CN114425719A - Ball end mill detection device and method based on CCD camera - Google Patents
Ball end mill detection device and method based on CCD camera Download PDFInfo
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- 238000000034 method Methods 0.000 title claims description 19
- 230000007246 mechanism Effects 0.000 claims abstract description 74
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- 238000003801 milling Methods 0.000 claims abstract description 31
- 230000001681 protective effect Effects 0.000 claims abstract description 18
- 238000005299 abrasion Methods 0.000 claims description 14
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- 239000011159 matrix material Substances 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 238000000498 ball milling Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0904—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool before or after machining
- B23Q17/0914—Arrangements for measuring or adjusting cutting-tool geometry machine tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2452—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/248—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves using special electromagnetic means or methods
- B23Q17/249—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves using special electromagnetic means or methods using image analysis, e.g. for radar, infrared or array camera images
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/28—Measuring arrangements characterised by the use of optical techniques for measuring areas
- G01B11/285—Measuring arrangements characterised by the use of optical techniques for measuring areas using photoelectric detection means
Abstract
The invention relates to a ball end mill detection device and a milling cutter detection method based on a CCD camera, which aims to overcome the problem that the existing detection device for a cutter in machine detection is complex and comprises a protective shell, a motion control card, a display module, a computer processing mechanism, an upper end camera mechanism and a lower end camera mechanism, wherein the upper end camera mechanism and the lower end camera mechanism are connected with the computer processing mechanism through the motion control card; the center of the cut image corresponds to the center of the original image; the pixel equivalent calibration factor calculates the relevant characteristic parameters of the tool wear and transmits the parameter information to the display module. The invention belongs to the technical field of cutter detection.
Description
Technical Field
The invention relates to a milling cutter detection device and a milling cutter detection method, in particular to a ball-end milling cutter detection device and a milling cutter detection method based on a CCD camera, and belongs to the technical field of cutter detection.
Background
In the rapid development of scientific computing, the manufacturing industry gradually goes into the era of intelligent processing and unmanned production. The intelligent manufacturing era greatly reduces the consumption of manpower and greatly promotes the development of the productivity of various industries. Meanwhile, the accuracy of products produced in the intelligent era is pursued, and the related intelligent detection device has great demands in the market. In the machining process, the quality of a machined product is related to a cutter to a great extent, the abrasion of the cutter causes the precision and the roughness of a workpiece to be poor, even causes the faults of scrapping of the workpiece, damage of expensive equipment, machine tool halt and the like, and directly influences the precision, the efficiency and the economic benefit of machining. According to statistics, more than 75% of equipment faults in the production process are caused by cutter failure, so that the detection of the cutter state becomes an essential link. In tool inspection, on-machine inspection of a tool being used in a machine tool is a new trend of research. According to recent investigations, machine tool down time due to tool change accounts for 25% of the total down time, and tool costs only account for 3% to 12% of the total machining costs. Therefore, to alleviate this problem, research on-machine inspection has been carried out. The time for processing is greatly reduced due to the fact that the cutter is assembled and disassembled on the machine tool due to detection, and the abrasion change of the cutter can be simply and clearly observed through on-machine detection research, so that the method has an important influence on improvement of processing precision.
In the prior art, the machine inspection method includes resistance measurement, tool and workpiece spacing measurement, radiation measurement, micro-structure coating method, optical measurement and the like. With the research of various industries on-line detection of the cutter, the on-line detection precision of the cutter is more accurate. The tool detection of the image processing is more qualified for the convenience of the tool detection and no addition of the tool. The existing detection device and detection method based on image information mostly perform graying processing, denoising and edge extraction on an image for detection of a cutter, and represent image wear information through quantitative proportion of pixel points. In this image processing method, the selection of the threshold value and the extraction of the boundary will have a great influence on the result of the wear state of the tool.
Therefore, the tool image needs to be processed by reasonably utilizing the division of the threshold value according to the distribution rule of the gray value of the tool wear image, and a plurality of characterization parameters reflecting the tool wear state are established, so that the probability of error problems when the tool state is characterized by a single parameter is reduced.
Disclosure of Invention
The invention aims to solve the problem that the existing detection device for the cutter in machine detection is complex, and provides a ball end mill detection device and a milling cutter detection method based on a CCD camera.
The invention relates to a ball end mill detection device based on a CCD camera, which comprises a protective shell, a motion control card, a display module, a computer processing mechanism, an upper end camera mechanism and a lower end camera mechanism, wherein the motion control card, the upper end camera mechanism and the lower end camera mechanism are arranged on the protective shell, the upper end camera mechanism and the lower end camera mechanism are connected with the computer processing mechanism through the motion control card, the display module is connected with the computer processing mechanism through a serial port, an air pump interface is arranged on the protective shell, and the air pump interface is connected with an external air pump device.
