CN115389519A - Crankshaft manufacturing surface detection and analysis method based on industrial camera - Google Patents
Crankshaft manufacturing surface detection and analysis method based on industrial camera Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8854—Grading and classifying of flaws
- G01N2021/8874—Taking dimensions of defect into account
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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Abstract
The invention relates to the technical field of crankshaft manufacturing surface detection and analysis, and particularly discloses a crankshaft manufacturing surface detection and analysis method based on an industrial camera, wherein the method comprises the steps of detecting and analyzing the number of depressions, the number of scratches, the total volume of the depressions and the total length of the scratches corresponding to each specified crankshaft, detecting the depth defects of each specified crankshaft through an electromagnetic flaw detector and a contourgraph, and further comprehensively analyzing to obtain the manufacturing quality evaluation coefficient corresponding to each specified crankshaft, so that on one hand, the detection strength of the depth defects corresponding to each specified crankshaft is enhanced to a great extent, and the basis of an analysis result is greatly improved; on the other hand, the apparent defects and the depth defects corresponding to the specified crankshafts are comprehensively analyzed, the limitation of the current manufacturing quality detection and analysis corresponding to the specified crankshafts is broken, and the accuracy and the reliability of the crankshaft manufacturing quality analysis result are improved to a great extent.
Description
Technical Field
The invention relates to the technical field of crankshaft manufacturing surface detection and analysis, in particular to a crankshaft manufacturing surface detection and analysis method based on an industrial camera.
Background
With the development of the science and technology society and the steady promotion of the living standard of people, more and more families can not drive the automobile, the automobile is convenient for people to go out, and the safety problem of the quality of parts is not negligible. As is known, the engine is one of the important parts of the automobile and the crankshaft is one of the most important parts of the engine, and in view of this, the importance of detecting and analyzing the manufacturing quality of the crankshaft is self evident.
At present, the detection and analysis of the manufacturing surface of the crankshaft mainly comprises the detection and analysis of the apparent mass of the crankshaft by a magnetic flaw detection method, which easily results in low accuracy of the analysis result, and is specifically embodied in the following aspects: 1. the defects on the surface of the crankshaft have certain influence on the surface quality and the service performance of the crankshaft. When the present manufacturing quality to the bent axle detects and the analysis, mainly through carrying out apparent defect detection and analysis to the bent axle to carry out the auxiliary detection analysis through the crack of magnetic flaw detection method to the bent axle, neglected and carried out the detection analysis to the burr of bent axle, reduced the detection dynamics, make the analysis result foundation not strong, still can not effectively promote the accurate nature and the reliability of bent axle manufacturing quality analysis result simultaneously.
2. The conformity of the crankshaft manufacturing dimensions is the most fundamental requirement for measuring the crankshaft manufacturing quality. At present, the shape outline and the hole site size of the crankshaft are mainly detected and analyzed, the circumference and the hole site position of the crankshaft are not detected and analyzed, the uneven quality of the crankshaft is easy to occur, the use experience of a user is reduced, the market reputation of a crankshaft manufacturer is influenced, and the contradiction between the user and the crankshaft manufacturer is caused.
Disclosure of Invention
In order to overcome the defects in the background art, the embodiment of the invention provides a crankshaft manufacturing surface detection and analysis method based on an industrial camera, which can effectively solve the problems related to the background art.
The purpose of the invention can be realized by the following technical scheme: a crankshaft manufacturing surface detection and analysis method based on an industrial camera comprises the following steps: a1, crankshaft three-dimensional model construction: counting the number of the crankshafts to be detected, numbering the crankshafts to be detected in sequence according to a preset sequence to be 1,2, 1, i, n, simultaneously collecting apparent images of the crankshafts to be detected through an industrial camera, and constructing a three-dimensional model corresponding to the crankshafts to be detected.
A2, crankshaft three-dimensional model contour matching analysis: and carrying out profile comparison analysis on the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft to obtain the coincidence index of the three-dimensional models corresponding to the crankshafts to be detected.
A3, crankshaft apparent image information matching analysis: and comparing and analyzing the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft to obtain the apparent image matching index corresponding to each crankshaft to be detected.
A4, crankshaft apparent state analysis and processing: comprehensively analyzing the three-dimensional model coincidence index and the apparent image matching index corresponding to each crankshaft to be detected to obtain the apparent state corresponding to each crankshaft to be detected, and screening the appointed crankshafts according to the apparent state corresponding to each crankshaft to be detected to obtain each appointed crankshaft.
A5, analyzing apparent defects of the specified crankshaft: and analyzing the apparent image corresponding to each appointed crankshaft to obtain an apparent defect parameter set corresponding to each appointed crankshaft, and further analyzing the apparent defect index corresponding to each appointed crankshaft.
A6, detecting and analyzing depth defects of the specified crankshaft: and carrying out depth defect detection on each specified crankshaft to obtain a depth defect parameter set corresponding to each specified crankshaft, and analyzing a depth defect index corresponding to each specified crankshaft.
A7, specified crankshaft manufacturing quality analysis: and comprehensively analyzing the apparent defect index and the depth defect index corresponding to each specified crankshaft to obtain the manufacturing quality evaluation coefficient corresponding to each specified crankshaft.
