CN115388769A - Method, device, equipment and medium for monitoring tool state in real time - Google Patents

Method, device, equipment and medium for monitoring tool state in real time Download PDF

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Publication number
CN115388769A
CN115388769A CN202210991152.7A CN202210991152A CN115388769A CN 115388769 A CN115388769 A CN 115388769A CN 202210991152 A CN202210991152 A CN 202210991152A CN 115388769 A CN115388769 A CN 115388769A
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Prior art keywords
light spot
coordinate data
tool
monitoring
spot image
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Inventor
唐嘉文
潘登
李东明
成一博
王志乾
郑伟涛
李涛
洪学玲
祝锦松
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Chengdu Aircraft Industrial Group Co Ltd
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Chengdu Aircraft Industrial Group Co Ltd
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/002Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64FGROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/10Manufacturing or assembling aircraft, e.g. jigs therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64FGROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/60Testing or inspecting aircraft components or systems

Abstract

The application discloses a method, a device, equipment and a medium for monitoring the state of a tool in real time, which relate to the technical field of tool state monitoring, and the method comprises the steps of acquiring theoretical coordinate data of monitoring points of the monitoring points and actual coordinate data of the monitoring points; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms; obtaining an initial light spot image and an actually measured light spot image; respectively extracting initial light spot image center coordinate data and actually measured light spot image center coordinate data based on the initial light spot image and the actually measured light spot image; constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points; and constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data. Through the technical scheme, the positioning state of the tool in the product assembling process can be monitored in real time.

Description

Tool state real-time monitoring method, device, equipment and medium
Technical Field
The application relates to the technical field of tool state monitoring, in particular to a method, a device, equipment and a medium for monitoring a tool state in real time.
Background
In the field of aircraft manufacturing, large aircraft components are supported and positioned through an assembly tool in the structural assembly stage, and the assembly of products into assemblies and components through parts is completed. Whether the space position of the tool to the product positioning point can be continuously and stably maintained or not in the assembling process is directly related to the assembling quality of the product. Therefore, the positioning state of the tool in the product assembling process can be monitored in real time.
However, in the prior art, the positioning state of the tool in the product assembling process cannot be monitored in real time, so that the assembling quality of the product installed on the tool is affected.
Disclosure of Invention
The application mainly aims to provide a tool state real-time monitoring method, a tool state real-time monitoring device, equipment and a medium, and aims to solve the technical problem that the positioning state of a tool in the product assembling process cannot be monitored in real time in the prior art, so that the assembling quality of a product installed on the tool is influenced.
In order to achieve the above object, a first aspect of the present application provides a method for monitoring a tool state in real time, where the method includes:
acquiring theoretical coordinate data and actual coordinate data of monitoring points of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms;
obtaining an initial light spot image and an actually measured light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed;
respectively extracting initial light spot image center coordinate data and actually measured light spot image center coordinate data based on the initial light spot image and the actually measured light spot image;
constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points;
and constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
Optionally, before the step of obtaining theoretical coordinate data of the monitoring point and actual coordinate data of the monitoring point, the method further comprises the following steps;
identifying a deformation point on the tool based on a tool finite element analysis model and a product assembling process; wherein the deformation points comprise monitoring points;
based on the monitoring points, obtaining a light spot emitting area and a light spot receiving area; wherein the light spot emitting area is used for emitting a light spot, and the light spot receiving area is used for receiving the light spot.
Optionally, several light spots are received simultaneously in the light spot receiving area, and the several light spots do not overlap with each other.
Optionally, before the step of obtaining the initial light spot image and the measured light spot image, the method further includes:
setting a tolerance threshold value, wherein the tolerance threshold value is used for representing whether the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is larger than an allowable range;
obtaining the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point;
and sending alarm information under the condition that the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold value.
Optionally, after the step of sending alarm information under the condition that the difference between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold, the method further includes:
acquiring an abnormal monitoring point based on the alarm information; and the abnormal monitoring point is a monitoring point of which the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold.
Optionally, the constructing a monitoring point position model based on the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point includes:
obtaining a monitoring point position model through the following relational expression:
P b =R 1 P a +T 1
wherein, P b Representing the actual coordinates of the monitoring point, P a Representing theoretical coordinates of the monitoring point, R 1 Representing the rotation matrix, T, before deformation of the tool 1 Representing a translation matrix before deformation of the tool;
the constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data comprises:
the spot position model is obtained by the following relation:
Q b =R 2 Q a +T 2
wherein Q is b Representing the centre coordinates, Q, of the measured spot image a Representing the initial spot image center coordinates, R 2 Representing the rotation matrix, T, after deformation of the tool 2 And representing a translation matrix after the tool is deformed.