The method is realized according to the following steps:
the method comprises the following steps: installing a ball end mill detection device based on a CCD camera on a workbench of a machine tool machining workpiece;
step two: the upper end camera mechanism and the lower end camera mechanism are connected with the computer processing mechanism through a motion control card, and the display module is connected with the computer processing mechanism in a serial port mode;
step three: the operation detection device inputs instructions through a user operation interface in the display module, the motion control card controls and adjusts the operation of a third stepping motor, so that a bottom CCD camera on the connecting rod motion assembly moves to a specified position and adjusts the position of the bottom CCD camera, the center line of the bottom CCD camera is perpendicular to the horizontal plane, and the camera compensation light source performs related compensation adjustment on the light source according to weight;
step four: when a machine tool is in a tool retracting state during machining, the cutter moves to a preset position, an external air pump device is started, the cutter is cleaned through an air pump interface, then a bottom surface image of the cutter is shot through a bottom CCD camera, a camera clamping piece is controlled to move on a horizontal sliding table through a second stepping motor, a camera focal length adjusting driving gear and a camera focal length adjusting driven gear are controlled to rotate through a first stepping motor, the focal length of an upper CCD camera is adjusted, a front image is shot through the upper CCD camera, and image information shot by the upper CCD camera and the bottom CCD camera is transmitted to a computer processing mechanism;
step five: after receiving image information, a computer processing mechanism sets the range of image cutting size, cuts an image characteristic area by utilizing image cutting, and corresponds the center of a cut image to the center of an original image through image translation and rotation calculation;
removing noise points from the cut image through image graying processing and bilateral filtering, wherein according to the gray value rule after the image graying, the difference value among the gray value values in three areas such as a background area, a worn area and an unworn area is small in the image, and the difference value between the gray value of the edge of the worn area and the gray value of the other two areas is large;
and selecting a variance based on the characteristic change degree as a threshold value according to the characteristics to divide a background area, a tool unworn area and a tool worn area of the target characteristics of the cutting area.
Step seven: extracting boundary information by using a canny operator, calculating an equivalent factor of a pixel by using edge information of the cutter, sequentially calculating a cutter abrasion characteristic parameter by using a pixel equivalent calibration factor, and transmitting the information to a display module by a computer processing mechanism for observation.
The most prominent characteristics and remarkable beneficial effects of the invention are as follows:
the cutter detection device is installed on a machine tool workbench, the occupied space of the detection device in the machine tool is greatly reduced through a designed connecting rod motion mechanism, the ball end milling cutter detection device based on the CCD camera can be installed outside the machine tool through a movable trolley under a certain condition, the cutter detection method for representing image abrasion information through gray processing, denoising and edge extraction of images and quantitative proportion of pixel points is provided.
The utility model provides a detection device is in detecting operating condition, and through camera compensation light source 21 according to the distance of light source and cutter, work piece self luminance of locating, compensation light source light intensity, the shared relevant proportion of factors such as measured work piece material attribute carry out near cutter light source brightness compensation, guarantee that the CCD camera gathers the image of better state under better external environment.
In the process of image processing, according to the distribution rule of the gray values of the tool wear image, a proper threshold value is solved by utilizing the difference between the gray values and solving the variance principle to divide the image into a background area, a tool wear area, a tool non-wear area and the like.
In the determination of the wear state, a plurality of characteristic parameters characterize the tool wear. Extracting information of the edge characteristics of the bottom ball end mill image, and solving the characteristic flank wear width VB and the average wear degree VB of the flank according to the quantitative calculation of the pixel proportionaveMaximum wear VB of flank facemaxFlank wear area AVBVolume of wear V of milling cutterVBAnd so on.
Drawings
Fig. 1 is a schematic view of the overall structure of a ball end mill detection device based on a CCD camera.
Fig. 2 is a schematic view of a ball end mill detection device based on a CCD camera without a protective housing 1.
Fig. 3 is a schematic view of a ball end mill detection device based on a CCD camera without a protective housing 1.
Fig. 4 is a schematic view of an upper end camera mechanism.
Fig. 5 is a schematic diagram of the third stepping motor 13 driving the link motion assembly 11 to drive the bottom CCD camera 12 and the camera compensation light source 21 to extend.
Fig. 6 is a schematic view of the threaded connection between the nut and the vertical screw of the sliding table when the CCD camera 12 at the bottom end and the camera compensation light source 21 extend out.
Fig. 7 is a schematic view of the connection of the fourth stepping motor 9 with two folding doors 18.
Fig. 8 is a schematic view of the CCD camera-based ball end mill detection device of the present invention mounted on a table 30 mounted on a workpiece to be machined by a machine tool, in which a ball end mill 28 is provided.
Fig. 9 is a detection flow chart of the milling cutter detection device of the present application.
Detailed Description
The first embodiment is as follows: the embodiment is described with reference to fig. 1 to 8, and the ball end mill detection device based on the CCD camera provided by the embodiment includes a protective casing 1, a motion control card 2, a display module, a computer processing mechanism, an upper end camera mechanism and a lower end camera mechanism, wherein the motion control card 2, the upper end camera mechanism and the lower end camera mechanism are mounted on the protective casing 1, the upper end camera mechanism and the lower end camera mechanism are both connected with the computer processing mechanism through the motion control card 2, the display module is connected with the computer processing mechanism through a serial port, an air pump interface 17 is arranged on the protective casing 1, and the air pump interface 17 is connected with an external air pump device.