A8, analyzing and displaying the specified crankshaft grade: and analyzing the grade corresponding to each appointed crankshaft, and displaying correspondingly.
In a preferred embodiment of the present invention, in the step A2, the profile comparison analysis is performed on the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft, and the specific comparison analysis process is as follows: carrying out volume coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapping part of the volume corresponding to each crankshaft to be detected and the standard volume corresponding to the standard crankshaft, marking as the overlapping volume and marking as the overlapping volume
I denotes the number of the respective crankshaft to be detected, i =1, 2.
Carrying out total circumference coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapping circumference of the total circumference corresponding to each crankshaft to be detected and the standard total circumference corresponding to the standard crankshaft, marking as the overlapping circumference and marking as the overlapping circumference
。
Extracting three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the crankshafts to be detected, extracting standard three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the set standard crankshafts, and then overlapping the three-dimensional images of the crankshafts to be detected corresponding to all directions with the corresponding standard three-dimensional images to obtain overlapping areas and overlapping circumferences of the crankshafts to be detected corresponding to all directions, which are respectively marked as
And
f denotes the number of each orientation, and f =1, 2.
According to the formula
Calculating the three-dimensional model coincidence index corresponding to each crankshaft to be detected,
expressed as the three-dimensional model coincidence index corresponding to the ith crankshaft to be detected, e is expressed as a natural constant,
respectively expressed as a standard volume and a standard total circumference corresponding to a set standard crankshaft,
respectively expressed as a standard area and a standard perimeter corresponding to the f-th position on the set standard crankshaft,
and respectively representing the weight factors corresponding to the set overlapping volume, the set overlapping perimeter, the set overlapping area and the set overlapping perimeter.
In a preferred embodiment of the present invention, in the step A3, the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft are compared and analyzed, and a specific comparison and analysis process is as follows: the number of the hole sites is extracted from the apparent image corresponding to each crankshaft to be detected, the hole sites on each crankshaft to be detected are sequentially numbered to be 1,2, a.
The shape outline corresponding to each hole position on each crankshaft to be detected is superposed and compared with the shape outline of the corresponding standard hole position to obtain the superposed area of each hole position on each crankshaft to be detected and the shape outline of the corresponding standard hole position, and the superposed area is marked as the hole position superposed area and marked as the standard hole position superposed area
R denotes the number of each hole site, r =1,2.
Acquiring the distance between the position corresponding to each hole position on each crankshaft to be detected and the standard position of the standard hole position corresponding to the position, marking the distance as the offset distance and marking the distance as the standard position
。
Recording the corresponding depth of each hole on each crankshaft to be detected as
Further according to the formula
Calculate each waitDetecting an apparent image matching index corresponding to the crankshaft,
expressed as the apparent image matching index corresponding to the ith crankshaft to be detected,
expressed as the number of hole sites corresponding to the ith crankshaft to be detected,
respectively expressed as the standard area and the standard depth of the position corresponding to the r-th hole position on the ith crankshaft to be detected,
expressed as the number of standard hole sites corresponding to a standard crankshaft,
indicated as the set allowed offset distance,
respectively expressed as weight factors corresponding to the preset hole site coincidence area, the number of hole sites, the depth and the offset distance.
In a preferred embodiment of the present invention, in the step A4, the designated crankshaft is screened according to the corresponding apparent state of each crankshaft to be detected, and the specific screening method is as follows: according to the formula
Calculating the apparent state evaluation index corresponding to each crankshaft to be detected,
expressed as an apparent state evaluation index corresponding to the ith crankshaft to be detected,
respectively expressed as a set three-dimensional model coincidence index and an appearance mapAnd the image matching index corresponds to a correction factor.
Comparing the apparent state evaluation index corresponding to each crankshaft to be detected with a set apparent state evaluation index threshold, if the apparent state evaluation index corresponding to a certain crankshaft to be detected is larger than the apparent state evaluation index threshold, judging that the apparent state corresponding to the crankshaft to be detected is qualified, marking the crankshaft to be detected as a designated crankshaft, otherwise, judging that the apparent state corresponding to the crankshaft to be detected is abnormal, and rejecting the crankshaft to be detected.
The number of the designated crankshafts is counted, and the designated crankshafts are numbered as 1,2, j, m in sequence according to a preset sequence.
In a preferred embodiment of the present invention, the step A5 analyzes the apparent image corresponding to each designated crankshaft in a specific analysis manner: extracting an apparent image corresponding to each appointed crankshaft from the apparent image corresponding to each crankshaft to be detected based on the number of each appointed crankshaft, and further extracting the number of depressions, the number of scratches, the total volume of depressions and the total length of scratches existing on each appointed crankshaft from the apparent image corresponding to each appointed crankshaft, wherein the total volume of depressions and the total length of scratches are respectively recorded as
And
j denotes the number of each designated crankshaft, and j =1, 2.
And constructing an apparent defect parameter set corresponding to each specified crankshaft according to the number of the depressions, the number of the scratches, the total volume of the depressions and the total length of the scratches corresponding to each specified crankshaft.