Optionally, the relationship among the rotation matrix before tool deformation, the translation matrix before tool deformation, the rotation matrix after tool deformation, and the translation matrix after tool deformation is obtained through the following relational expression:
Figure BDA0003801362810000031
Figure BDA0003801362810000032
wherein alpha represents the deformation angle of the monitoring point relative to the tool before deformation, and alpha represents the deformation angle of the monitoring point relative to the tool before deformation x Representing the angle α resolved in the x-direction under the aircraft coordinate system, α y Representing the angle of alpha resolved in the y-direction under the aircraft coordinate system, alpha z The angle of alpha decomposition along the Z direction under an airplane coordinate system is shown, M is the distance between a monitoring point stand column and the intersection line of a light receiving plate and the ground, H is the height of the monitoring stand column, L is the Z-direction difference value of the central coordinate of a first initial light spot image and the theoretical coordinate of a first monitoring point when the monitoring point stand column is at an initial position, K is the displacement value before and after light spot deformation, N is the height value of the central coordinate of a first actually measured light spot image and the ground, theta is the angle between the light receiving plate and the ground, and gamma is the included angle between a laser beam in an initial state and the horizontal plane.
In a second aspect, the present application provides a real-time tool state monitoring device, the device includes:
the acquisition module is used for acquiring theoretical coordinate data and actual coordinate data of monitoring points of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms;
the acquisition module is used for acquiring an initial light spot image and an actual measurement light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed;
the extraction module is used for respectively extracting the central coordinate data of the initial light spot image and the central coordinate data of the actually measured light spot image based on the initial light spot image and the actually measured light spot image;
the first construction module is used for constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points;
and the second construction module is used for constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
In a third aspect, the present application provides a computer device, which includes a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the method described in the embodiment.
In a fourth aspect, the present application provides a computer-readable storage medium having a computer program stored thereon, wherein a processor executes the computer program to implement the method described in the embodiments.
Through above-mentioned technical scheme, this application has following beneficial effect at least:
according to the method, the device, the equipment and the medium for monitoring the tool state in real time, theoretical coordinate data of monitoring points of the monitoring points and actual coordinate data of the monitoring points are obtained firstly; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms; then obtaining an initial light spot image and an actually measured light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed; then based on the initial light spot image and the actually measured light spot image, respectively extracting central coordinate data of the initial light spot image and central coordinate data of the actually measured light spot image; then, building a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points; and then constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data. Namely, the technical scheme of the application can be through measuring the theoretical coordinate data of monitoring point and the initial light spot image central coordinate data of product installation before the frock, and measuring the actual coordinate data of monitoring point and the actual measurement light spot image central coordinate data of product installation behind the frock, then establish monitoring point position model and light spot position model respectively based on above coordinate data, rethread monitoring point position model and light spot position model can real-timely learn the position change condition of product installation on the frock, thereby can real-timely monitoring the location state of frock in the product assembling process, and then according to the location state of frock, can improve the assembly quality of product installation on the frock.
Drawings
FIG. 1 is a schematic diagram of a computer device in a hardware operating environment according to an embodiment of the present application;
fig. 2 is a flowchart of a tool state real-time monitoring method according to an embodiment of the present application;
FIG. 3 is a schematic diagram illustrating a real-time monitoring principle of a tool state according to an embodiment of the present disclosure;
FIG. 4 is a schematic view of a system for monitoring the state of the aircraft assembly tool in real time according to the present application;
FIG. 5 is a schematic diagram of coordinate transformation according to an embodiment of the present application;
FIG. 6 is a schematic view of a process for constructing a real-time environment for monitoring the status of a tool according to the present application;
FIG. 7 is a schematic view of a process for utilizing theoretical coordinate data of a monitoring point and actual coordinate data of the monitoring point according to the present application;
FIG. 8 is a schematic view illustrating a monitoring principle of the present application when the pillar deforms in one direction;
fig. 9 is a schematic view of a tool state real-time monitoring device according to an embodiment of the present application.
The implementation, functional features and advantages of the objectives of the present application will be further explained with reference to the accompanying drawings.
