CN115214135A - Full-automatic feeding system and method for forging line based on 3D vision - Google Patents
Full-automatic feeding system and method for forging line based on 3D vision Download PDFInfo
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- CN115214135A CN115214135A CN202210603656.7A CN202210603656A CN115214135A CN 115214135 A CN115214135 A CN 115214135A CN 202210603656 A CN202210603656 A CN 202210603656A CN 115214135 A CN115214135 A CN 115214135A
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- 238000005242 forging Methods 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims abstract description 22
- 238000012545 processing Methods 0.000 claims abstract description 111
- 239000000463 material Substances 0.000 claims abstract description 83
- 238000004519 manufacturing process Methods 0.000 claims abstract description 30
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- 238000004891 communication Methods 0.000 claims description 15
- 230000003139 buffering effect Effects 0.000 claims description 7
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- 238000004148 unit process Methods 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 6
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/321—Feeding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/379—Handling of additively manufactured objects, e.g. using robots
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
Abstract
The invention discloses a 3D vision-based full-automatic feeding system and a method for a forging production line, wherein the system comprises a bar transmission unit, a robot grabbing unit, a camera identification unit and a master control processing unit which is communicated with the three information; the bar transmission unit comprises a moving unit base, light rails arranged on the moving unit base in parallel at intervals, a driving cylinder, a position sensing assembly, moving wheels, a flat trolley arranged on the moving wheels and a material box arranged on the flat trolley; the robot grabbing unit comprises a robot base and a robot; the camera identification unit comprises a camera bracket and a camera; the camera identification unit shoots the bar information in the material box and then transmits the bar information to the master control processing unit, and the master control processing unit processes the bar information acquired by the camera and then transmits the bar information to the robot, so that the robot can grasp the bar information in the material box in real time in an optimal path and posture and transmit the bar information to a designated position, and further full-automatic and intelligent feeding of a forging production line is realized.
Description
Technical Field
The invention belongs to the technical field of bar processing equipment, and particularly relates to a full-automatic feeding system and method for a forging production line based on 3D vision.
Background
Forging is a process of using forging machinery to apply pressure to a metal blank to make it plastically deform to obtain a forging with certain mechanical properties, certain shape and size. The defects of as-cast porosity and the like generated in the smelting process of metal can be eliminated through forging, the microstructure is optimized, and meanwhile, because the complete metal streamline is preserved, the mechanical property of the forging is generally superior to that of a casting made of the same material. Important parts with high load and severe working conditions in related machines are mainly forged pieces except for plates, sections or welding pieces which are simple in shape and can be rolled.
In the field of forging, the traditional feeding mode is usually manual feeding, so that the labor intensity of operators is high, more operators are needed to ensure the production efficiency, and the labor cost is increased; therefore, the automation degree of feeding of the forged piece is low, a large amount of manpower is consumed, and the production efficiency is low; in addition, the forging production line has various product types and large change of the length-diameter ratio of the blank, and the traditional feeding machine cannot meet the requirement of continuous and stable feeding for the intermediate frequency furnace; the traditional feeding machine is complex in structure and high in failure rate; part of the machine types also need to manually process the blocking or stacking condition; the intelligent degree of traditional material loading machine structure is not high, carries out digital factory information with the future and can not directly dock.
Therefore, a full-automatic feeding system of a forging production line, which has the advantages of simple structure, low failure rate, large load capacity, high automation degree and low labor consumption and can meet the continuous and stable feeding requirement of the intermediate frequency furnace, is urgently needed.
Disclosure of Invention
Aiming at the defects or improvement requirements in the prior art, the invention provides a full-automatic feeding system and method of a forging production line based on 3D vision, wherein position information of a bar in a material box is identified through a camera 32, high-precision 3D point cloud data of the bar is obtained and is transmitted to a master control processing unit; the master control processing unit obtains a three-dimensional model of the bar according to high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, combines original calibration data between the robot and the camera, converts the data into a relation between the robot and the bar, further obtains data that the robot grabs the bar to a specified position in an optimal posture and transmits the data to the robot, the robot grabs the bar in the optimal posture and path and transmits the bar to the specified position, and when the camera photographs and recognizes that no bar exists in the material box, a frame empty instruction is sent to the master control processing unit; the master control processing unit receives the empty frame instruction and then controls the flat trolley to move, and the empty box is moved out of the grabbing area; after the master control processing unit controls the empty frame to remove the grabbing area, a prompt of adding bars in the material changing box or the feeding box is sent; then, moving the prepared full material box to a position grabbing area, and repeating the steps to complete the full-automatic grabbing of the bar; thereby realizing the full-automatic and intelligent feeding of the forging line; compared with the traditional manual feeding, the automatic feeding device has the advantages of simple structure, low failure rate, large carrying capacity, high automation degree and low labor consumption, and can meet the continuous and stable feeding requirement of the intermediate frequency furnace; the automatic feeding device can solve a series of defects that the automation degree of the prior art is low, a large amount of manpower is consumed, the production efficiency is low, the failure rate is high, partial machine types need to be manually processed to clamp materials or stack the materials, the requirement for continuous stable feeding of the intermediate frequency furnace cannot be met, and the digital factory information cannot be directly butted with the future.
