; the laser measurement module is arranged in the large component cylinder section and used for acquiring external shape data of the inner surface of the butt joint part of the large component cylinder section; the cylinder section supporting and posture adjusting module is arranged below the large component cylinder section and used for controlling the position and the posture of the large component cylinder section; the control and display module is arranged on the periphery of the large part cylinder section and is used for processing data of each module of the experiment table, realizing data communication among the modules of the experiment table, performing simulation verification on the butt joint process of the large part cylinder section and displaying the data in real time through a visualization technology;
the camera measurement module acquires position information of key feature points of the large part cylinder section, generates control information after comparing the position information with preset large part cylinder section assembly primary butt joint design deviation in the control and display module, and controls the cylinder section support posture adjusting module to adjust the posture of the movable end cylinder section until the requirement of large part cylinder section assembly primary butt joint design deviation is met; then, the laser measurement module is used for obtaining the shape data of the inner surface of the butt joint part of the large component cylinder section, after the control and display module is compared with the preset assembly secondary butt joint design deviation of the large component cylinder section, control information is generated, and the control cylinder section support posture adjusting module is used for adjusting the posture of the movable end cylinder section until the requirement of the assembly secondary butt joint design deviation of the large component cylinder section is met; the control and display module acquires end surface point cloud data of the large part cylinder section, simulation verification is carried out by combining the point cloud data of the side surface of the large part cylinder section acquired by the photographic measurement module, and the butt joint process of the movable end cylinder section and the static end cylinder section is displayed in real time through a visualization technology.
2. The large component barrel section docking experimental bench based on trial assembly simulation as claimed in claim 1, wherein the camera calibration module comprises a calibration scale, a calibration scale supporting device, a calibration camera and a calibration camera supporting device; the calibration camera supporting device comprises a camera holder, a telescopic rod and a movable support;
the calibration ruler is placed on the calibration ruler supporting device; the calibration camera is arranged on the camera cloud deck, and the camera cloud deck is used for controlling the pitching and the deflection motion of the calibration camera; the camera cloud platform is arranged at the upper end of the telescopic rod, and the lower end of the telescopic rod is fixed on the movable support; the telescopic rod is used for adjusting the height of the calibration camera, and the movable support enables the calibration camera to move on a horizontal plane; the calibration scale and the photographing measurement module are photographed at a plurality of positions by moving the calibration camera, the photographed image information is transmitted to the control and display module in a wireless mode, and the control and display module automatically calibrates the phase measurement module.
3. The large component barrel section butt joint experiment table based on trial assembly simulation as claimed in claim 1, wherein the photogrammetry module comprises two high-precision real-time measurement cameras and two camera support frames; the camera support frame comprises a camera pan-tilt head, an expansion rod and a base, wherein the camera pan-tilt head and the expansion rod are the same as those in the calibration camera support device;
the two high-precision real-time measuring cameras are respectively arranged on the camera cloud platforms on the two camera supporting frames; the camera holder in the camera support frame is used for controlling the functions of high-precision real-time measurement of pitching and deflection of the camera, and can realize measurement at different angles; the camera holder in the camera support frame is arranged at the upper end of a telescopic rod in the camera support frame, and the lower end of the telescopic rod is fixed on the base; the telescopic rod in the camera support frame is used for adjusting the height of the high-precision real-time measurement camera; the two high-precision real-time measuring cameras are placed at a distance of A meters, the two cameras are both B meters away from the large part cylinder section, and the high-precision real-time measuring cameras are C meters away from the base; the camera calibration module calibrates the position relation between the two high-precision real-time measurement cameras.
4. The large component barrel section butt joint experiment table based on trial assembly simulation as claimed in claim 1, wherein the laser measurement module comprises two supporting devices, a horizontal plate, a stepping motor, a coupler, a rotating shaft, a connecting rod, a sensor support and a laser profile sensor;
the horizontal plate is arranged inside the static end cylinder section, and the two supporting devices are both arranged on the horizontal plate and are separated by a certain distance; a stepping motor is arranged at the top end of one supporting device and used for providing power for rotary motion; the rotating shaft is connected with a rotating shaft of the stepping motor through the coupler; a through hole is processed on the other supporting device, and the rotating shaft penetrates through the through hole to support the rotating shaft; the rotating shaft is positioned in the central axis of the static end cylinder section, the rotating shaft is connected with a connecting rod perpendicular to the rotating shaft, and the connecting rod rotates along with the rotating shaft on the circular section of the butt joint part of the movable end cylinder section and the static end cylinder section; a sensor support is arranged at the other end of the connecting rod, and the laser profile sensor is arranged on the sensor support; the connecting rod rotates, and the laser profile sensor can scan the butt joint part of the movable end cylinder section and the static end cylinder section by 360 degrees.
5. The large component cylinder section butt joint experiment table based on trial assembly simulation as claimed in claim 1, wherein the cylinder section supporting and posture adjusting module comprises a static supporting table, a six-degree-of-freedom motion platform and two shape-preserving tool brackets; the six-degree-of-freedom motion platform comprises an upper platform, a lower platform, 6 electric cylinders, 6 servo motors and a central integrated system;
the static support platform and the six-degree-of-freedom motion platform are aligned to be placed on the ground, the distance between the static support platform and the six-degree-of-freedom motion platform is set to be between D meters and E meters, and a shape-preserving tool bracket is respectively arranged on the static support platform and the six-degree-of-freedom motion platform; the static end cylinder section is arranged on a shape-retaining tool bracket on the static support platform, and the movable end cylinder section is arranged on a shape-retaining tool bracket on the six-degree-of-freedom motion platform; the upper platform is used for mounting a movable end shape-preserving tool bracket, the lower platform is placed on the ground, and the 6 electric cylinders, the 6 servo motors and the central integrated system are mounted between the upper platform and the lower platform;
each electric cylinder is provided with a servo motor for providing power, and the servo motor drives the electric cylinder to stretch and retract so as to realize the motion of the six-freedom-degree motion platform in six-freedom-degree directions; the six-degree-of-freedom motion platform is in data communication with the control and display module through the central integrated system, the control and display module sends an instruction to the central integrated system 33, and the central integrated system controls the servo motor to drive the electric cylinder to stretch.