Detailed Description
It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.
In the field of aircraft manufacturing, large aircraft components are supported and positioned by an assembly tool in the structural assembly stage. The finished product is assembled into a component and a part by parts, and whether the space position of a tool to a product positioning point can be continuously and stably maintained in the assembling process is directly related to the assembling quality of the product. Therefore, the positioning state of the tool in the product assembling process can be monitored in real time. At present, a laser tracker is mostly adopted for measuring positioning points of an assembly tool for large parts of an airplane, and whether the state of the tool meets the assembly requirement is judged by comparing space coordinates and theoretical coordinate values of the positioning points and TP points on the measurement tool in the same coordinate system. However, in the product assembling process, the field working condition is complex, the shielding is more, and all assembling activities need to be stopped as far as possible when the laser tracker is used for measurement. Meanwhile, if the laser tracker is adopted to monitor the state of the tool in real time, the monitoring process needs to occupy equipment for several months for a long time, and the monitoring cost is extremely high due to the fact that the value of a single piece of equipment of the laser tracker is over million. To sum up, measurement to big parts of aircraft assembly fixture stops measuring before the product is put on the shelf and the product is put off the shelf after the order is examined at present, can't accomplish the real-time supervision to the frock state among the product assembling process. The development of work such as light tool structure design, product assembly process optimization and the like is greatly limited, and the problems that the tool design rigidity is too high or the local rigidity is insufficient, the local assembly process of the product is unreasonable and the like are caused. Therefore, if a monitoring system with low cost and simple and rapid deployment can be adopted to realize the real-time monitoring of the tool state in the product assembly process, the scheduled inspection link can be eliminated, and the assembly efficiency of the airplane is greatly improved. Meanwhile, the tool structure and the product assembling process can be optimized according to the monitoring data in the product assembling process, and the tool quality and the product assembling quality are further improved. However, currently, the positioning state of the tool in the product assembling process cannot be monitored in real time, so that the assembling quality of the product mounted on the tool is affected.
In order to solve the technical problems, the present application provides a method, an apparatus, a device and a medium for monitoring a tool status in real time, and before introducing a specific technical scheme of the present application, a hardware operating environment related to the scheme of the embodiment of the present application is introduced first.
Referring to fig. 1, fig. 1 is a schematic structural diagram of a computer device in a hardware operating environment according to an embodiment of the present application.
As shown in fig. 1, the computer apparatus may include: a processor 1001, such as a Central Processing Unit (CPU), a communication bus 1002, a user interface 1003, a network interface 1004, and a memory 1005. The communication bus 1002 is used to implement connection communication among these components. The user interface 1003 may include a Display screen (Display), an input unit such as a Keyboard (Keyboard), and the optional user interface 1003 may also include a standard wired interface, a wireless interface. The network interface 1004 may optionally include a standard wired interface, a WIreless interface (e.g., a WIreless-FIdelity (WI-FI) interface). The Memory 1005 may be a Random Access Memory (RAM) Memory, or may be a Non-Volatile Memory (NVM), such as a disk Memory. The memory 1005 may alternatively be a storage device separate from the processor 1001.
Those skilled in the art will appreciate that the configuration shown in FIG. 1 does not constitute a limitation of a computer device and may include more or fewer components than those shown, or some components may be combined, or a different arrangement of components.
As shown in fig. 1, a memory 1005, which is a storage medium, may include therein an operating system, a data storage module, a network communication module, a user interface module, and an electronic program.
In the computer device shown in fig. 1, the network interface 1004 is mainly used for data communication with a network server; the user interface 1003 is mainly used for data interaction with a user; the processor 1001 and the memory 1005 in the computer device of the present invention may be disposed in the computer device, and the computer device calls the tool state real-time monitoring device stored in the memory 1005 through the processor 1001, and executes the tool state real-time monitoring method provided in the embodiment of the present invention.
Referring to fig. 2 to 3, based on the hardware environment of the foregoing embodiment, an embodiment of the present application provides a method for monitoring a tool state in real time, where the method includes:
s10: acquiring theoretical coordinate data and actual coordinate data of monitoring points of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms.