In order to achieve the above object, one aspect of the present invention provides a full-automatic feeding system for a forging line based on 3D vision, which includes a bar material transmission unit, a robot grabbing unit, a camera recognition unit, and a general control processing unit; the bar material transmission unit, the robot grabbing unit and the camera identification unit are respectively in communication connection with the master control processing unit; wherein the content of the first and second substances,
the bar material transmission unit comprises a moving unit base, light rails arranged on the moving unit base in parallel at intervals, a driving cylinder, a position sensing assembly, moving wheels running on the light rails, a flat trolley arranged on the moving wheels and a material box arranged on the flat trolley; the robot grabbing unit comprises a robot base arranged on one side of the bar material transmission unit and a robot arranged on the robot base; the camera identification unit comprises a camera support arranged on one side of the bar material transmission unit, which is far away from the robot grabbing unit, and a camera arranged on the camera support;
the camera is a structured light 3D camera, is arranged right above the material box, is sequentially projected on the surface of the measured bar stock according to a time sequence through a grating projection module, photographs the grating on the surface of an object through two eyes, and performs decoding and two-eye parallax matching based on a pre-coding rule, so that high-precision 3D point cloud data of the bar stock is obtained and is transmitted to the master control processing unit; the master control processing unit obtains a three-dimensional model of the bar according to high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot and the bar by combining original calibration data between the robot and the camera, further obtains data that the robot grabs the bar to a specified position in an optimal posture and transmits the data to the robot, and the robot grabs the bar in the optimal posture and path and transmits the data to the specified position, so that full-automatic and intelligent feeding of a forging production line is realized.
Further, the master control processing unit comprises an industrial personal computer and a PLC controller;
the position sensing assembly comprises a position sensor bracket arranged beside the moving wheel and a position sensor arranged on the position sensor bracket;
the position sensor is in communication connection with the master control processing unit; the position sensor records the position of the flat car so as to identify the position information of the material box, and the position information of the material box is transmitted to the master control processing unit.
Furthermore, the motion unit base is integrally formed in one step;
the driving cylinder is connected with a double-end electromagnetic valve which is in communication connection with the master control processing system;
the driving cylinder is connected with the bottom of the flat trolley; the master control processing unit controls the two-way electromagnetic valve to act so as to control the driving cylinder to drive the flat trolley to move left and right on the light rail, so that the work bin is driven to move left and right on the light rail, the automatic work bin changing function of the work bin is realized, and bar stock replacement without shutdown is realized.
Furthermore, the number of the light rails is two, and the light rails are arranged along the direction of the longitudinal central axis of the base of the motion unit;
two ends of the light rail are respectively provided with a buffer block;
the bottom of the buffer block is fixed with the base of the motion unit, and the top of the buffer block is higher than the lowest position of the flat car; and the flat car decelerates and stops through the buffering of the buffering block when moving left and right.
Further, the moving wheel is matched with the surface contour of the light rail;
the driving cylinder is arranged between the two light rails along the direction of the longitudinal central axis of the motion unit base;
lifting lugs are arranged on two sides of the material box.
The invention further provides a full-automatic feeding method of a forging line based on 3D vision, which comprises the following steps:
s1: calibrating the position relation between the robot and the camera to obtain original calibration data between the robot and the camera;
s2: shooting through a camera, identifying the position information of the bar in the material box, obtaining high-precision 3D point cloud data of the bar and transmitting the point cloud data to a master control processing unit;
s3: the master control processing unit obtains a three-dimensional model of the bar according to the high-precision 3D point cloud data of the bar obtained in the step S2, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot and the bar by combining the original calibration data between the robot and the camera obtained in the step S1, obtains real position data of the bar, and further obtains data of the robot grabbing the bar to a specified position in an optimal posture;
s4: the master control processing unit transmits the data of grabbing the bar stock by the robot from the optimal posture to the designated position obtained in the step S3 to the robot, and the robot grabs the bar stock from the optimal posture and path and transmits the bar stock to the designated position;
s5: and (5) repeating the steps S1-S4 to complete the full-automatic and intelligent feeding of the bars on the forging production line.
Further, the step S2 also comprises the step of sending an empty frame instruction to the master control processing unit after the camera photographs and recognizes that no bar material exists in the material box;
the master control processing unit receives the empty frame instruction and then controls the flat car to move, and the empty box is moved out of the grabbing area;
after the master control processing unit controls the empty frame to remove the grabbing area, a prompt of adding bars in a material changing box or a feeding box is sent; and then, moving the prepared full material box to a position grabbing area, and repeating the steps S2 to S5 to finish the full-automatic grabbing of the bar.