And establishes communication with the computer processing mechanism through the display module. The display module can be used for inputting relevant characteristic parameters, displaying the cutter wear characteristic parameters and controlling the user terminal. The air pump interface 17 is used to clean the tool surface chips at the beginning of the inspection. The display module manufacturer is Shenzhen constant domain Wei electronics Limited company, and the product model is HYWO7 OE.
The second embodiment is as follows: the embodiment is described with reference to fig. 1 to 4, and the upper camera mechanism of the ball end mill detection device based on the CCD camera in the embodiment includes a first stepping motor 3, a camera focal length adjustment driving gear 4, a camera clamping member 5, an upper CCD camera 6, a horizontal sliding table 7, an upper sliding table support frame 8, a second stepping motor 15 and a camera focal length adjustment driven gear 20; second step motor 15 and horizontal slip table 7 are installed on upper end slip table support frame 8, second step motor 15 is connected with the slip end of horizontal slip table 7, upper end slip table support frame 8 fixed mounting is on protective housing 1, camera holder 5 is installed on the slip end of horizontal slip table 7, upper end CCD camera 6 is installed on 5 holding ends of camera holder, first step motor 3 is installed on camera holder 5, and the cover is equipped with camera focus regulation drive gear 4 on the output of first step motor 3, camera focus regulation driven gear 20 is installed on the focusing end of upper end CCD camera 6, camera focus regulation drive gear 4 and 20 tooth meshes of camera focus regulation driven gear, first step motor 3, second step motor 15 and upper end CCD camera 6 are connected with motion control card 2.
And a horizontal sliding table 7 is controlled by a second stepping motor 15 to drive an upper CCD camera 6 to collect the front image of the cutter. The camera focal length adjusting driving gear 4 and the camera focal length adjusting driven gear 20 are driven by the first stepping motor 3 to adjust the focal length of the upper end CCD camera 6. The camera clamping piece 5 can ensure that the upper end CCD camera 6 moves along with the horizontal sliding table 7 and the clamping part adopts a spring pressing mechanism, so that the stability of the upper end CCD camera 6 in the moving process is ensured. Other structures are connected in the same manner as in the first embodiment.
The third concrete implementation mode: the embodiment is described with reference to fig. 1 to 4, and the horizontal sliding table 7 of the ball end mill detection device based on the CCD camera in the embodiment includes a sliding table horizontal lead screw, a sliding block, two polished rods and two supporting end plates; the two ends of a horizontal lead screw of the sliding table are respectively rotatably connected and installed on the supporting end plate, the two polished rods are respectively arranged on the two sides of the lead screw, the two ends of each polished rod are respectively installed on the supporting end plate, the horizontal lead screw of the sliding table is connected and inserted on the sliding block in a threaded mode, the sliding block is connected with the two polished rods in a sliding mode, and the CCD camera 6 at the upper end is fixedly connected with the sliding block. Other structural connection relationships are the same as in the second embodiment.
The fourth concrete implementation mode: the embodiment is described with reference to fig. 1, 5 and 6, and the lower end camera mechanism of the ball end mill detection device based on the CCD camera in the embodiment includes a light source connecting piece 10, a connecting rod motion assembly 11, a bottom end CCD camera 12, a third stepping motor 13, a vertical sliding table 14 and a camera compensation light source 21; the third stepping motor 13 is connected with the vertical sliding table 14, the vertical sliding table 14 is installed on the protective shell 1, one end of the connecting rod motion assembly 11 is connected with the vertical sliding table 14, the bottom CCD camera 12 is installed at the other end of the connecting rod motion assembly 11, the camera compensation light source 21 is installed on the connecting rod motion assembly 11 above the bottom CCD camera 12 through the light source connecting piece 10, and the bottom CCD camera 12 and the third stepping motor 13 are connected with the motion control card 2.
The camera compensation light source 21 and the compensation control unit are connected with the computer processing mechanism by using a USB mode. The display module is connected with the computer processing mechanism by adopting a USB (universal serial bus) and uses a serial SPI (serial peripheral interface) protocol. The camera compensating light source 21 is manufactured by kirschner (china) limited and has a product model of CA-DC 21E. Other structures are connected in the same manner as in the first embodiment.