6. The large component barrel section docking experimental bench based on trial assembly simulation as claimed in claim 1, wherein the control and display module comprises a PC, a network data line and a handheld 3D scanner;
the PC is connected with the central integrated system through a network data line, the position information of key characteristic points of the large component cylinder section measured by the camera measurement module is wirelessly transmitted to the PC, then the data is processed through data processing software in the PC, the next data parameter for adjusting the posture of the cylinder section at the moving end is obtained, and the next data parameter is transmitted to the six-degree-of-freedom motion platform; the handheld 3D scanner obtains end face point cloud data of the large component cylinder section before the camera measurement module starts to measure, carries out simulation verification by combining the point cloud data of the side face of the large component cylinder section obtained by the camera measurement module, and displays the butt joint process of the movable end cylinder section and the static end cylinder section in real time through a visualization technology.
7. A large component barrel section butt joint method based on trial assembly simulation is characterized by comprising the following steps:
step 1: building a test bed;
the method comprises the following steps of (1) aligning a static supporting platform and a six-degree-of-freedom motion platform on the ground, setting the distance between the static supporting platform and the six-degree-of-freedom motion platform to be D-meter to E-meter, and respectively placing two shape-preserving tool brackets, a static end cylinder section and a dynamic end cylinder section on the static supporting platform and the six-degree-of-freedom motion platform; placing a calibration ruler, a photographic measuring module and a PC machine at a specified position, wherein the calibration ruler is placed right in front of the butt joint end surfaces of the cylinder sections of the static end cylinder section and the movable end cylinder section from F meters to G meters; the camera measurement module is placed at the position B meters right in front of the butt joint platform, the distance between the two high-precision real-time measurement cameras is A meters, and the height is C meters;
step 2: arranging the mark points of the photographic codes;
photographic code mark points are uniformly distributed on the butt joint end face and the appearance profile face of the movable end cylinder section and the butt joint end face and the appearance profile face of the static end cylinder section, so that the position posture relation of the static end cylinder section and the movable end cylinder section is conveniently monitored in the butt joint and measurement processes;
and step 3: collecting surface profile information by a handheld 3D scanner;
pasting a certain number of circular mark points on the butt joint end faces of a static end cylinder section and a movable end cylinder section to be scanned, measuring by adopting a laser triangulation method, and forming a triangle by a laser transmitter, a camera lens and the butt joint end faces of a handheld 3D scanner; in the measuring process, the handheld 3D scanner keeps a certain distance and moves at a constant speed, point cloud data collection is carried out on the butt joint end face, and a collected butt joint end face point cloud data model is displayed in real time;
and 4, step 4: calibrating a camera calibration photogrammetry module;
placing a calibration scale in front of a butt joint experiment table, and calibrating a phase measurement module through a calibration camera after finishing the arrangement work of the photographic code mark points; moving the calibration cameras, respectively carrying out photographing calibration at a plurality of positions, and automatically calibrating the position relation of two high-precision real-time measurement cameras in the photographing measurement module;
and 5: taking a picture, measuring and acquiring initial pose information;
starting a photographing measurement module to perform photographing measurement, acquiring pose information of the static end cylinder section and the moving end cylinder section, and transmitting the pose information to a PC (personal computer);
step 6: adjusting the posture of the large component cylinder section;
processing the pose information acquired in the step 5 through data processing software matched in a PC, comparing the pose information with the preset assembly primary butt joint design deviation of the large component cylinder section, obtaining data parameters of pose adjusting movement, generating control information and transmitting the control information to a six-degree-of-freedom movement platform; the six-degree-of-freedom motion platform controls the movable end cylinder section to adjust the posture;
and 7: repeating the photographic measurements;
repeating the step 5 and the step 6 until the preset primary butt joint design deviation of the large component cylinder section assembly is met;
and 8: line laser scanning measurement verification
After meeting the preset primary butt joint design deviation of the large component barrel section, starting a stepping motor to enable a laser profile sensor to obtain the external shape data of the internal surface of the butt joint part and transmit the external shape data to a PC (personal computer) for data processing, and after comparing the external shape data with the preset secondary butt joint design deviation of the large component barrel section, generating control information and transmitting the control information to a six-freedom-degree motion platform; the six-degree-of-freedom motion platform controls the movable end cylinder section to adjust the posture; until the preset secondary butt joint design deviation of the large component cylinder section assembly is met;
and step 9: verifying the docking accuracy;
performing simulation verification on the actual measurement point cloud data acquired by the camera measuring module each time through the large component barrel section butt joint end surface point cloud data model acquired in the step 3, and visualizing the assembly state on a PC in real time; before each actual butt joint, performing one-time trial assembly on a PC (personal computer) to verify whether the posture adjustment meets the butt joint requirement;
step 10: completing butt joint;
and when the verification of the step 9 is passed, performing final plug-in docking to finish docking.
8. The large component barrel section butting method based on the trial assembly simulation is characterized in that a is 3, B is 2, C is 1.7, D is 0.6, E is 0.8, F is 0.2, and G is 0.3.
9. The large component barrel section butting method based on trial assembly simulation, according to claim 7, wherein the high-precision real-time measurement camera is an M20 high-precision real-time measurement camera; the stepping motor is a 57BYGH301 stepping motor; the laser profile sensor is a Gocator 3D laser profile sensor.
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