Further, the step S2 of obtaining the high-precision 3D point cloud data of the bar stock comprises the steps that a camera sequentially projects on the surface of the measured bar stock through a grating projection module according to a time sequence, the grating on the surface of an object is shot through a binocular, and decoding and binocular parallax matching are carried out based on a pre-coding rule.
Further, the step S3 further comprises the step of comparing the originally collected point cloud data of the bar stock for analysis and processing through a 3D measurement point cloud processing algorithm and a software integration point cloud processing algorithm to obtain a three-dimensional model of the bar stock.
Further, step S3 also includes that the master control processing unit judges whether the three-dimensional model of the bar generated by the point cloud is complete or not so as to judge whether the bar is shielded or not, judges the posture of the bar according to the height of the close point cloud, judges whether the robot collides with other bars or the edge of the bin after entering a grabbing state through simulation analysis, calculates the posture data of the optimal bar grabbing at the specified position, and then screens out the best-grabbed bar.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
(1) According to the full-automatic feeding system of the forging production line based on the 3D vision, the position information of the bar in the material box is identified through the camera, high-precision 3D point cloud data of the bar are obtained and transmitted to the master control processing unit; the master control processing unit obtains a three-dimensional model of the bar according to high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, combines original calibration data between the robot and the camera, converts the data into a relation between the robot and the bar, further obtains data that the robot grabs the bar to a specified position in an optimal posture and transmits the data to the robot, the robot grabs the bar in the optimal posture and path and transmits the bar to the specified position, and when the camera photographs and recognizes that no bar exists in the material box, a frame empty instruction is sent to the master control processing unit; the master control processing unit receives the empty frame instruction and then controls the flat trolley to move, and the empty box is moved out of the grabbing area; after the master control processing unit controls the empty frame to remove the grabbing area, a prompt of adding bars in the material changing box or the feeding box is sent; then, moving a prepared full material box to a position grabbing area, and repeating the steps to complete the full-automatic grabbing of the bar; thereby realizing full-automatic and intelligent feeding of the forging production line; compared with the traditional manual feeding, the automatic feeding device has the advantages of simple structure, low failure rate, large carrying capacity, high automation degree and low labor consumption, and can meet the continuous and stable feeding requirement of the intermediate frequency furnace; the automatic feeding device can solve a series of defects that the automation degree of the prior art is low, a large amount of manpower is consumed, the production efficiency is low, the failure rate is high, partial machine types need to be manually processed to clamp materials or stack the materials, the requirement for continuous stable feeding of the intermediate frequency furnace cannot be met, and the digital factory information cannot be directly butted with the future.
(2) According to the full-automatic feeding system of the forging production line based on the 3D vision, the whole master control processing system is communicated through the profinet bus, data transmission is more accurate and faster, all information is sent out after being processed through the master control system, and the automation degree is high; when a product needs to be replaced, the size or the model of the corresponding product is selected on the touch screen of the control system, so that the product can be replaced by one key, and the efficiency is greatly improved;
(3) According to the full-automatic feeding system of the forging production line based on the 3D vision, the driving cylinder is connected with the double-end electromagnetic valve which is in communication connection with the master control processing system; the master control processing unit controls the bidirectional electromagnetic valve to act so as to control the driving cylinder to drive the flat trolley to move left and right on the light rail, so that the work bin is driven to move left and right on the light rail, the automatic work bin changing function of the work bin is realized, and bar stock is changed without stopping; the automatic feeding system is driven by the driving cylinder with a large cylinder diameter, has a simple structure, low failure rate and large load capacity, does not need to electrify the electromagnetic valve all the time, can avoid the error movement of the flat trolley caused by the sudden power failure of a production line, and ensures the stable reliability of the automatic feeding system;
(3) According to the full-automatic feeding system of the forging production line based on the 3D vision, the two ends of each light rail are respectively provided with the buffer blocks, the position sensor support is arranged beside the moving wheels, and the position sensor is arranged on the position sensor support; the position sensor is in communication connection with the master control processing unit; the position sensor records the position of the flat trolley so as to identify the position information of the material box, and the position information of the material box is transmitted to the master control processing unit, and the master control processing unit controls the accurate identification bar information of the identification camera unit, the accurate grabbing of the bar by the robot grabbing unit and the movement direction of the flat trolley according to the position of the material box; the flat car slows down and stops through the buffering of buffer block during side to side movement, avoids damaging dolly and base, and then increases the life of flat car and base.
(4) According to the full-automatic feeding system of the forging production line based on the 3D vision, the bar detecting unit in communication connection with the master control processing system is arranged at the tail end of a feeding transmission chain of the intermediate frequency furnace, the feeding condition of the intermediate frequency furnace is monitored in real time through the bar detecting unit, and the bar detecting unit is directly transmitted to the master control processing system; when the bar stock of the intermediate frequency furnace is sufficient, the feeding system automatically pauses and stops feeding; when the bar stock is less than the lower limit, the automatic feeding system restarts feeding, so as to realize intelligent feeding of the bar stock.