In a preferred embodiment of the present invention, the specific calculation formula of the apparent defect index corresponding to each specified crankshaft in the step A5 is
，
Expressed as apparent absence corresponding to the j-th designated crankshaftThe number of the sink marks is,
respectively expressed as a set number of allowable depressions, a number of allowable scratches, a total volume of allowable depressions, a total length of allowable scratches,
respectively representing the weight factors corresponding to the set number of the recesses, the number of the scratches, the total volume of the recesses and the total length of the scratches.
In a preferred embodiment of the present invention, the depth defect detection is performed on each designated crankshaft in step A6, and the specific detection method is as follows: detecting the crack lines of each specified crankshaft by an electromagnetic flaw detector to obtain the number of the crack lines, the total length of the crack lines and the distribution density of the crack lines on each specified crankshaft, and recording the number, the total length and the distribution density of the crack lines as
And
。
carrying out burr profile detection on each appointed crankshaft through a profiler to obtain the number of burrs, the distribution area of the burrs and the highest burr height on each appointed crankshaft, and recording the number of the burrs, the distribution area of the burrs and the highest burr height respectively
And
。
and constructing a depth defect parameter set corresponding to each appointed crankshaft by the number of crack lines, the total length of the crack lines, the distribution density of the crack lines, the number of burrs, the distribution area of the burrs and the highest burr height on each appointed crankshaft.
In a preferred embodiment of the present invention, the depth defect index corresponding to each specified crankshaft is analyzed in the step A6, and the specific analysis process is as follows: according to the formula
Calculating the crack influence index corresponding to each appointed crankshaft,
expressed as crack impact index for the jth designated crankshaft,
respectively expressed as the set number of allowable crack lines, the total length of the allowable crack lines and the distribution concentration of the allowable crack lines,
and respectively representing the influence factors corresponding to the set number of the crack lines, the total length of the crack lines and the distribution density of the crack lines.
According to the formula
Calculating the burr influence index corresponding to each appointed crankshaft,
expressed as the glitch impact index corresponding to the jth designated crankshaft,
respectively expressed as the set allowable burr quantity, the allowable burr distribution area and the allowable maximum burr height,
respectively expressed as the impact factors corresponding to the set burr quantity, burr distribution area and highest burr height.
According to the formula
Calculating the depth defect index corresponding to each appointed crankshaft,
expressed as the depth defect index corresponding to the jth specified crankshaft,
and respectively representing the weight factors corresponding to the set crack influence index and burr influence index.
In a preferred embodiment of the present invention, the manufacturing quality evaluation coefficient corresponding to each specified crankshaft in the step A7 is calculated by the following formula
，
Expressed as a manufacturing quality evaluation coefficient corresponding to the jth specified crankshaft,
the values are expressed as coefficient factors corresponding to the set apparent defect index and depth defect index, respectively.
In a preferred embodiment of the present invention, the step A8 analyzes the grade corresponding to each designated crankshaft in a specific analysis manner: and comparing the manufacturing quality evaluation coefficient corresponding to each designated crankshaft with the manufacturing quality evaluation coefficient threshold corresponding to each set grade to obtain the grade corresponding to each designated crankshaft.
Compared with the prior art, the embodiment of the invention has at least the following advantages or beneficial effects: 1. according to the method, the appearance images of the crankshafts to be detected are collected through the industrial camera, the three-dimensional models corresponding to the crankshafts to be detected are constructed, and meanwhile, the three-dimensional model coincidence indexes and the appearance image matching indexes corresponding to the crankshafts to be detected are comprehensively analyzed, so that on one hand, the strength of detection and analysis of the apparent states of the crankshafts is improved, the multi-dimensional analysis of the apparent states of the crankshafts is realized, the objectivity, the accuracy and the reliability of analysis results are guaranteed, and the persuasion of the apparent states of the crankshafts is improved; on one hand, the designated crankshafts are screened out from the crankshafts to be detected according to the apparent state evaluation indexes corresponding to the crankshafts to be detected, and then the quality of the designated crankshafts is evaluated, so that the problem of abnormal manufacturing quality evaluation caused by the fact that the sizes of the crankshafts to be detected do not meet the specifications is solved, and the reliability and the scientificity of detection and analysis results are improved to a great extent; on the other hand, the three-dimensional model coincidence index and the apparent image matching index corresponding to each crankshaft to be detected are analyzed, so that the limitation of an analysis result is effectively avoided, the problem that the three-dimensional model cannot detect the position conformity of the crankshaft is solved, and the persuasion of the apparent state evaluation index of the crankshaft to be detected is improved.
2. According to the method, the number of the depressions, the number of scratches, the total volume of the depressions and the total length of the scratches corresponding to each specified crankshaft are detected and analyzed, meanwhile, the depth defect detection is carried out on each specified crankshaft through the electromagnetic flaw detector and the contourgraph, and then the manufacturing quality evaluation coefficient corresponding to each specified crankshaft is obtained through comprehensive analysis, so that on one hand, the defects of the current crankshaft burr detection and analysis are effectively overcome, the detection strength of the depth defects corresponding to each specified crankshaft is enhanced to a great extent, and the foundation of the analysis result is greatly improved; on the other hand, the appearance defects and the depth defects corresponding to the specified crankshafts are comprehensively analyzed, the limitation of the current manufacturing quality detection and analysis corresponding to the specified crankshafts is broken, and the accuracy and the reliability of the crankshaft manufacturing quality analysis result are improved to a great extent.