The fifth concrete implementation mode: the present embodiment is described with reference to fig. 1, 5 and 6, in which the link motion assembly 11 includes a sliding table moving connector 23, a sliding table fixing connector 24, a camera clamping carrier 25, a camera side knob 26, a camera bottom knob 27, two connecting shafts 22 and two sets of 'X' -shaped links, the rod body at the bottom of one end of one set of 'X' -shaped links is rotatably connected to the vertical sliding table 14 through the sliding table fixing connector 24, the rod body at the top of one end of one set of 'X' -shaped links is rotatably connected to the movable end of the vertical sliding table 14 through the sliding table moving connector 23, the other end of one set of 'X' -shaped links is rotatably connected to one end of the other set of 'X' -shaped links through the two connecting shafts 22, the rod body at the bottom of the other set of 'X' -shaped links and the camera clamping carrier 25 are rotatably connected through the camera side knob 26, The camera bottom knob 27 is fixedly connected, and the camera compensation light source 21 is installed on the other group of the top rod body at the bottom of the X-shaped connecting rod through the light source connecting piece 10. Other structures are connected in the same manner as in the first embodiment.
The sixth specific implementation mode: the embodiment is described with reference to fig. 1, 5 and 6, and the vertical sliding table 14 of the ball end mill detection device based on the CCD camera in the embodiment includes a sliding table frame, a sliding table vertical lead screw, a nut and two bevel gears; the vertical setting of slip table vertical lead screw is on the slip table framework, and the vertical lead screw of slip table rotates with the slip table framework to be connected, and the bottom fixedly connected with bevel gear of the vertical lead screw of slip table, installs another bevel gear in the pivot of third step motor 13, and two bevel gear tooth meshes, and screw threaded connection suit is on the vertical lead screw of slip table, screw and slip table fixed connection 24 fixed connection.
Through the third step motor 13 drive the vertical lead screw of slip table and rotate through the bevel gear transmission to make the screw move on the vertical lead screw of slip table, drive connecting rod motion subassembly 11 through screw and slip table fixed connection 24 and move, and then drive bottom CCD camera 12 and camera compensation light source 21 and stretch out and draw back the removal, and then gather milling cutter bottom surface image. Other structural connection relations are the same as those of the fifth embodiment.
The seventh embodiment: the embodiment is described with reference to fig. 1 and 7, and the embodiment provides a ball end mill detection device based on a CCD camera, which further includes a folding door mechanism, the folding door mechanism includes a door frame, a fourth stepping motor 9, a transmission bevel gear shaft, a transmission straight gear shaft, two folding doors 18, two racks and two connecting rods, a bevel gear is sleeved on an output end of the four stepping motor 9, the bevel gear of the four stepping motor 9 is in meshing transmission with one end of the transmission bevel gear shaft, the other end of the transmission bevel gear shaft is in meshing transmission with the top end of the transmission straight gear shaft, the two racks are both in meshing engagement with the bottom end of the transmission straight gear shaft, the two racks are oppositely disposed on both sides of the transmission straight gear shaft, the door frame is disposed at the bottom of the protective housing 1, the transmission bevel gear shaft is rotatably connected to be mounted on the door frame, the connecting end of the transmission straight gear shaft is rotatably connected to be mounted on the door frame, two folding doors 18 set up relatively, two folding door plant on every folding door 18 rotate through folding paper and connect, every folding door 18 moves the door of end and is connected through the rack middle part of connecting rod and top, and the one end of rack is passed through even board and is connected with the door frame rotation, fourth step motor 9 rotates and drives transmission bevel gear axle and transmission straight gear axle and rotate, the gear through transmission straight gear axle drives the rack of both sides and moves in opposite directions or dorsad, and then drives two folding doors 18 and fold and open or close. The fourth stepping motor 9 is connected with the motion control card 2. The door frame is installed on the protective shell 1, and when the detection device works, the window at the front end of the shell adopts a folding door design, so that the space required by the operation of the device is further reduced, and the internal elements are protected importantly under the condition that the detection is not carried out by the device. Other structures are connected in the same manner as in the first embodiment.
The specific implementation mode eight: the embodiment is described with reference to fig. 1 to 9, and the milling cutter detection method of the ball end mill detection device based on the CCD camera according to the embodiment is implemented according to the following steps:
the method comprises the following steps: installing a ball end mill detection device 29 based on a CCD camera on a workbench 30 of a machine tool for processing a workpiece;
step two: the upper end camera mechanism and the lower end camera mechanism are connected with a computer processing mechanism through a motion control card 2, and a display module is connected with the computer processing mechanism in a serial port mode;
step three: the operation detection device inputs instructions through a user operation interface in the display module, the motion control card 2 controls and adjusts the operation of the third stepping motor 13, so that the bottom CCD camera 12 on the connecting rod motion assembly 11 moves to a specified position and adjusts the position of the bottom CCD camera 12, the center line of the bottom CCD camera 12 is vertical to the horizontal plane, and the camera compensation light source 21 performs related compensation adjustment on the light source according to the weight;
and compiling a machine tool running program to ensure that the machine tool moves the cutter to a proper visual field range of the camera when in a cutter retracting state, and quantifying the rotation angle in the range to ensure that the acquired image is proper.