Drawings
FIG. 1 is a schematic structural diagram of a full-automatic feeding system of a forging line based on 3D vision according to an embodiment of the invention;
FIG. 2 is a schematic structural diagram of a bar conveying unit of a full-automatic feeding system of a forging line based on 3D vision according to an embodiment of the invention;
FIG. 3 is a schematic diagram of an information interaction structure of a full-automatic feeding system of a forging line based on 3D vision according to an embodiment of the present invention;
FIG. 4 is a schematic flow chart illustrating a full-automatic feeding method for a forging line based on 3D vision according to an embodiment of the present invention;
fig. 5 is a schematic flow chart illustrating a process of acquiring bar data grabbed by a robot to a designated position in a full-automatic feeding method of a forging line based on 3D vision according to an embodiment of the invention.
Throughout the drawings, like reference numerals designate like features, and in particular: the system comprises a bar material transmission unit 1, a motion unit base 11, a light rail 12, a driving cylinder 13, a position sensing assembly 14, a motion wheel 15, a flat car 16, a material box 17, a lifting lug 171, a buffer block 18, a robot grabbing unit 2, a robot base 21, a robot 22, a camera recognition unit 3, a camera support 31, a camera 32 and a master control processing unit 4.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, when an element is referred to as being "fixed to", "disposed on" or "provided on" another element, it may be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element; the terms "mounted," "connected," and "provided" are to be construed broadly and may include, for example, fixed connections, removable connections, or integral connections; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood according to specific situations by those of ordinary skill in the art.
As shown in fig. 1-4, one aspect of the present invention provides a full-automatic feeding system for a forging line based on 3D vision, which includes a bar material transmission unit 1, a robot gripping unit 2, a camera recognition unit 3, and a general control processing unit 4; the bar material conveying unit 1 is used for feeding the intermediate frequency furnace, and a bar material detecting unit is arranged at the tail end of a feeding conveying chain of the intermediate frequency furnace; the bar material transmission unit 1, the robot grabbing unit 2, the identification camera unit 3 and the bar material detection unit are respectively in communication connection with the master control processing unit 4; monitoring the feeding condition of the intermediate frequency furnace in real time through the bar detecting unit, and directly transmitting the feeding condition to the master control processing system 4; when the bar stock of the intermediate frequency furnace is sufficient, the feeding system can automatically pause to stop feeding; when the bar stock is less than the lower limit, the automatic feeding system restarts feeding; the bar conveying unit 1 comprises a moving unit base 11, light rails 12 arranged on the moving unit base 11 at intervals in parallel, a driving cylinder 13, a position sensing assembly 14, moving wheels 15 running on the light rails 12, a flat car 16 arranged on the moving wheels 15 and a material box 17 arranged on the flat car 16; the robot grabbing unit 2 comprises a robot base 21 arranged on one side of the bar material transmission unit 1 and a robot 22 arranged on the robot base 21; the camera identification unit 3 comprises a camera bracket 31 arranged on one side of the bar material transmission unit 1 far away from the robot grabbing unit 2 and a camera 32 arranged on the camera bracket 31; according to the invention, the position information of the bar stock in the bin 17 is identified through the camera 32, high-precision 3D point cloud data of the bar stock is obtained and is transmitted to the master control processing unit 4; the master control processing unit 4 obtains a three-dimensional model of the bar stock according to the high-precision 3D point cloud data of the bar stock, further obtains a space coordinate of the bar stock, converts the space coordinate into a relation between the robot 22 and the bar stock by combining with original calibration data between the robot 22 and the camera 32, further obtains data that the robot grabs the bar stock from an optimal posture to an appointed position and transmits the data to the robot, the robot grabs the bar stock from the optimal posture and path and transmits the bar stock to the appointed position, and further full-automatic and intelligent feeding of a forging production line is achieved; compared with the traditional manual feeding, the automatic feeding device has the advantages of simple structure, low failure rate, large carrying capacity, high automation degree and low labor consumption, and can meet the continuous and stable feeding requirement of the intermediate frequency furnace; the automatic feeding device can solve a series of defects that the automation degree of the prior art is low, a large amount of manpower is consumed, the production efficiency is low, the failure rate is high, partial machine types need to be manually processed to clamp materials or stack the materials, the requirement for continuous stable feeding of the intermediate frequency furnace cannot be met, and the digital factory information cannot be directly butted with the future.
Further, as shown in fig. 1 to 4, the bar stock transfer unit 1 is used for supplying a bar stock; the camera identification unit 3 is used for identifying the position and the posture of the bar on the bar conveying unit 1 and transmitting the identified position and the posture of the bar to the master control processing unit 4; the robot grabbing unit 2 is used for grabbing the bar stock on the bar stock transmission unit 1 in an optimal path and posture according to the control instruction of the master control processing unit 4 and transmitting the bar stock to a specified position.
