CN115728313A - Automatic measuring device for detecting surface defects of blade and using method - Google Patents
Automatic measuring device for detecting surface defects of blade and using method Download PDFInfo
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- CN115728313A CN115728313A CN202211581400.7A CN202211581400A CN115728313A CN 115728313 A CN115728313 A CN 115728313A CN 202211581400 A CN202211581400 A CN 202211581400A CN 115728313 A CN115728313 A CN 115728313A
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Abstract
An automatic measuring device for detecting surface defects of blades and a using method thereof are disclosed, the device comprises a workbench, a cooperative mechanical arm and a camera which are arranged on the workbench, and a blade material box for containing the blades, wherein the blade material box is arranged on the workbench; the cooperative mechanical arm is connected with the mechanical arm controller; an end effector is arranged on the cooperative mechanical arm; the camera is used for collecting the image of the blade to be measured; the camera and the mechanical arm controller are both connected with a client computer, and the client computer is connected with the server through the switch. The blade material box is placed into a corresponding station, the cooperation mechanical arm and the end effector are coordinated and matched, the path track of the cooperation mechanical arm is planned, ordered grabbing of blades in the blade material box is achieved, the camera is arranged at a fixed station, the cooperation mechanical arm clamps the blades to a corresponding detection station and moves according to a design posture, image collection of the surface quality of the blades is completed, and then defect detection is completed through a manual intelligent algorithm.
Description
Technical Field
The invention relates to the technical field of surface quality detection of compressor blades, in particular to an automatic measuring device for detecting surface defects of blades and a using method thereof.
Background
The rotor blade of the gas compressor is a core part of an aeroengine and a gas turbine, is mainly used for compressing air and gas to do work, and the product quality of the rotor blade of the gas compressor plays an important role in the service performance and the safety and reliability of the engine; the compressor blade belongs to an engine wearing part, and is affected by the use environment of the engine, working air flow and foreign objects in the long-term service process of the engine, the surface of the compressor blade is easy to damage, and the compressor blade needs to be periodically returned to a factory for inspection and maintenance so as to ensure the use safety of the engine.
At present, the surface defect inspection after the compressor blade of the engine is inspected and repaired and returned to the factory mainly depends on the conventional manual means such as manual visual inspection, manual touch and the like, the inspection and judgment depend on the experience and skill, the labor intensity is high, the inspection efficiency is low, the quality file information of the defect position cannot be recorded in the inspection process, and the quality tracking of the inspection process cannot be carried out.
Disclosure of Invention
The invention mainly aims to provide an automatic measuring device for detecting surface defects of a blade and a using method thereof, and aims to solve the technical problems.
In order to achieve the above object, in one aspect, the present invention provides an automated measuring device for detecting surface defects of a blade, comprising a worktable, and a cooperative mechanical arm and a camera mounted on the worktable; the blade material box is used for containing blades and is placed on the workbench; the cooperative mechanical arm is connected with the mechanical arm controller; an end effector is arranged on the cooperative mechanical arm; the camera is used for collecting the image of the blade to be measured; the camera and the mechanical arm controller are both connected with a client computer, and the client computer is connected with the server through the switch.
Preferably, the teaching device further comprises a teaching device which is in control connection with the cooperative mechanical arm.
Preferably, the joints of the cooperative mechanical arm sequentially comprise a base, a shoulder, an elbow, a first wrist, a second wrist and a third wrist from bottom to top, so as to form six joints; arm tube connections are used between the shoulder and the elbow, and between the elbow and the first wrist.
Preferably, an office table is placed on one side of the workbench, the mechanical arm controller is arranged on the office table, a display is placed on the office table, and the display is connected to the client computer; the camera is installed on the workbench through the camera mounting frame.
Preferably, an auxiliary light source is provided on the table. The method aims to increase the display effect of the surface of the blade in a shot picture, adjust the tone of the picture, determine the contrast of the picture, improve the identification success rate of the surface defects of the blade and avoid the problems of light reflection and the like.
Preferably, a plurality of blank spaces are arranged in the blade material box and used for vertically inserting the blades to be tested into the blank spaces; the plurality of blank spaces are distributed in a rectangular array.
In another aspect, the present invention further provides a method for using the above automatic measuring device, including the following processes:
planning a space track: collecting object position information, object size information and safety distance which are placed on a workbench, inputting the object position information, the object size information and the safety distance into a control system of the cooperative mechanical arm, and judging an object interference area and information of each surface when the cooperative mechanical arm moves;
building a database: constructing different databases for each blade to be tested, wherein the databases comprise the size of a blade material box, the space interval inside the blade material box and the surface attribute information of the blade to be tested; establishing a lightweight database for the information of the motion trail of the cooperative mechanical arm, and carrying out one-to-one corresponding matching on each blade to be tested and the corresponding trail information;
detecting defects of the blade: the detection process comprises the steps of carrying out image acquisition on the blade to be detected, carrying out image processing, feature extraction and algorithm judgment on the acquired image; establishing an algorithm model aiming at blade flaws by using a CNN convolutional neural network and an RPN network structure, and establishing a blade real-time monitoring model through updating and iteration to generate a detection result of whether the surface of the blade has defects and specific defect types;
and (3) result feedback: and after comparing with the blade model to be detected, feeding back the state of the blade in the detection process in real time and prompting the error type of the defects on the surface of the blade.