Fig. 4 is a real-time monitoring system of the state of an aircraft assembly fixture used in the present application, in fig. 4, reference numeral 001 denotes an assembly fixture mounting base, reference numeral 002 denotes an assembly fixture column, reference numeral 003 denotes a fixture positioner, reference numeral 004 denotes a laser emitter, reference numeral 005 denotes an equipment rack, reference numeral 006 denotes a high-definition camera, reference numeral 007 denotes a light receiving plate, reference numeral 008 denotes a terminal computer, reference numeral 009 denotes a camera support, and reference numeral 010 denotes a light receiving plate support. In a specific implementation process, the 'tool is not deformed' refers to the state of the tool when a product is not installed on the tool, the 'tool is deformed' refers to the state of the tool when the product is installed on the tool, a monitoring point refers to a point for monitoring the deformation condition of the tool, a laser transmitter can be installed on the monitoring point, the laser transmitter can emit laser, and the laser forms a light spot on the light receiving plate; wherein, connect the tabula rase to install in the relative position of laser emitter, connect tabula rase and laser emitter and all can obtain through prior art.
S11: obtaining an initial light spot image and an actually measured light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of a light spot corresponding to the monitoring point when the tool is deformed.
In the specific implementation process, a laser emitter is installed at a monitoring point according to a conventional mode, when a product is not installed on a tool, the laser emitter emits laser, the laser is irradiated on a light receiving plate to form an initial light spot, and the initial light spot on the light receiving plate is acquired in real time through an industrial camera to obtain an initial light spot image; when the product is installed on a tool, a laser emitter emits laser which is irradiated on a light receiving plate to form an actual measurement light spot, and an industrial camera acquires the actual measurement light spot on the light receiving plate in real time so as to obtain an actual measurement light spot image; the number of the monitoring points can be multiple, so that a plurality of laser transmitters can be installed, and a plurality of laser transmitters can emit a plurality of light spots, so that a plurality of initial light spots and a plurality of actual measurement light spots can be formed on the light receiving plate, and a plurality of initial light spot images and a plurality of actual measurement light spot images can be obtained.
S12: and respectively extracting the central coordinate data of the initial light spot image and the central coordinate data of the actually measured light spot image based on the initial light spot image and the actually measured light spot image.
In a specific implementation process, in order to improve the accuracy of the coordinates of the initial light spot image and the actually measured light spot image, the coordinates of the centers of the initial light spot image and the actually measured light spot image are selected as the coordinates of the initial light spot image and the actually measured light spot image. Specifically, the coordinate values of the center points of the initial light spot image and the measured light spot image can be extracted based on python-OpenCV. In conclusion, the one-to-one correspondence relationship between the light spot image information and the spatial coordinates of the monitored point can be established by combining the coordinates of the central points of the initial light spot image and the actually measured light spot image with the deformation angle value of the tool.
S13: and constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points.
In the specific implementation process, the prediction algorithm of the actual position of the monitoring point is the core for realizing stable, efficient and accurate automatic measurement. It is known that when each monitoring point of the tool is located at a theoretical position (before a product is put on the shelf and assembled) under an airplane design coordinate system (a Cartesian coordinate system), the theoretical coordinate data of the monitoring point of the monitored point is P a When the coordinate value of the center of the corresponding light spot image, namely the coordinate data of the center of the initial light spot image is Q a . Assuming that an equipment rack (a light receiving plate and a camera mounting bracket) is a rigid body, all laser transmitters are stably mounted, and after a product is assembled on a rack and a tool is deformed under stress, the actual coordinate data of a monitoring point of the monitoring point is P b The coordinate data of the center of the actually measured light spot image is Q b As shown in fig. 5. The relation of coordinate values before and after the space displacement of the tool monitoring point is generated due to the deformation, and the relation of a function related to the deformation angle alpha exists between the relation of the coordinate values of the central point of the corresponding light spot image before and after the deformation. Theoretical coordinate data of monitoring pointP a Known as Q a And Q b The coordinate value can be obtained by the light spot image processing software, and alpha can be obtained by P a And P b Calculating space coordinates, and obtaining the actual measurement coordinates P of the monitoring points after the tool is deformed by using the relative relation between the monitoring points before and after deformation and the central points of the corresponding light points b The relative position relationship is as follows:
specifically, the monitoring point position model is obtained through the following relational expression:
P b =R 1 P a +T 1
wherein, P b Representing the actual coordinates of the monitoring point, P a Representing theoretical coordinates of the monitoring point, R 1 Representing the rotation matrix, T, before deformation of the tool 1 Representing a translation matrix before deformation of the tool; wherein, T 1 And R 1 Obtained by step S14.