Step four: when a machine tool is in a tool retracting state during machining, the cutter moves to a preset position, an external air pump device is started, the cutter is cleaned through an air pump interface 17, then a bottom surface image of the cutter is shot through a bottom CCD camera 12, a camera clamping piece 5 is controlled to move on a horizontal sliding table 7 through a second stepping motor 15, a camera focal length adjusting driving gear 4 and a camera focal length adjusting driven gear 20 are controlled to rotate through a first stepping motor 3, the focal length of an upper end CCD camera 6 is adjusted, a front image is shot through the upper end CCD camera 6, and image information shot by the upper end CCD camera 6 and the bottom CCD camera 12 is transmitted to a computer processing mechanism; the computer processing means checks whether the image is reasonable and transfers the image taken by the CCD camera to the computer processing means for image processing,
step five: after receiving image information, a computer processing mechanism sets the range of image cutting size, cuts an image characteristic area by utilizing image cutting, and corresponds the center of a cut image to the center of an original image through image translation and rotation calculation;
removing noise points from the cut image through image graying processing and bilateral filtering, wherein according to the gray value rule after the image graying, the difference value among the gray value values in three areas such as a background area, a worn area and an unworn area is small in the image, and the difference value between the gray value of the edge of the worn area and the gray value of the other two areas is large; in the process of processing the worn tool image, the gray values of different partitions are changed regularly during the image graying process. In the gray value numerical comparison of the background area, the tool wear area and the tool non-wear area, the image color of the background area is more than that of a single tool image, so that the numerical value of the image gray value of the background area is larger than that of the tool image gray value as a whole; in the comparison of the gray values of the worn and unworn regions of the tool, the overall gray value between the worn and unworn regions of the tool will also have a certain difference due to the increased tool surface roughness of the worn region and the more bright nature of the worn surface.
On the basis of the rule of the difference of the gray values in the image, a certain gray value in the image can be subjected to variance processing in nine fields, variance is calculated between each gray value in the image and the gray values around the gray value, then statistical sorting processing can be performed on the variance, and a value which has large variance and is more frequently appeared in sorting can be selected as a threshold value to divide the regions.
And selecting a variance based on the characteristic change degree as a threshold value according to the characteristics to divide a background area, a tool unworn area and a tool worn area of the target characteristics of the cutting area.
Step seven: extracting boundary information by using a canny operator, calculating an equivalent factor of a pixel by using edge information of the cutter, calculating a cutter abrasion characteristic parameter sequentially through the pixel equivalent calibration factor, transmitting the information to a display module through a computer processing mechanism for observation, wherein the cutter abrasion parameter transmitted into the display module mainly comprises an average abrasion degree VB of a cutter rear cutter faceaveMaximum wear VB of the flank face of the toolmaxFlank wear width VB and tool wear volume VVBAnd the parameters and the characteristics can be used as the wear standard of the cutter to judge the wear degree of the cutter.
The specific implementation method nine: the embodiment is described with reference to fig. 1 to 8, in the milling cutter detection method of the ball end mill detection device based on the CCD camera provided by the embodiment, in the second step, the upper end CCD camera 6 and the bottom end CCD camera 12 are connected with the computer processing mechanism through the ethernet to establish network communication, the first stepping motor 3, the second stepping motor 15, the third stepping motor 13 and the fourth stepping motor 9 are connected with the computer processing mechanism through the motion control card 2, and the motion control card 2 and the computer processing mechanism are connected by using a USB-to-serial interface to establish a control mode of the computer and the motors;
in the detection work of the third step, the bottom CCD camera 12 and the camera compensation light source 21 loaded in the connecting rod motion assembly 11 move to the position under the detected cutter, the camera compensation light source 21 controls to adjust the light brightness through the weight of the compensation control unit, in the definition of the compensation weight, due to the fact that materials of the ball head cutter are different, the weight proportion used for different materials is adjusted according to the reflection degree of the materials generated by the ball head cutter, in the division of the weight, for the ball head cutter material, the distance between the light source and the cutter, the brightness of the workpiece, the light intensity of the compensation light source and other related influence factors are divided into different levels;
the weight compensation is as follows: distance y of light source and tool in factor selection1Brightness y of the workpiece itself2Compensating the light intensity y of the light source3Material property y of the workpiece to be measured4And the like account for major factors affecting the brightness of the image. According to the reflecting characteristic of the material and the importance of detecting the ambient factors of the ball end mill on the influence of the light intensity and brightness, a 4 multiplied by 4 distribution matrix Y related to the importance of the influence of all the factors on the light intensity can be obtained4×4. And further calculating to obtain:
definition of Zj＝{Yi1,Yi2,Yi3,Yi4}
Obtaining a new matrix
Further obtain the weight of each influence factor
In the fifth step, the size of image cutting is set, the length L is selected to be approximate to the radius of the milling cutter, the width H is the cutting area of the width of the characteristic target image, the center of the cut image can be coincided with the center of the original image through translation and rotation after the image cutting is finished, and the calculation formula is as follows: the slope of the edge line segment is calculated from the equation, and the angle θ of rotation is calculated from the slope K, where the rotation equation can be defined as the hypothesis (x)0,y0) The coordinate is (x) after rotating around (a, b) by theta angle1,y1) The coordinates of the center after rotation are (c, d) and the following formula is obtained for the rotation:
The detailed implementation mode is ten: the embodiment is described with reference to fig. 1 to 9, and in the sixth step, a computer processing mechanism is used to perform graying processing on the acquired front surface image and bottom surface image of the tool and remove noise points by using a bilateral filtering method, a threshold is used to classify the background, the worn region of the tool and the unworn region of the tool in the image, a distinguishing method using variance difference of gray values is proposed in the threshold setting, the difference between the gray values in the image background and the unworn region of the tool is small, the fluctuation of the edge gray value in the worn region of the tool is large, so that the variance between the gray value of the whole gray image sampling point and the gray value of the neighboring points around the sampling point in the same region can show a small change, and in the worn region of the image, because the smoothness of the surface of the wear area is poor, the variance of the gray values between the edge sampling point of the wear area and the surrounding neighborhood sampling points is changed greatly, and a threshold value is set according to the variance change range generated by the gray value distribution of the ball end mill, so that target characteristic points in the image are distinguished;
and selecting the variance value with the highest frequency as a threshold value for boundary division in the range with larger variance.