3. The shape contour, the depth and the position corresponding to each hole site in each crankshaft to be detected are detected and analyzed to obtain the apparent image matching index corresponding to each crankshaft to be detected, the defects of detecting and analyzing the perimeter and the position of the hole site of the crankshaft at present are overcome, the condition that the quality of the crankshaft is uneven is avoided to a great extent, the use experience of a purchasing user is effectively improved, the market reputation of a crankshaft manufacturer is further ensured, and the contradiction between the purchasing user and the crankshaft manufacturer is effectively avoided.
Drawings
The invention is further illustrated by means of the attached drawings, but the embodiments in the drawings do not constitute any limitation to the invention, and for a person skilled in the art, other drawings can be obtained on the basis of the following drawings without inventive effort.
FIG. 1 is a flow chart illustrating the steps of the method of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the invention provides a crankshaft manufacturing surface detection and analysis method based on an industrial camera, comprising the following steps: a1, crankshaft three-dimensional model construction: counting the number of the crankshafts to be detected, and numbering the crankshafts to be detected in sequence according to a preset sequence
And meanwhile, collecting the apparent image of each crankshaft to be detected through an industrial camera, and constructing a three-dimensional model corresponding to each crankshaft to be detected.
A2, crankshaft three-dimensional model contour matching analysis: and carrying out contour comparison analysis on the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft to obtain the three-dimensional model coincidence index corresponding to each crankshaft to be detected.
In a preferred embodiment of the present invention, in the step A2, the profile comparison analysis is performed on the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft, and the specific comparison analysis process is as follows: carrying out volume coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapping part of the volume corresponding to each crankshaft to be detected and the standard volume corresponding to the standard crankshaft, recording as the overlapping volume, and marking as the overlapping volume
I denotes the number of the respective crankshaft to be detected, i =1, 2.
Carrying out total circumference coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapped circumference of the total circumference corresponding to each crankshaft to be detected and the standard total circumference corresponding to the standard crankshaft, marking as the overlapped circumference and marking as the overlapped circumference
。
Extracting three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the crankshafts to be detected, extracting standard three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the set standard crankshafts, and then overlapping the three-dimensional images of the crankshafts to be detected corresponding to all directions with the corresponding standard three-dimensional images to obtain overlapping areas and overlapping circumferences of the crankshafts to be detected corresponding to all directions, which are respectively marked as
And
f denotes the number of each orientation, and f =1,2.
According to the formula
Calculating the three-dimensional model coincidence index corresponding to each crankshaft to be detected,
expressed as the three-dimensional model coincidence index corresponding to the ith crankshaft to be detected, and e is expressed as a natural constant,
respectively expressed as the standard volume and the standard total perimeter corresponding to the set standard crankshaft,
respectively expressed as a standard area and a standard perimeter corresponding to the f-th position on the set standard crankshaft,
and respectively representing the weight factors corresponding to the set overlapping volume, the overlapping perimeter, the overlapping area and the overlapping perimeter.
It should be noted that the three-dimensional image of each crankshaft to be detected corresponding to each direction specifically includes: and each crankshaft to be detected is correspondingly set with a front three-dimensional image, a rear three-dimensional image, a left three-dimensional image, a right three-dimensional image, an upper three-dimensional image and a bottom three-dimensional image.
In a specific embodiment, the coincidence area and the coincidence perimeter of each crankshaft to be detected corresponding to each direction are detected and analyzed, so that the three-dimensional model coincidence index scientificity and rationality corresponding to each crankshaft to be detected are improved to a great extent, and the comprehensiveness of analysis dimensionality is increased.
A3, crankshaft apparent image information matching analysis: and comparing and analyzing the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft to obtain the apparent image matching index corresponding to each crankshaft to be detected.
In a preferred embodiment of the present invention, in the step A3, the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft are compared and analyzed, and a specific comparison and analysis process is as follows: the number of the hole sites is extracted from the apparent image corresponding to each crankshaft to be detected, the hole sites on each crankshaft to be detected are sequentially numbered to be 1,2, a.
The shape outline corresponding to each hole position on each crankshaft to be detected is superposed and compared with the shape outline of the corresponding standard hole position to obtain the superposed area of each hole position on each crankshaft to be detected and the shape outline of the corresponding standard hole position, and the superposed area is marked as the hole position superposed area and marked as the standard hole position superposed area
R denotes the number of each hole site, r =1, 2.
Acquiring the distance between the position corresponding to each hole position on each crankshaft to be detected and the standard position of the standard hole position corresponding to the position, marking the distance as the offset distance and marking the distance as the standard position
。
Recording the depth corresponding to each hole position on each crankshaft to be detected
Further according to the formula
Calculating the apparent image matching index corresponding to each crankshaft to be detected,
expressed as the apparent image matching index corresponding to the ith crankshaft to be detected,
expressed as the number of hole sites corresponding to the ith crankshaft to be detected,
respectively expressed as the standard area and the standard depth of the position corresponding to the r-th hole position on the ith crankshaft to be detected,
expressed as the number of standard hole sites corresponding to a standard crankshaft,
indicated as the set allowed offset distance,
individual watchShowing the weight factors corresponding to the preset hole site coincidence area, the hole site number, the depth and the offset distance.