S14: and constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
Specifically, the light spot position model is obtained by the following relation:
Q b =R 2 Q a +T 2
wherein Q is b Representing the centre coordinates, Q, of the image of the measured spot a Representing the initial spot image center coordinates, R 2 Representing the rotation matrix, T, after deformation of the tool 2 And representing a translation matrix after the tool is deformed.
Specifically, the relationship among the rotation matrix before tool deformation, the translation matrix before tool deformation, the rotation matrix after tool deformation and the translation matrix after tool deformation is obtained through the following relational expression:
Figure BDA0003801362810000101
Figure BDA0003801362810000102
wherein alpha represents the deformation angle of the monitoring point relative to the tool before deformation, and alpha represents x Representing the angle α resolved in the x-direction under the aircraft coordinate system, α y Representing the angle of alpha resolved in the y-direction under the aircraft coordinate system, alpha z The angle of alpha decomposition along the Z direction under an airplane coordinate system is shown, M is the distance between a monitoring point stand column and the intersection line of a light receiving plate and the ground, H is the height of the monitoring stand column, L is the Z-direction difference value of the central coordinate of a first initial light spot image and the theoretical coordinate of a first monitoring point when the monitoring point stand column is at an initial position, K is the displacement value before and after light spot deformation, N is the height value of the central coordinate of a first actually measured light spot image and the ground, theta is the angle between the light receiving plate and the ground, and gamma is the included angle between a laser beam in an initial state and the horizontal plane.
In the specific implementation process, except for alpha, the parameters can be directly obtained by measurement in the prior art, so that the deformation angle alpha of the monitoring point relative to the tool before deformation can be obtained through the parameters; the rotation matrix before tool deformation, the translation matrix before tool deformation, the rotation matrix after tool deformation and the translation matrix after tool deformation can be directly obtained by the prior art.
In the application, theoretical coordinate data of monitoring points and central coordinate data of initial light spot images can be installed in front of a tool through measuring products, actual coordinate data of monitoring points and central coordinate data of actual measurement light spot images are installed behind the tool through measuring the products, then a monitoring point position model and a light spot position model are respectively constructed based on the coordinate data, and then the position change condition of the products installed on the tool can be known in real time through the monitoring point position model and the light spot position model, so that the positioning state of the tool in the product assembling process can be monitored in real time, and further the assembling quality of the products installed on the tool can be improved according to the positioning state of the tool.
In some embodiments, as shown in fig. 6, before the step of obtaining theoretical coordinate data of a monitoring point and actual coordinate data of the monitoring point, the method further includes;
s20: identifying a deformation point on the tool based on a tool finite element analysis model and a product assembling process; wherein the deformation points comprise monitoring points.
In the specific implementation process, the tooling finite element analysis model refers to a model established by using a finite element analysis method, the product assembly process refers to the product assembly process, and specifically, both the tooling finite element analysis model and the product assembly process can be obtained by the prior art. The deformation point refers to a position which is easy to deform on the tool, specifically, the split type stand column of the tool is easy to deform based on a finite element simulation calculation model, the characteristics of the tool and a product assembling process, the deformation is larger after the stand column is stressed, the monitoring point is arranged at the top of each stand column, and the initial coordinate value of each monitoring point is input into the monitoring software.
S21: based on the monitoring points, obtaining a light spot emitting area and a light spot receiving area; wherein the light spot emitting area is used for emitting a light spot, and the light spot receiving area is used for receiving the light spot.
In the specific implementation process, the light spot emitting area refers to an area for mounting the laser emitter, and the light spot receiving area refers to a mounting area of the light receiving plate. Specifically, install laser emitter on each monitoring point, erect equipment rack installation and connect the worn-out fur, fixed industry camera before this station navigation, adjust laser emitter initial angle simultaneously, guarantee that all measuring point light beams can evenly strike on connecing the worn-out fur, then lock the laser emitter angle.
In this embodiment, before the step of obtaining the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point, a real-time tool state monitoring environment is also constructed. Specifically, the laser tracker is used for completing installation and debugging of the assembly tool, and the actual measurement positions of the positioning points are ensured to meet the assembly requirements. Identifying key monitoring points which are easy to deform on a tool framework according to a tool finite element analysis model and a product assembling process, mounting laser transmitters on the monitoring points, mounting an equipment rack for fixing an industrial camera and a light receiving plate on the periphery of an assembling station to be monitored, and ensuring that light beams emitted by the laser transmitters on each monitoring point position can strike the same light receiving plate to form light spots at equal and non-interfering intervals, namely, a plurality of light spots are received in a light spot receiving area at the same time and are not overlapped; therefore, more accurate light spots can be obtained, and more accurate theoretical coordinate data of the monitoring points, actual coordinate data of the monitoring points, initial light spot images and actual measurement light spot images of the monitoring points can be obtained.