At the whole gray level image sampling point pijF (x, y) is defined as the gray value of the image at (x, y), and a 3 × 3 grid is established according to the gray value of the image itself and eight adjacent gray values, that is, the grid can be expressed as a matrix:
calculating the average gray value of the neighborhood grid at 3 x 3
Calculating the variance of the nine gray values
And as the value of the point, after the variance is calculated for the whole image, the variance values in the range of the background area and the tool non-worn area are similar, and the difference between the gray values in the boundary range of the tool worn area is larger because of the larger difference between the gray valuesThe variance value obtained is large, and the variance value with the highest frequency of occurrence is selected from the range with large variance as a threshold value for boundary division. Other structural connection relationships are the same as those in the eighth embodiment.
The concrete implementation mode eleven: the embodiment is described with reference to fig. 1 to 9, and the milling cutter detection method of the ball milling cutter detection device based on the CCD camera according to the embodiment includes the following steps: extracting image boundary information by using a canny operator, calibrating the pixel equivalent by taking the diameter of a milling cutter as a reference standard in the process of calibrating the pixel equivalent, and defining a pixel calibration factor of the image if the diameter of the milling cutter is D and the length of a pixel in the image is N
Multiplying the wear amount detected in the image by a pixel calibration factor to obtain the real wear amount of the milling cutter, in order to improve the calculated amount, performing column scanning on a wear area, wherein the coordinate difference value of the upper boundary and the lower boundary in the bottom image is the wear width VB of the rear cutter face of the milling cutter, and performing statistical sorting on the wear values of the rear cutter face to obtain the average wear degree VB of the rear cutter faceaveAnd maximum wear VB of the flank face of the toolmaxThe flank wear area A can be obtained by integrating the flank wear width VB in the horizontal directionVBMeanwhile, after the edge of the image on the front surface of the milling cutter is extracted, the height range value of the milling cutter abrasion can be calculated through the pixel equivalent calibration factor, and the abrasion area A of the milling cutter and the rear cutter surface is calculatedVBThe integral can calculate the abrasion volume V of the milling cutterVB. Other structural connection relationships are the same as those in the eighth embodiment.
The present invention is capable of other embodiments and its several details are capable of modifications in various obvious respects, all without departing from the spirit and scope of the present invention.
Claims (10)
1. The utility model provides a ball end mill detection device based on CCD camera which characterized in that: it includes protective housing (1), motion control board (2), a display module, computer processing mechanism, upper end camera mechanism and lower extreme camera mechanism, motion control board (2), upper end camera mechanism and lower extreme camera mechanism install on protective housing (1), upper end camera mechanism and lower extreme camera mechanism all are connected with computer processing mechanism through motion control board (2), display module is connected through the mode of serial ports with computer processing mechanism, be equipped with air pump interface (17) on protective housing (1), air pump interface (17) are connected with external air pump device.
2. The CCD camera-based ball end mill detection device according to claim 1, wherein: the upper camera mechanism comprises a first stepping motor (3), a camera focal length adjusting driving gear (4), a camera clamping piece (5), an upper CCD camera (6), a horizontal sliding table (7), an upper sliding table supporting frame (8), a second stepping motor (15) and a camera focal length adjusting driven gear (20); a second stepping motor (15) and a horizontal sliding table (7) are arranged on an upper end sliding table supporting frame (8), the second stepping motor (15) is connected with the sliding end of the horizontal sliding table (7), the upper end sliding table supporting frame (8) is fixedly arranged on the protective shell (1), a camera clamping piece (5) is arranged on the sliding end of the horizontal sliding table (7), an upper end CCD camera (6) is arranged on the clamping end of the camera clamping piece (5), a first stepping motor (3) is arranged on the camera clamping piece (5), and the output end of the first stepping motor (3) is sleeved with a camera focal length adjusting driving gear (4), a camera focal length adjusting driven gear (20) is installed on the focusing end of the upper end CCD camera (6), the camera focal length adjusting driving gear (4) is in tooth meshing with the camera focal length adjusting driven gear (20), and the first stepping motor (3), the second stepping motor (15) and the upper end CCD camera (6) are connected with the motion control card (2).