In a specific embodiment, the shape profile, the depth and the position corresponding to each hole site in each crankshaft to be detected are detected and analyzed to obtain the apparent image matching index corresponding to each crankshaft to be detected, the defects of detecting and analyzing the circumference and the position of the hole site of the crankshaft at present are overcome, the condition that the quality of the crankshaft is uneven is avoided to a great extent, the use experience of a purchasing user is effectively improved, the market reputation of a crankshaft manufacturer is further ensured, and the contradiction between the purchasing user and the crankshaft manufacturer is effectively avoided.
A4, crankshaft apparent state analysis and processing: comprehensively analyzing the three-dimensional model coincidence index and the apparent image matching index corresponding to each crankshaft to be detected to obtain the apparent state corresponding to each crankshaft to be detected, and screening the appointed crankshafts according to the apparent state corresponding to each crankshaft to be detected to obtain each appointed crankshaft.
In a preferred embodiment of the present invention, in the step A4, the designated crankshaft is screened according to the corresponding apparent state of each crankshaft to be detected, and the specific screening method is as follows: according to the formula
Calculating the apparent state evaluation index corresponding to each crankshaft to be detected,
expressed as an apparent state evaluation index corresponding to the ith crankshaft to be detected,
and respectively representing the correction factors corresponding to the set three-dimensional model registration index and the set apparent image matching index.
Comparing the apparent state evaluation index corresponding to each crankshaft to be detected with a set apparent state evaluation index threshold, if the apparent state evaluation index corresponding to a certain crankshaft to be detected is larger than the apparent state evaluation index threshold, judging that the apparent state corresponding to the crankshaft to be detected is qualified, marking the crankshaft to be detected as a designated crankshaft, otherwise, judging that the apparent state corresponding to the crankshaft to be detected is abnormal, and rejecting the crankshaft to be detected.
The number of the designated crankshafts is counted, and the designated crankshafts are numbered as 1,2, j, m in sequence according to a preset sequence.
In a specific embodiment, the method acquires the apparent images of the crankshafts to be detected through the industrial camera, constructs the three-dimensional models corresponding to the crankshafts to be detected, and comprehensively analyzes the three-dimensional model coincidence indexes and the apparent image matching indexes corresponding to the crankshafts to be detected, so that on one hand, the strength of detection and analysis of the apparent states of the crankshafts is improved, the multi-dimensional analysis of the apparent states of the crankshafts is realized, the objectivity, the accuracy and the reliability of analysis results are guaranteed, and the persuasion of the apparent states of the crankshafts is improved; on one hand, the designated crankshafts are screened out from the crankshafts to be detected according to the apparent state evaluation indexes corresponding to the crankshafts to be detected, and then the quality of the designated crankshafts is evaluated, so that the problem of abnormal manufacturing quality evaluation caused by the fact that the sizes of the crankshafts to be detected do not meet the specifications is solved, and the reliability and the scientificity of detection and analysis results are improved to a great extent; on the other hand, the three-dimensional model coincidence index and the apparent image matching index corresponding to each crankshaft to be detected are analyzed, so that the limitation of an analysis result is effectively avoided, the problem that the three-dimensional model cannot detect the coincidence degree of the crankshaft hole sites is solved, and the persuasion of the evaluation index of the apparent state of the crankshaft to be detected is improved.
A5, analyzing apparent defects of the specified crankshaft: and analyzing the apparent image corresponding to each appointed crankshaft to obtain an apparent defect parameter set corresponding to each appointed crankshaft, and further analyzing the apparent defect index corresponding to each appointed crankshaft.
In a preferred embodiment of the present invention, the step A5 analyzes the apparent image corresponding to each designated crankshaft in a specific analysis manner: extracting the apparent image corresponding to each appointed crankshaft from the apparent image corresponding to each crankshaft to be detected based on the number of each appointed crankshaft, and performingAnd extracting the number of the pits, the number of the scratches, the total volume of the pits and the total length of the scratches existing on each specified crankshaft from the apparent image corresponding to each specified crankshaft, and recording the extracted number, the total volume and the total length as
And
j denotes the number of each designated crankshaft, and j =1, 2.
And constructing an apparent defect parameter set corresponding to each specified crankshaft according to the number of the depressions, the number of the scratches, the total volume of the depressions and the total length of the scratches corresponding to each specified crankshaft.
In a preferred embodiment of the present invention, the specific calculation formula of the apparent defect index corresponding to each specified crankshaft in the step A5 is
，
Expressed as the apparent defect index corresponding to the jth designated crankshaft,
respectively expressed as a set number of allowable depressions, a number of allowable scratches, a total volume of allowable depressions, a total length of allowable scratches,
respectively representing the weight factors corresponding to the set number of the recesses, the number of the scratches, the total volume of the recesses and the total length of the scratches.