In some embodiments, as shown in fig. 7, before the step of obtaining the initial spot image and the measured spot image, the method further includes:
s30: and setting a tolerance threshold value, wherein the tolerance threshold value is used for representing whether the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is larger than an allowable range.
In a specific implementation, the tolerance threshold may be set by a worker according to the relevant requirements and experience.
S31: obtaining the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point;
s32: and sending alarm information under the condition that the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold value.
In the specific implementation process, judging whether the spatial deformation of the monitoring point exceeds the permitted tolerance range; when the position of the monitoring point is out of tolerance, namely the difference value between theoretical coordinate data of the monitoring point and actual coordinate data of the monitoring point is larger than a tolerance threshold value, the system sends alarm information and prompts the out-of-tolerance point, and if the position of the monitoring point is not out of tolerance, the process is repeated until the product finishes assembly activity, namely an abnormal monitoring point is obtained based on the alarm information; and the abnormal monitoring point is a monitoring point of which the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold.
In this embodiment, whether the difference between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is reasonable can be judged quickly and accurately by setting the tolerance threshold, so that when the product is judged to be installed on the tool more quickly and accurately, the deformation condition of the tool is suitable, and the installation position of the product on the tool can be adjusted more timely.
In conclusion, the monitoring method is applied to a certain flexible assembly positioning tool, the flexible assembly positioning tool mainly comprises distributed flat columns and positioners, the columns are firmly connected with the ground through pins and bolts and cannot be displaced, but because the columns are of a flat structure, the columns can be subjected to lateral bending deformation by lateral force (course direction) generated in the product assembly process, and the positioning precision of positioning points of the tool is further influenced, so that the deformation condition of the columns and the deformation condition of the positioners need to be monitored in real time in the product assembly process, the real-time monitoring of the lateral deformation condition of the columns can be realized by using the monitoring method, in the monitoring project, only the condition that the columns are subjected to the lateral force to generate integral deformation is concerned, and the default columns are absolute rigid bodies.
The specific real-time mode is as follows:
step 1: the installation and debugging of the flexible assembly positioning system are completed through a laser tracker according to a drawing;
step 2: the split type stand column of the tool is easy to deform based on a finite element simulation calculation model, the characteristics of the tool and the product assembly process, the deformation is larger after the split type stand column is stressed closer to the top end of the stand column, so that the monitoring points are arranged at the top of each stand column, and the initial coordinate values of the monitoring points are input into monitoring software;
and step 3: installing laser transmitters on each monitoring point, erecting equipment racks on the station before navigation, installing a light receiving plate and fixing an industrial camera, adjusting the initial angle of each laser transmitter simultaneously, ensuring that light beams of all measuring points can uniformly strike the light receiving plate, and then locking the angle of each laser transmitter;
and 4, step 4: an industrial camera captures an image of a light spot group in an initial state of a tool before a product is put on a shelf, and image processing software acquires coordinate values of a central point of each light spot image;
and 5: setting a permitted tolerance zone of deformation of each monitoring point in monitoring software;
step 6: putting the product on shelf, starting assembly activity, starting real-time monitoring by a state monitoring system, and acquiring a light spot group image every 1 min;
and 7: acquiring the coordinates of the central point of each light spot image in the light spot group image in real time through image processing software, and acquiring the deflection angle alpha of the monitored point based on the following formula so as to further acquire the space deformation generated by the monitored point;
Figure BDA0003801362810000131
as shown in fig. 8, M is the distance (known) from the intersection line of the light receiving plate and the ground of the monitored point, H is the height (known) of the monitored column, and L is Q when the initial position is set a1 And P a1 K is the displacement value before and after the light spot deformation (known), and N is Q b1 The height from the ground is known, theta is the angle between the light receiving plate and the ground is known, and gamma is the angle between the laser beam and the horizontal plane in the initial state is known.