Further, as shown in fig. 1 to 4, the base 11 of the motion unit is integrally formed in one step, and can adapt to a multi-site environment; the driving cylinder 13 is connected with a double-end electromagnetic valve which is in communication connection with the master control processing system 4; the driving cylinder 13 is connected with the bottom of the flat car 16, the flat car 16 is driven by the driving cylinder 13 to move left and right on the light rail 12, and the automatic feed box changing function of the feed box 17 on the flat car 16 is realized, so that the bar stock is changed without stopping; according to the invention, the master control processing unit 4 controls the action of the two-way electromagnetic valve to control the driving cylinder 13 to drive the flat trolley 16 to move left and right on the light rail 12, so that the work bin 17 is driven to move left and right on the light rail 12, the automatic work bin changing function of the work bin 17 is realized, and bar stock replacement without shutdown is realized; the automatic feeding system has the advantages that the automatic feeding system is driven by the driving air cylinder with a large cylinder diameter, the structure is simple, the fault rate is low, the load capacity is large, the electromagnetic valve does not need to be electrified all the time, the flat trolley can be prevented from moving by mistake due to sudden power failure of a production line, and the stability and the reliability of the automatic feeding system are ensured.
Further, as shown in fig. 1 to fig. 3, the position sensing assembly 14 includes a position sensor bracket 141 disposed beside the moving wheel 15 and a position sensor 142 disposed on the position sensor bracket 141; the position sensor 142 is in communication connection with the general control processing unit 4; the position sensor 142 records the position of the flat car 16 so as to identify the position information of the material box 17, and the position information is transmitted to the master control processing unit 4; two ends of each light rail 12 are respectively provided with a buffer block 18 for enabling the flat car 16 to timely decelerate and stop when moving left and right on the light rail 12; according to the invention, the position information of the bin 17 is transmitted to the general control processing unit 4 through the position sensor 142, and the general control processing unit 4 controls the accurate identification bar information of the identification camera unit 3 and the accurate bar grabbing of the robot grabbing unit 2 according to the position of the bin 17; the position information of the material box 17 acquired by the position sensor 142 is transmitted to the master control processing unit 4, and the movement direction of the flat car 16 is controlled by the master control processing unit 4; when the flat car 16 moves left and right, the car and the base are prevented from being damaged by the buffering and speed reduction stop of the buffer block 18, and the service life of the flat car and the base is prolonged.
Further, as shown in fig. 1 to 3, there are two light rails 12 arranged along the longitudinal central axis of the motion unit base 11; the moving wheel 15 is matched with the surface contour of the light rail 12; the driving cylinder 13 is arranged between the two light rails 12 along the direction of the longitudinal central axis of the moving unit base 11; the bottom of the buffer block 18 is fixed with the moving unit base 11, and the top of the buffer block is higher than the lowest position of the flat car 16, so that the flat car 16 can be stopped quickly after colliding with the flat car; lifting lugs 171 are arranged on two sides of the material box 17, so that the material box 17 can be conveniently carried.
Further, as shown in fig. 1 to 4, the camera 32 is a structured light 3D camera, and is disposed right above the bin 17; the structured light 3D camera adopts a plurality of stripe gratings, sequentially projects the stripe gratings on the surface of a detected bar according to a time sequence through a grating projection module, photographs the gratings on the surface of an object through a binocular, and performs decoding and binocular parallax matching based on a pre-coding rule, so that high-precision 3D point cloud data of the bar are obtained and transmitted to a master control processing unit 4; the master control processing unit 4 integrates a common point cloud processing algorithm with software through a 3D measurement point cloud processing algorithm according to high-precision 3D point cloud data of the bar stock obtained by the structured light 3D camera, analyzes and processes the originally acquired bar stock point cloud data to generate detailed data, so that a three-dimensional model of the bar stock is obtained, and further the shape, the size, the posture and the position relative to the camera, namely a space coordinate, of the bar stock are obtained; the master control processing unit 4 screens the best-grabbed bar according to the three-dimensional model of the bar and the original calibration data between the robot 22 and the camera 32, further obtains data that the robot grabs the bar at the specified position in the optimal posture, and transmits the data to the robot in a bus communication mode; the robot accurately grabs the bar stock; the structured light 3D camera adopts a plurality of gratings for coding, the coding precision can be as fine as 1 pixel to a sub-pixel, and the point cloud quality and precision are better compared with those of other principles; whether the three-dimensional model of the bar generated by the point cloud is complete or not is judged by the master control processing unit 4, whether the bar is shielded or not is judged, the posture of the bar is judged according to the height of the close point cloud, and after the robot is judged to enter a grabbing state through simulation analysis, whether the robot can collide with other bars or the edge of a material box or not is judged, so that the optimal posture data of the grabbing bar at the specified position is calculated, and the best grabbing bar is screened out.