A6, detecting and analyzing the depth defects of the specified crankshaft: and carrying out depth defect detection on each specified crankshaft to obtain a depth defect parameter set corresponding to each specified crankshaft, and analyzing a depth defect index corresponding to each specified crankshaft.
In a preferred embodiment of the present invention, the depth defect detection is performed on each designated crankshaft in step A6, and the specific detection method is as follows: by electromagnetic meansThe flaw detector detects the crack lines of each specified crankshaft to obtain the number, total length and distribution density of the crack lines on each specified crankshaft, and the number, total length and distribution density are recorded as
And
。
it should be noted that the specific application method of the electromagnetic flaw detector is as follows: magnetizing the crankshaft by an electromagnetic flaw detector, scattering iron powder on a part to be inspected, lightly knocking the crankshaft by a small hammer, and if cracks exist, generating clear crack lines at the position where the iron powder is accumulated.
As a further improvement of the present invention, specific acquisition modes of the crack line distribution density include, but are not limited to: and counting the number of the crack lines in the set area, and carrying out comprehensive analysis on the area corresponding to the set area to obtain the distribution density of the crack lines.
Carrying out burr profile detection on each appointed crankshaft through a profiler to obtain the number of burrs on each appointed crankshaft, the distribution area of the burrs and the highest burr height which are respectively recorded as
And
。
and constructing a depth defect parameter set corresponding to each appointed crankshaft by the number of crack lines, the total length of the crack lines, the distribution density of the crack lines, the number of burrs, the distribution area of the burrs and the highest burr height on each appointed crankshaft.
In a preferred embodiment of the present invention, the depth defect index corresponding to each specified crankshaft is analyzed in the step A6, and the specific analysis process is as follows: according to the formula
Calculate each assignmentThe crack impact index corresponding to the crankshaft,
expressed as crack impact index for the jth designated crankshaft,
respectively expressed as the set number of allowable crack lines, the total length of the allowable crack lines and the distribution concentration of the allowable crack lines,
and respectively representing the influence factors corresponding to the set number of the crack lines, the total length of the crack lines and the distribution density of the crack lines.
According to the formula
Calculating the burr influence index corresponding to each appointed crankshaft,
expressed as the glitch impact index for the jth designated crankshaft,
respectively expressed as a set allowable burr number, an allowable burr distribution area, an allowable maximum burr height,
respectively expressed as the impact factors corresponding to the set burr quantity, burr distribution area and highest burr height.
According to the formula
Calculating the depth defect index corresponding to each appointed crankshaft,
depth defect finger corresponding to the j-th designated crankshaftThe number of the first and second groups is counted,
and respectively representing the crack influence indexes and the burr influence indexes as weight factors corresponding to the set crack influence indexes and burr influence indexes.
A7, specified crankshaft manufacturing quality analysis: and comprehensively analyzing the apparent defect index and the depth defect index corresponding to each specified crankshaft to obtain the manufacturing quality evaluation coefficient corresponding to each specified crankshaft.
In a preferred embodiment of the present invention, the manufacturing quality evaluation coefficient corresponding to each specified crankshaft in the step A7 is calculated by the following formula
，
Expressed as a manufacturing quality evaluation coefficient corresponding to the jth specified crankshaft,
the values are expressed as coefficient factors corresponding to the set apparent defect index and the set depth defect index, respectively.
In a specific embodiment, the number of the corresponding depressions, the number of scratches, the total number of the depressions and the total length of the scratches of each specified crankshaft are detected and analyzed, meanwhile, the depth defect detection is performed on each specified crankshaft through the electromagnetic flaw detector and the contourgraph, and then the manufacturing quality evaluation coefficient corresponding to each specified crankshaft is obtained through comprehensive analysis, so that on one hand, the defects of the current crankshaft burr detection and analysis are effectively overcome, the detection strength of the depth defects corresponding to each specified crankshaft is enhanced to a great extent, and the foundation of the analysis result is greatly improved; on the other hand, the appearance defects and the depth defects corresponding to the specified crankshafts are comprehensively analyzed, the limitation of the current manufacturing quality detection and analysis corresponding to the specified crankshafts is broken, and the accuracy and the reliability of the crankshaft manufacturing quality analysis result are improved to a great extent.
A8, analyzing and displaying the assigned crankshaft grade: and analyzing the grade corresponding to each appointed crankshaft, and displaying correspondingly.