3. The CCD camera-based ball end mill detection device according to claim 2, wherein: the horizontal sliding table (7) comprises a sliding table horizontal lead screw, a sliding block, two polished rods and two supporting end plates; the two ends of a horizontal lead screw of the sliding table are respectively rotatably connected and installed on the supporting end plate, the two polished rods are respectively arranged on the two sides of the lead screw, the two ends of each polished rod are respectively installed on the supporting end plate, the horizontal lead screw of the sliding table is connected and inserted on the sliding block in a threaded mode, the sliding block is connected with the two polished rods in a sliding mode, and a CCD camera (6) at the upper end is fixedly connected with the sliding block.
4. The CCD camera-based ball end mill detection device according to claim 1, wherein: the lower end camera mechanism comprises a light source connecting piece (10), a connecting rod motion assembly (11), a bottom CCD camera (12), a third stepping motor (13), a vertical sliding table (14) and a camera compensation light source (21); the third step motor (13) is connected with the vertical sliding table (14), the vertical sliding table (14) is installed on the protective shell (1), one end of the connecting rod motion assembly (11) is connected with the vertical sliding table (14), the bottom CCD camera (12) is installed at the other end of the connecting rod motion assembly (11), the camera compensation light source (21) is installed on the connecting rod motion assembly (11) above the bottom CCD camera (12) through the light source connecting piece (10), and the bottom CCD camera (12) and the third step motor (13) are connected with the control card motion (2).
5. The CCD camera-based ball end mill detection device according to claim 4, wherein: the connecting rod motion assembly (11) comprises a sliding table moving connecting piece (23), a sliding table fixed connecting piece (24), a camera clamping carrier (25), a camera side surface knob (26), a camera bottom knob (27), two connecting shafts (22) and two groups of X-shaped connecting rods, wherein a rod body at the bottom of one end of one group of X-shaped connecting rods is rotatably connected with the vertical sliding table (14) through the sliding table fixed connecting piece (24), a rod body at the top of one end of one group of X-shaped connecting rods is rotatably connected with the movable end of the vertical sliding table (14) through the sliding table moving connecting piece (23), the other end of one group of X-shaped connecting rods is rotatably connected with one end of the other group of X-shaped connecting rods through the two connecting shafts (22), the other group of X-shaped connecting rods is fixedly connected with the camera clamping carrier (25) through the camera side surface knob (26) and the camera bottom knob (27), and a camera compensating light source (21) is installed at the top of the other group of X-shaped connecting rods through the light source connecting piece (10) The rod body.
6. The CCD camera-based ball end mill detection device according to claim 5, wherein: the vertical sliding table (14) comprises a sliding table frame body, a sliding table vertical screw rod, a nut and two bevel gears; the vertical lead screw of slip table sets up on the slip table framework, and the vertical lead screw of slip table rotates with the slip table framework to be connected, and the bottom fixedly connected with bevel gear of the vertical lead screw of slip table, installs another bevel gear in the pivot of third step motor (13), and two bevel gear tooth meshes, and screw threaded connection suit is on the vertical lead screw of slip table, screw and slip table fixed connection spare (24) fixed connection.
7. The tool detection method using the CCD camera-based ball end mill detection device as claimed in claim 3 or 6, wherein: the method is realized according to the following steps:
the method comprises the following steps: installing a ball end mill detection device (29) based on a CCD camera on a workbench (30) of a machine tool for processing a workpiece;
step two: the upper end camera mechanism and the lower end camera mechanism are connected with a computer processing mechanism through a motion control card (2), and a display module is connected with the computer processing mechanism in a serial port mode;
step three: the operation detection device inputs instructions through a user operation interface in the display module, the motion control card (2) controls and adjusts the operation of a third stepping motor (13), so that the bottom CCD camera (12) on the connecting rod motion assembly (11) moves to a specified position and adjusts the position of the bottom CCD camera (12), the central line of the bottom CCD camera (12) is vertical to the horizontal plane, and the camera compensation light source (21) performs related compensation adjustment on the light source according to the weight;
step four: when a machine tool is in a tool retracting state during machining, the cutter moves to a preset position, an external air pump device is started, the cutter is cleaned through an air pump interface (17), then a bottom surface image of the cutter is shot through a bottom CCD camera (12), a camera clamping piece (5) is controlled to move on a horizontal sliding table (7) through a second stepping motor (15), a camera focal length adjusting driving gear (4) and a camera focal length adjusting driven gear (20) are controlled to rotate through a first stepping motor (3), the focal length of an upper end CCD camera (6) is adjusted, a front image is shot through the upper end CCD camera (6), and image information shot by the upper end CCD camera (6) and the bottom CCD camera (12) is transmitted to a computer processing mechanism;
step five: after receiving image information, a computer processing mechanism sets the range of image cutting size, cuts an image characteristic area by utilizing image cutting, and corresponds the center of a cut image to the center of an original image through image translation and rotation calculation;
removing noise points from the cut image through image graying processing and bilateral filtering, wherein according to the gray value rule after the image graying, the difference value among the gray value values in three areas such as a background area, a worn area and an unworn area is small in the image, and the difference value between the gray value of the edge of the worn area and the gray value of the other two areas is large;
step seven: extracting boundary information by using a canny operator, calculating an equivalent factor of a pixel by using edge information of the cutter, sequentially calculating a cutter abrasion characteristic parameter by using a pixel equivalent calibration factor, and transmitting the information to a display module by a computer processing mechanism for observation.