Further, as shown in fig. 1 to 4, the general control processing unit 4 includes an industrial personal computer and a PLC controller; identifying the position information of the bar stock in the bin 17 through the camera 32, obtaining high-precision 3D point cloud data of the bar stock and transmitting the point cloud data to the master control processing unit 4; the master control processing unit 4 obtains a three-dimensional model of the bar according to the high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot 22 and the bar by combining with original calibration data between the robot 22 and the camera 32, further obtains data that the robot grabs the bar at an appointed position in an optimal posture and transmits the data to the robot, and the robot grabs the bar at the optimal posture and path and transmits the data to the appointed position; when the camera 32 takes a picture and recognizes that no bar is in the feed box 17, an empty frame instruction is sent to the master control processing unit 4; the master control processing unit 4 receives the empty frame instruction and then controls the flat trolley 16 to move, and moves the empty box 17 out of the grabbing area; after the master control processing unit 4 controls the empty frame to remove the grabbing area, a prompt of adding bars in the material changing box or the feeding box is sent; then, the prepared full material box 17 is shifted to be arranged in the grabbing area, and the full-automatic grabbing operation of the bar stock is urgently needed.
As shown in fig. 4 and 5, another aspect of the present invention provides a full-automatic feeding method for a forging line based on 3D vision, comprising the following steps:
s1: calibrating the position relation between the robot 22 and the camera 32 to obtain original calibration data between the robot 22 and the camera 32;
s2: shooting through a camera 32, identifying the position information of the bar in the material box 17, obtaining high-precision 3D point cloud data of the bar and transmitting the point cloud data to the master control processing unit 4; the method specifically comprises the steps that a structured light 3D camera sequentially projects on the surface of a measured bar according to a time sequence through a grating projection module, then photographs the grating on the surface of an object through a binocular, and performs decoding and binocular parallax matching based on a pre-coding rule, so that high-precision 3D point cloud data of the bar are obtained and transmitted to a master control processing unit 4;
s3: the master control processing unit 4 obtains a three-dimensional model of the bar according to the high-precision 3D point cloud data of the bar obtained in the step S2, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot 22 and the bar by combining the original calibration data between the robot 22 and the camera 32 obtained in the step S1, obtains real position data of the bar, and further obtains data that the robot grabs the bar from an optimal posture to a specified position; specifically, the master control processing unit 4 integrates a point cloud processing algorithm with software through a 3D measurement point cloud processing algorithm according to high-precision 3D point cloud data of the bar stock obtained by the structured light 3D camera, analyzes and processes the originally acquired point cloud data of the bar stock to generate detailed data, thereby obtaining a three-dimensional model of the bar stock, and further obtaining the shape, size, posture of the bar stock and the position relative to the camera, namely a spatial coordinate; the master control processing unit 4 screens the bar stock which is best grabbed according to the three-dimensional model of the bar stock and the original calibration data between the robot 22 and the camera 32, further obtains data that the robot grabs the bar stock to the specified position in the optimal posture, and transmits the data to the robot in a bus communication mode; the master control processing unit 4 judges whether the bar stock is shielded or not by judging whether a three-dimensional bar stock model generated by point cloud is complete or not, judges the posture of the bar stock according to the height of the close point cloud, judges whether the robot collides with other bar stocks or the edge of a bin or not after entering a grabbing state through simulation analysis, calculates the optimal posture data for grabbing the bar stock at a specified position and further screens out the bar stock which is best grabbed;
s4: the master control processing unit 4 transmits the data of grabbing the bar stock by the robot from the optimal posture to the designated position obtained in the step S3 to the robot, and the robot grabs the bar stock by the optimal posture and path and transmits the bar stock to the designated position;
s5: and (5) repeating the steps S1-S4 to finish the full-automatic and intelligent feeding of the bars on the forging production line.
The step S2 also comprises the step of sending an empty frame instruction to the master control processing unit 4 after the camera 32 takes a picture and identifies that no bar material exists in the material box 17; the master control processing unit 4 receives the empty frame instruction and then controls the flat trolley 16 to move, and moves the empty box 17 out of the grabbing area; after the master control processing unit 4 controls the empty frame to remove the grabbing area, a prompt of adding bars in a material changing box or a feeding box is sent; and then, the prepared full material box 17 is shifted to be arranged in the grabbing area, and the steps S2 to S5 are repeated to finish the full-automatic grabbing of the bar.