And 8: judging whether the space deformation of the monitoring point exceeds the allowable tolerance range;
and step 9: and if the position of the monitoring point is out of tolerance, the system gives an alarm and prompts the out-of-tolerance point, and if the position of the monitoring point is not out of tolerance, the process is repeatedly circulated until the product finishes assembly activities.
Therefore, the tool state can be monitored in real time in the product assembling process, the scheduled inspection link can be eliminated, the airplane assembling efficiency is greatly improved, and meanwhile, the tool structure and the product assembling process can be optimized according to the monitoring data in the product assembling process, so that the tool quality and the product assembling quality are improved.
In another embodiment, as shown in fig. 9, based on the same inventive concept as the previous embodiment, an embodiment of the present application further provides a warehouse logistics distribution path planning apparatus, including:
the acquisition module is used for acquiring theoretical coordinate data and actual coordinate data of monitoring points of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms;
the acquisition module is used for acquiring an initial light spot image and an actual measurement light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed;
the extraction module is used for respectively extracting the central coordinate data of the initial light spot image and the central coordinate data of the actually measured light spot image based on the initial light spot image and the actually measured light spot image;
the first construction module is used for constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points;
and the second construction module is used for constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
It should be noted that, in this embodiment, each module in the device for monitoring a tool state in real time corresponds to each step in the method for monitoring a tool state in real time in the foregoing embodiment one by one, and therefore, the specific implementation manner and the achieved technical effect of this embodiment may refer to the implementation manner of the method for monitoring a tool state in real time, which is not described herein again.
Furthermore, in an embodiment, the present application also provides a computer device, which includes a processor, a memory and a computer program stored in the memory, and when the computer program is executed by the processor, the method in the foregoing embodiment is implemented.
Furthermore, in an embodiment, the present application further provides a computer storage medium having a computer program stored thereon, where the computer program is executed by a processor to implement the method in the foregoing embodiment.
In some embodiments, the computer-readable storage medium may be memory such as FRAM, ROM, PROM, EPROM, EEPROM, flash, magnetic surface memory, optical disk, or CD-ROM; or may be various devices including one or any combination of the above memories. The computer may be a variety of computing devices including intelligent terminals and servers.
In some embodiments, executable instructions may be written in any form of programming language (including compiled or interpreted languages), in the form of programs, software modules, scripts or code, and may be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.
By way of example, executable instructions may, but need not, correspond to files in a file system, and may be stored in a portion of a file that holds other programs or data, such as in one or more scripts in a hypertext Markup Language (HTML) document, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code).
As an example, executable instructions may be deployed to be executed on one computing device or on multiple computing devices located at one site or distributed across multiple sites and interconnected by a communication network.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or system. Without further limitation, an element defined by the phrases "comprising one of 8230; \8230;" 8230; "does not exclude the presence of additional like elements in a process, method, article, or system that comprises the element.
The above-mentioned serial numbers of the embodiments of the present application are merely for description and do not represent the merits of the embodiments.
Through the above description of the embodiments, those skilled in the art will clearly understand that the method of the above embodiments can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware, but in many cases, the former is a better implementation manner. Based on such understanding, the technical solutions of the present application may be embodied in the form of a software product, which is stored in a storage medium (e.g., a rom/ram, a magnetic disk, an optical disk) and includes instructions for enabling a multimedia terminal (e.g., a mobile phone, a computer, a television receiver, or a network device) to execute the method according to the embodiments of the present application.
The above description is only a preferred embodiment of the present application, and not intended to limit the scope of the present application, and all modifications of equivalent structures and equivalent processes, which are made by the contents of the specification and the drawings of the present application, or which are directly or indirectly applied to other related technical fields, are included in the scope of the present application.

Claims (10)

1. A real-time tool state monitoring method is characterized by comprising the following steps:
acquiring theoretical coordinate data and actual coordinate data of monitoring points of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms;
obtaining an initial light spot image and an actually measured light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed;
respectively extracting initial light spot image center coordinate data and actually measured light spot image center coordinate data based on the initial light spot image and the actually measured light spot image;
constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points;
and constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
2. The tool state real-time monitoring method according to claim 1, wherein before the step of obtaining theoretical coordinate data of monitoring points and actual coordinate data of the monitoring points, the method further comprises the steps of;
identifying a deformation point on the tool based on a tool finite element analysis model and a product assembling process; wherein the deformation points comprise monitoring points;
based on the monitoring points, obtaining a light spot emitting area and a light spot receiving area; wherein the light spot emitting area is used for emitting a light spot, and the light spot receiving area is used for receiving the light spot.