8. The tool detection method of the CCD camera-based ball end mill detection device according to claim 7, wherein the tool detection method comprises the following steps: in the second step, the upper end CCD camera (6) and the bottom end CCD camera (12) are connected with a computer processing mechanism through Ethernet to establish network communication, a first stepping motor (3), a second stepping motor (15), a third stepping motor (13) and a fourth stepping motor (9) are connected with the computer processing mechanism through a motion control card (2), and the motion control card (2) is connected with the computer processing mechanism through a USB-to-serial port connection mode to establish a control mode of the computer and the motors;
in the detection work of the third step, a bottom CCD camera (12) and a camera compensation light source (21) loaded in a connecting rod motion assembly (11) move to the position under a detected cutter, the camera compensation light source (21) controls adjustable lamplight brightness through the weight of a compensation control unit, in the definition of compensation weight, due to the fact that materials of the ball head cutter are different, the weight proportion used for different materials is adjusted according to the reflection degree of the materials generated by the ball head cutter, in the division of weight, for the ball head cutter material, the distance between the light source and the cutter, the brightness of a workpiece, the light intensity of the compensation light source and other related influence factors are divided into high and low levels;
in the fifth step, the size of image cutting is set, the length L is selected to be approximate to the radius of the milling cutter, the width H is the cutting area of the width of the characteristic target image, the center of the cut image can be coincided with the center of the original image through translation and rotation after the image cutting is finished, and the calculation formula is as follows: the slope of the edge line segment of the knife edge is calculated according to an equation, and the angle theta of rotation is calculated according to the slope K, wherein the rotation equation can be defined as an assumption (x)0,y0) The coordinate is (x) after rotating around (a, b) by theta angle1,y1) The coordinates of the center after rotation are (c, d) and the following formula is obtained for the rotation:
9. the tool detection method of the CCD camera-based ball end mill detection device according to claim 7, wherein the tool detection method comprises the following steps:
step six, using a computer processing mechanism to perform graying processing on the acquired front surface image and the bottom surface image of the cutter and remove noise points by using a bilateral filtering method, using a threshold to classify a background, a worn area and an unworn area of the cutter in the image, and providing a distinguishing method using variance difference of gray values in threshold setting, wherein the difference between the gray values in the background of the image and the unworn area of the cutter is small, the fluctuation of the gray value at the edge of the worn area of the cutter is large, so that the variance between the gray values of the whole gray image sampling point and the neighboring points around the gray image sampling point can show a small change in the same area, and in the worn area of the image, the variance of the gray value between the edge sampling point of the worn area and the neighboring sampling points around the gray image sampling point can change greatly due to poor smoothness of the surface of the worn area, setting a threshold value according to the size of a variance variation range generated by gray value distribution of the ball end mill, and further distinguishing target characteristic points in the image; and selecting the variance value with the highest frequency as a threshold value of boundary division in the range with larger variance.
10. The tool detection method of the CCD camera-based ball end mill detection device according to claim 7, wherein the tool detection method comprises the following steps: the seventh step is as follows: extracting image boundary information by using a canny operator, calibrating the pixel equivalent by taking the diameter of a milling cutter as a reference standard in calibrating the pixel equivalent, and if the diameter of the milling cutter is D and the length of a pixel in the image is N, defining a pixel calibration factor of the image
Multiplying the wear amount detected in the image by a pixel calibration factor to obtain the real wear amount of the milling cutter, in order to improve the calculated amount, performing column scanning on a wear area, wherein the coordinate difference value of the upper boundary and the lower boundary in the bottom image is the wear width VB of the rear cutter face of the milling cutter, and performing statistical sorting on the wear values of the rear cutter face to obtain the average wear degree VB of the rear cutter faceaveAnd maximum wear VB of the flank face of the toolmaxThe flank wear area A can be obtained by integrating the flank wear width VB in the horizontal directionVBMeanwhile, after the edge of the image on the front surface of the milling cutter is extracted, the height range value of the milling cutter abrasion can be calculated through the pixel equivalent calibration factor, and the abrasion area A of the milling cutter and the rear cutter surface is calculatedVBThe integral can calculate the abrasion volume V of the milling cutterVB。
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