The invention provides a full-automatic feeding system and a method of a forging production line based on 3D vision, which have the working principles that: identifying the position information of the bar stock in the stock box 17 through the camera 32, obtaining high-precision 3D point cloud data of the bar stock and transmitting the point cloud data to the master control processing unit 4; the master control processing unit 4 obtains a three-dimensional model of the bar according to the high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot 22 and the bar by combining with original calibration data between the robot 22 and the camera 32, further obtains data that the robot grabs the bar to a specified position in an optimal posture and transmits the data to the robot, the robot grabs the bar in the optimal posture and path and transmits the bar to the specified position, and when the camera 32 photographs and recognizes that no bar exists in the material box 17, an empty frame instruction is sent to the master control processing unit 4; the master control processing unit 4 receives the empty frame instruction and then controls the flat car 16 to move, and moves the empty box 17 out of the grabbing area; after the master control processing unit 4 controls the empty frame to remove the grabbing area, a prompt of adding bars in the material changing box or the feeding box is sent; then, the prepared full material box 17 is shifted to be arranged in a grabbing area, and the steps are repeated to complete the full-automatic grabbing of the bar; thereby realizing the full-automatic and intelligent feeding of the forging line; the whole master control system 4 of the invention communicates through a profinet bus, the data transmission is more accurate and rapid, all information is sent out after being processed by the master control system, and the automation degree is high; when a product needs to be replaced, the size or the model of the corresponding product is selected on the touch screen of the control system, so that the product can be replaced by one key, and the efficiency is greatly improved; the driving cylinder 13 is connected with a double-end electromagnetic valve which is in communication connection with the master control processing system 4; the master control processing unit 4 controls the action of a two-way electromagnetic valve to control the driving cylinder 13 to drive the flat trolley 16 to move left and right on the light rail 12, so as to drive the work bin 17 to move left and right on the light rail 12, thereby realizing the automatic work bin changing function of the work bin 17 and realizing the replacement of bars without stopping; the automatic feeding system is driven by the large-cylinder-diameter driving cylinder, has a simple structure, low failure rate and large load capacity, does not need to electrify the electromagnetic valve all the time, can avoid the error movement of the flat trolley caused by sudden power failure of a production line, and ensures the stable reliability of the automatic feeding system; according to the invention, the buffer blocks 18 are respectively arranged at the two ends of each light rail 12, the position information of the material box 17 is transmitted to the master control processing unit 4 through the position sensor 142, and the master control processing unit 4 controls the accurate identification bar information of the identification camera unit 3 and the accurate bar grabbing of the robot grabbing unit 2 according to the position of the material box 17; the position information of the material box 17 acquired by the position sensor 142 is transmitted to the master control processing unit 4, and the movement direction of the flat car 16 is controlled by the master control processing unit 4; when the flat car 16 moves left and right, the car and the base are prevented from being damaged by the buffering and speed reduction stop of the buffer block 18, and the service life of the flat car and the base is prolonged. Compared with the traditional manual feeding, the automatic feeding device has the advantages of simple structure, low failure rate, large carrying capacity, high automation degree and low labor consumption, and can meet the continuous and stable feeding requirement of the intermediate frequency furnace; the automatic feeding device can solve a series of defects that the automation degree of the prior art is low, a large amount of manpower is consumed, the production efficiency is low, the failure rate is high, partial machine types need to be manually processed to clamp materials or stack the materials, the requirement for continuous stable feeding of the intermediate frequency furnace cannot be met, and the digital factory information cannot be directly butted with the future.
It will be understood by those skilled in the art that the foregoing is only an exemplary embodiment of the present invention, and is not intended to limit the invention to the particular forms disclosed, since various modifications, substitutions and improvements within the spirit and scope of the invention are possible and within the scope of the appended claims.
Claims (10)
1. The utility model provides a full automatic feeding system of forging line based on 3D vision which characterized in that: the device comprises a bar material transmission unit (1), a robot grabbing unit (2), a camera identification unit (3) and a master control processing unit (4); the bar material transmission unit (1), the robot grabbing unit (2) and the camera identification unit (3) are in communication connection with the master control processing unit (4) respectively;
the bar conveying unit (1) comprises a moving unit base (11), light rails (12) arranged on the moving unit base (11) in parallel at intervals, a driving cylinder (13), a position sensing assembly (14), moving wheels (15) running on the light rails (12), a flat trolley (16) arranged on the moving wheels (15) and a material box (17) arranged on the flat trolley (16); the robot grabbing unit (2) comprises a robot base (21) arranged on one side of the bar material transmission unit (1) and a robot (22) arranged on the robot base (21); the camera identification unit (3) comprises a camera support (31) arranged on one side, away from the robot grabbing unit (2), of the bar conveying unit (1) and a camera (32) arranged on the camera support (31); the camera (32) is a structured light 3D camera, is arranged right above the material box (17), is sequentially projected on the surface of the detected bar stock according to a time sequence through a grating projection module, photographs the grating on the surface of an object through a binocular, and performs decoding and binocular parallax matching based on a pre-coding rule, so that high-precision 3D point cloud data of the bar stock is obtained and transmitted to the master control processing unit (4); the master control processing unit (4) obtains a three-dimensional model of the bar according to high-precision 3D point cloud data of the bar, further obtains a space coordinate of the bar, converts the space coordinate into a relation between the robot (22) and the bar by combining original calibration data between the robot (22) and the camera (32), further obtains data that the robot grabs the bar to an appointed position in an optimal posture, and transmits the data to the robot, and the robot grabs the bar in the optimal posture and path and transmits the bar to the appointed position, so that full-automatic and intelligent feeding of a forging production line is realized.