3. The tool state real-time monitoring method according to claim 2, wherein a plurality of light spots are received in the light spot receiving area simultaneously, and the plurality of light spots are not overlapped with each other.
4. The tool state real-time monitoring method of claim 1, wherein before the step of obtaining the initial spot image and the measured spot image, the method further comprises:
setting a tolerance threshold value, wherein the tolerance threshold value is used for representing whether the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is larger than an allowable range;
obtaining the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point;
and sending alarm information under the condition that the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold value.
5. The tool state real-time monitoring method according to claim 4, wherein after the step of sending alarm information under the condition that the difference between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold, the method further comprises the following steps:
acquiring an abnormal monitoring point based on the alarm information; and the abnormal monitoring point is a monitoring point of which the difference value between the theoretical coordinate data of the monitoring point and the actual coordinate data of the monitoring point is greater than the tolerance threshold value.
6. The tool state real-time monitoring method according to claim 1, wherein the construction of the monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points comprises:
obtaining a monitoring point position model through the following relation:
P b =R 1 P a +T 1
wherein, P b Representing the actual coordinates of the monitoring point, P a Representing theoretical coordinates of the monitoring point, R 1 Representing the rotation matrix, T, before deformation of the tool 1 Representing a translation matrix before deformation of the tool;
the method for constructing the light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data comprises the following steps:
the spot position model is obtained by the following relation:
Q b =R 2 Q a +T 2
wherein Q is b Representing the centre coordinates, Q, of the image of the measured spot a Representing the initial spot image center coordinates, R 2 Representing the rotation matrix, T, after deformation of the tool 2 And representing a translation matrix after the tool is deformed.
7. The tool state real-time monitoring method according to claim 6, wherein the relationship among the rotation matrix before tool deformation, the translation matrix before tool deformation, the rotation matrix after tool deformation and the translation matrix after tool deformation is obtained through the following relational expressions:
Figure FDA0003801362800000031
Figure FDA0003801362800000032
wherein alpha represents the deformation angle of the monitoring point relative to the tool before deformation, and alpha represents x Representing the angle α resolved in the x-direction under the aircraft coordinate system, α y Representing the angle of alpha resolved in the y-direction under the aircraft coordinate system, alpha z The angle of alpha decomposition along the Z direction under an airplane coordinate system is shown, M is the distance between a monitoring point stand column and the intersection line of a light receiving plate and the ground, H is the height of the monitoring stand column, L is the Z-direction difference value of the central coordinate of a first initial light spot image and the theoretical coordinate of a first monitoring point when the monitoring point stand column is at an initial position, K is the displacement value before and after light spot deformation, N is the height value of the central coordinate of a first actually measured light spot image and the ground, theta is the angle between the light receiving plate and the ground, and gamma is the included angle between a laser beam in an initial state and the horizontal plane.
8. The utility model provides a frock state real-time supervision device which characterized in that, the device includes:
the acquisition module is used for acquiring theoretical coordinate data and actual coordinate data of the monitoring points; the theoretical coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool is not deformed; the actual coordinate data of the monitoring points are coordinate data of the monitoring points on the tool when the tool deforms;
the acquisition module is used for acquiring an initial light spot image and an actual measurement light spot image; the initial light spot image is an image of a light spot corresponding to the monitoring point when the tool is not deformed, and the actually measured light spot image is an image of the light spot corresponding to the monitoring point when the tool is deformed;
the extraction module is used for respectively extracting the central coordinate data of the initial light spot image and the central coordinate data of the actually measured light spot image based on the initial light spot image and the actually measured light spot image;
the first construction module is used for constructing a monitoring point position model based on the theoretical coordinate data of the monitoring points and the actual coordinate data of the monitoring points;
and the second construction module is used for constructing a light spot position model based on the initial light spot image center coordinate data and the actually measured light spot image center coordinate data.
9. A computer device, characterized in that it comprises a memory in which a computer program is stored and a processor which executes said computer program implementing the method according to any one of claims 1-7.
10. A computer-readable storage medium, having stored thereon a computer program, which, when executed by a processor, performs the method of any one of claims 1-7.
CN202210991152.7A 2022-08-17 2022-08-17 Method, device, equipment and medium for monitoring tool state in real time Pending CN115388769A (en)

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