In a preferred embodiment of the present invention, the step A8 analyzes the grade corresponding to each designated crankshaft in a specific analysis manner: and comparing the manufacturing quality evaluation coefficient corresponding to each designated crankshaft with the manufacturing quality evaluation coefficient threshold corresponding to each set grade to obtain the grade corresponding to each designated crankshaft.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (10)
1. A crankshaft manufacturing surface detection and analysis method based on an industrial camera is characterized by comprising the following steps:
a1, crankshaft three-dimensional model construction: counting the number of crankshafts to be detected, numbering each crankshaft to be detected in sequence according to a preset sequence to be 1,2, i, n, simultaneously collecting an apparent image of each crankshaft to be detected through an industrial camera, and constructing a three-dimensional model corresponding to each crankshaft to be detected;
a2, crankshaft three-dimensional model contour matching analysis: carrying out contour comparison analysis on the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft to obtain the coincidence index of the three-dimensional models corresponding to the crankshafts to be detected;
a3, crankshaft apparent image information matching analysis: comparing and analyzing the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft to obtain an apparent image matching index corresponding to each crankshaft to be detected;
a4, crankshaft apparent state analysis and processing: comprehensively analyzing the three-dimensional model coincidence index and the apparent image matching index corresponding to each crankshaft to be detected to obtain an apparent state corresponding to each crankshaft to be detected, and screening specified crankshafts according to the apparent states corresponding to the crankshafts to obtain the specified crankshafts;
a5, analyzing apparent defects of the specified crankshaft: analyzing the apparent image corresponding to each appointed crankshaft to obtain an apparent defect parameter set corresponding to each appointed crankshaft, and further analyzing an apparent defect index corresponding to each appointed crankshaft;
a6, detecting and analyzing the depth defects of the specified crankshaft: carrying out depth defect detection on each specified crankshaft to obtain a depth defect parameter set corresponding to each specified crankshaft, and analyzing a depth defect index corresponding to each specified crankshaft;
a7, specified crankshaft manufacturing quality analysis: comprehensively analyzing the apparent defect index and the depth defect index corresponding to each appointed crankshaft to obtain the manufacturing quality evaluation coefficient corresponding to each appointed crankshaft;
a8, analyzing and displaying the specified crankshaft grade: and analyzing the grade corresponding to each appointed crankshaft, and displaying correspondingly.
2. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 1, characterized in that: in the step A2, the three-dimensional model corresponding to each crankshaft to be detected and the three-dimensional model corresponding to the set standard crankshaft are subjected to contour comparative analysis, and the specific comparative analysis process is as follows:
carrying out volume coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapping part of the volume corresponding to each crankshaft to be detected and the standard volume corresponding to the standard crankshaft, recording as the overlapping volume, and marking as the overlapping volume
I denotes the number of the respective crankshaft to be detected, i =1, 2.... N;
carrying out total circumference coincidence comparison on the three-dimensional model contour corresponding to each crankshaft to be detected and the three-dimensional model contour corresponding to the standard crankshaft to obtain the overlapping circumference of the total circumference corresponding to each crankshaft to be detected and the standard total circumference corresponding to the standard crankshaft, marking as the overlapping circumference and marking as the overlapping circumference
；
Extracting three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the crankshafts to be detected, extracting standard three-dimensional images of the crankshafts to be detected corresponding to all directions from the three-dimensional models corresponding to the set standard crankshafts, and then overlapping the three-dimensional images of the crankshafts to be detected corresponding to all directions with the corresponding standard three-dimensional images to obtain overlapping areas and overlapping circumferences of the crankshafts to be detected corresponding to all directions, which are respectively marked as
And
f denotes the number of each orientation, f =1, 2.... G;
according to the formula
Calculating the three-dimensional model coincidence index corresponding to each crankshaft to be detected,
expressed as the three-dimensional model coincidence index corresponding to the ith crankshaft to be detected, e is expressed as a natural constant,
respectively expressed as the standard volume and the standard total perimeter corresponding to the set standard crankshaft,
respectively expressed as a standard area and a standard perimeter corresponding to the f-th position on the set standard crankshaft,
and respectively representing the weight factors corresponding to the set overlapping volume, the overlapping perimeter, the overlapping area and the overlapping perimeter.
3. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 2, characterized in that: in the step A3, the apparent image corresponding to each crankshaft to be detected and the apparent image corresponding to the set standard crankshaft are contrasted and analyzed, and the specific contrasted and analyzed process is as follows:
extracting the number of the existing hole sites from the apparent image corresponding to each crankshaft to be detected, sequentially numbering each hole site on each crankshaft to be detected according to the numbering sequence of each standard hole site in the standard crankshaft to be 1,2, a, r, a, p, and simultaneously extracting the shape profile and the depth corresponding to each hole site in each crankshaft to be detected;
the shape outline corresponding to each hole position on each crankshaft to be detected is superposed and compared with the shape outline of the corresponding standard hole position to obtain the superposed area of each hole position on each crankshaft to be detected and the shape outline of the corresponding standard hole position, and the superposed area is marked as the hole position superposed area and marked as the standard hole position superposed area
R denotes the number of each hole site, r =1, 2.... P;
acquiring the distance between the position corresponding to each hole position on each crankshaft to be detected and the standard position of the standard hole position corresponding to the position, marking the distance as the offset distance and marking the distance as the standard position
；
Recording the depth corresponding to each hole position on each crankshaft to be detected
Further according to the formula
Calculating the apparent image matching index corresponding to each crankshaft to be detected,
expressed as the apparent image matching index corresponding to the ith crankshaft to be detected,
expressed as the number of hole sites corresponding to the ith crankshaft to be detected,
respectively expressed as the standard area and the standard depth of the position corresponding to the r-th hole position on the ith crankshaft to be detected,
expressed as the number of standard hole sites corresponding to a standard crankshaft,
indicated as the set allowed offset distance,
respectively expressed as weight factors corresponding to the preset hole site coincidence area, the number of hole sites, the depth and the offset distance.
4. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 3, wherein: in the step A4, the designated crankshafts are screened according to the corresponding apparent states of the crankshafts to be detected, and the specific screening mode is as follows:
according to the formula
Calculating the apparent state evaluation index corresponding to each crankshaft to be detected,
expressed as an apparent state evaluation index corresponding to the ith crankshaft to be detected,
respectively representing the correction factors corresponding to the set three-dimensional model coincidence index and the apparent image matching index;
comparing the apparent state evaluation index corresponding to each crankshaft to be detected with a set apparent state evaluation index threshold, if the apparent state evaluation index corresponding to a certain crankshaft to be detected is greater than the apparent state evaluation index threshold, judging that the apparent state corresponding to the crankshaft to be detected is qualified, marking the crankshaft to be detected as a designated crankshaft, otherwise, judging that the apparent state corresponding to the crankshaft to be detected is abnormal, and rejecting the crankshaft to be detected;
the number of the designated crankshafts is counted, and the designated crankshafts are numbered as 1,2, j, m in sequence according to a preset sequence.
5. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 4, wherein: in the step A5, the apparent image corresponding to each designated crankshaft is analyzed, and the specific analysis mode is as follows:
extracting an apparent image corresponding to each appointed crankshaft from the apparent image corresponding to each crankshaft to be detected based on the number of each appointed crankshaft, and further extracting the number of depressions, the number of scratches, the total volume of depressions and the total length of scratches existing on each appointed crankshaft from the apparent image corresponding to each appointed crankshaft, wherein the total volume of depressions and the total length of scratches are respectively recorded as
And
j denotes the number of each designated crankshaft, j =1, 2.... M;
and constructing an apparent defect parameter set corresponding to each specified crankshaft according to the number of the depressions, the number of the scratches, the total volume of the depressions and the total length of the scratches corresponding to each specified crankshaft.
6. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 5, wherein: each finger in the step A5Determining the corresponding apparent defect index of the crankshaft, wherein the specific calculation formula is
，
Expressed as the apparent defect index corresponding to the jth designated crankshaft,
respectively expressed as a set number of allowable depressions, a number of allowable scratches, a total volume of allowable depressions, a total length of allowable scratches,
respectively expressed as weight factors corresponding to the set number of the pits, the number of the scratches, the total volume of the pits and the total length of the scratches.
7. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 6, wherein: in the step A6, the depth defect detection is performed on each designated crankshaft, and the specific detection method is as follows:
detecting the crack lines of each specified crankshaft by an electromagnetic flaw detector to obtain the number of the crack lines, the total length of the crack lines and the distribution density of the crack lines on each specified crankshaft, and recording the number, the total length and the distribution density of the crack lines as
And
；
carrying out burr profile detection on each appointed crankshaft through a profiler to obtain the number of burrs, the distribution area of the burrs and the highest burr height on each appointed crankshaft, and recording the number of the burrs, the distribution area of the burrs and the highest burr height respectively
And
；
and constructing a depth defect parameter set corresponding to each appointed crankshaft by the number of crack lines, the total length of the crack lines, the distribution density of the crack lines, the number of burrs, the distribution area of the burrs and the highest burr height on each appointed crankshaft.
8. The industrial camera-based crankshaft manufacturing surface detection analysis method according to claim 7, characterized in that: in the step A6, the depth defect index corresponding to each specified crankshaft is analyzed, and the specific analysis process is as follows:
according to the formula
Calculating the crack influence index corresponding to each appointed crankshaft,
expressed as crack impact index for the jth designated crankshaft,
respectively expressed as the set allowable crack line number, the allowable crack line total length and the allowable crack line distribution concentration,
respectively representing the number of the crack lines, the total length of the crack lines and the corresponding influence factors of the distribution density of the crack lines;
according to the formula
Calculating the burr influence index corresponding to each appointed crankshaft,
expressed as the burr shadow corresponding to the jth specified crankshaftThe number of the sounds is the index of the sound,
respectively expressed as the set allowable burr quantity, the allowable burr distribution area and the allowable maximum burr height,
respectively representing the number of the burrs, the distribution area of the burrs and the influence factors corresponding to the highest burr height;
according to the formula
Calculating the depth defect index corresponding to each appointed crankshaft,
expressed as the depth defect index corresponding to the jth specified crankshaft,
and respectively representing the weight factors corresponding to the set crack influence index and burr influence index.
9. The industrial camera-based crankshaft manufacturing surface detection and analysis method according to claim 8, wherein: the manufacturing quality evaluation coefficient corresponding to each specified crankshaft in the step A7 is specifically calculated by the formula
，
Expressed as a manufacturing quality evaluation coefficient corresponding to the jth specified crankshaft,
the values are expressed as coefficient factors corresponding to the set apparent defect index and the set depth defect index, respectively.
10. The industrial camera-based crankshaft manufacturing surface inspection analysis method of claim 9, wherein: in the step A8, the grade corresponding to each designated crankshaft is analyzed, and the specific analysis mode is as follows:
and comparing the manufacturing quality evaluation coefficient corresponding to each designated crankshaft with the manufacturing quality evaluation coefficient threshold corresponding to each set grade to obtain the grade corresponding to each designated crankshaft.
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