2. The full-automatic feeding system of forging line based on 3D vision of claim 1, characterized in that: the master control processing unit (4) comprises an industrial personal computer and a PLC controller;
the position sensing assembly (14) comprises a position sensor bracket (141) arranged beside the moving wheel (15) and a position sensor (142) arranged on the position sensor bracket (141);
the position sensor (142) is in communication connection with the master control processing unit (4); the position of the flat car (16) is recorded through the position sensor (142) so as to identify the position information of the material box (17), and the position information of the material box (17) is transmitted to the master control processing unit (4).
3. The full-automatic feeding system of forging line based on 3D vision of claim 2, characterized in that: the motion unit base (11) is integrally formed in one step;
the driving cylinder (13) is connected with a double-end electromagnetic valve which is in communication connection with the master control processing system (4);
the driving cylinder (13) is connected with the bottom of the flat trolley (16); the master control processing unit (4) controls the bidirectional electromagnetic valve to act so as to control the driving cylinder (13) to drive the flat trolley (16) to move left and right on the light rail (12) and further drive the work bin (17) to move left and right on the light rail (12), so that the automatic work bin changing function of the work bin (17) is realized, and the bar stock is changed without stopping.
4. The full-automatic feeding system of forging line based on 3D vision as recited in any one of claims 1 to 3, wherein: the number of the light rails (12) is two, and the light rails are arranged along the direction of the longitudinal central axis of the motion unit base (11);
two ends of the light rail (12) are respectively provided with a buffer block (18);
the bottom of the buffer block (18) is fixed with the base (11) of the motion unit, and the top of the buffer block is higher than the lowest position of the flat car (16); when the flat car (16) moves left and right, the flat car is decelerated and stopped through the buffering of the buffering block (18).
5. The full-automatic feeding system of forging line based on 3D vision of claim 4, wherein: the moving wheel (15) is matched with the surface contour of the light rail (12);
the driving cylinder (13) is arranged between the two light rails (12) along the direction of the longitudinal central axis of the moving unit base (11);
lifting lugs (171) are arranged on two sides of the feed box (17).
6. The full-automatic feeding method for the forging line based on the 3D vision is realized by applying the full-automatic feeding system for the forging line based on the 3D vision as claimed in any one of claims 1 to 5, and comprises the following steps:
s1: calibrating the position relation between the robot (22) and the camera (32) to obtain original calibration data between the robot (22) and the camera (32);
s2: photographing through a camera (32), identifying position information of the bar stock in the stock box (17), obtaining high-precision 3D point cloud data of the bar stock and transmitting the point cloud data to a master control processing unit (4);
s3: the master control processing unit (4) obtains a three-dimensional model of the bar material according to the high-precision 3D point cloud data of the bar material obtained in the step S2, further obtains a space coordinate of the bar material, converts the space coordinate into a relation between the robot (22) and the bar material by combining the original calibration data between the robot (22) and the camera (32) obtained in the step S1, obtains real position data of the bar material, and further obtains data of the robot grabbing the bar material at an appointed position in an optimal posture;
s4: the master control processing unit (4) transmits the data of the robot obtained in the step S3 for grabbing the bar stock to the designated position in the optimal posture to the robot, and the robot grabs the bar stock in the optimal posture and path and transmits the bar stock to the designated position;
s5: and (5) repeating the steps S1-S4 to finish the full-automatic and intelligent feeding of the bars on the forging production line.
7. The 3D vision-based full-automatic feeding method for the forging line is characterized in that the step S2 further comprises the step of sending an empty frame instruction to the master control processing unit (4) after the camera (32) photographs and recognizes that no bar stock exists in the material box (17);
the master control processing unit (4) receives the empty frame instruction and then controls the flat trolley (16) to move, and moves the empty box (17) out of the grabbing area;
after the master control processing unit (4) controls the empty frame to remove the grabbing area, a prompt of adding bars in a material changing box or a feeding box is sent; and then, shifting the prepared full material box (17) to a grabbing area, and repeating the steps S2 to S5 to finish the full-automatic grabbing of the bar.
8. The full-automatic feeding method for the forging line based on the 3D vision is characterized in that the obtaining of the high-precision 3D point cloud data of the bar in the step S2 comprises the steps that a camera sequentially projects on the surface of the measured bar according to a time sequence through a grating projection module, a grating on the surface of an object is photographed through two eyes, and decoding and binocular parallax matching are carried out based on a pre-coding rule.
9. The full-automatic feeding method for the forging production line based on the 3D vision as claimed in claim 8, wherein the step S3 further comprises analyzing and processing the point cloud data of the bar stock which is originally collected through a 3D measurement point cloud processing algorithm and a software integration point cloud processing algorithm to obtain a three-dimensional model of the bar stock.
10. The 3D vision-based full-automatic feeding method for the forging production line is characterized in that the step S3 further comprises a master control processing unit (4) judging whether a three-dimensional bar model generated by point cloud is complete or not so as to judge whether the bar is blocked or not, judging the posture of the bar according to the height of the close point cloud, judging whether the robot collides with other bars or the edge of a bin or not after entering a grabbing state through simulation analysis so as to calculate the optimal posture data of grabbing the bar at a specified position, and further screening the bar which is best grabbed.
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