Preferably, when an object interference area is judged when the cooperative mechanical arm moves, and when the cooperative mechanical arm enters the interference area in the two-point movement posture process, a new posture is automatically added to avoid the interference area; when the two postures of the same plane enter an interference region in the motion process, adding new sites to enable the cooperative mechanical arm to reach the target pose in a progressive mode; when the two postures of different planes enter the interference area in the motion process, the two postures of different planes move to the position of the two-plane coincident angle outside the interference area, then the posture of the same plane is judged, and finally the target posture is reached, so that obstacle avoidance is completed.
Preferably, when a lightweight database is established for information of a motion track of the cooperative mechanical arm, if the cooperative mechanical arm supports a drag teaching function, a current position and posture is recorded by dragging, and an automatic obstacle avoidance function is assisted.
Preferably, the dragging teaching aid is used for: the cooperative mechanical arm starts from an initial pose and moves to a first blade grabbing pose, a signal is sent to the end effector, the end effector clamps the blades, the cooperative mechanical arm moves to the next pose, image data acquisition of the surface quality of the blades is completed in a shooting area of the camera, the blades are placed back to an original vacancy of the original blade material box, the end effector loosens the blades, the cooperative mechanical arm carries out grabbing shooting on the next blade until surface data of all the blades on the material tray are obtained, and the cooperative mechanical arm returns to the set finishing pose.
Due to the adoption of the technical scheme, compared with the manual visual observation in the prior art, the automatic measuring device has the following beneficial effects:
(1) By adopting the automatic measuring device provided by the invention, the blade material box is placed in the corresponding station, the cooperative mechanical arm and the end effector are in cooperative fit, the path track of the cooperative mechanical arm is planned, the blades in the blade material box are orderly grabbed, the camera is arranged at the fixed station, the cooperative mechanical arm clamps the blades to the corresponding detection station and moves according to the designed posture, the image acquisition of the surface quality of the blades is completed, and then the defect detection is completed through the artificial intelligent algorithm.
(2) The automatic measuring device provided by the invention has the advantages of simple structure, high degree of automation of operation and high measuring efficiency; the detection efficiency is high, the detection result is reliable, the application range is wide, various types of blades can be measured, and the application prospect is good;
(3) The automatic measuring device provided by the invention can quickly, efficiently and accurately detect the surface defect position, and record, store and archive in real time in the system;
(4) The automatic measuring device provided by the invention has strong universality, and can be popularized to the surface defect detection of other parts by intelligently learning the surface defect conditions of other parts.
(5) The automatic measuring device provided by the invention can realize non-contact detection of the micro-defects on the surface of the complex curved surface of the blade and can realize three-dimensional detection of the micro-defects on the surface of the blade.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.
FIG. 1 is a perspective view of an automated measuring device for blade surface defect inspection provided by the present invention;
FIG. 2 is a schematic diagram of a hardware connection of an automatic measuring device provided by the present invention;
FIG. 3 is a schematic view of the joints of the cooperating robotic arms of the present invention;
FIG. 4 is a first schematic view of a working space of a cooperating robotic arm of the present invention;
FIG. 5 is a second schematic workspace illustration of a cooperating robotic arm of the present invention;
FIG. 6 is a schematic diagram of an automatic obstacle avoidance function of the cooperative mechanical arm in space trajectory planning according to the present invention;
fig. 7 is a block diagram of a motion trajectory planning process of the cooperative mechanical arm in the present invention.
The reference numbers illustrate: 1. a client computer; 2. a switch; 3. a server; 4. a robot arm controller; 5. a camera; 6. a blade material box; 7. a cooperating robotic arm; 701. a base; 702. a shoulder portion; 703. an elbow; 704. a first wrist portion; 705. a second wrist portion; 706. a third wrist portion; 8. a demonstrator; 9. an end effector; 10. a mechanical arm main control cabinet; 11. an office table; 12. a work table; 13. camera mounting bracket.
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.
It should be noted that all the directional indicators (such as upper, lower, left, right, front, and rear … …) in the embodiment of the present invention are only used to explain the relative position relationship between the components, the motion situation, and the like in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indicator is changed accordingly.
In addition, the descriptions related to "first", "second", etc. in the present invention are for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the feature. In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.
With reference to fig. 1 and 2, an automatic measuring device for detecting surface defects of blades is characterized by comprising a workbench 12, and a cooperative mechanical arm 7 and a camera 5 which are arranged on the workbench 12; the device also comprises a blade material box 6 for containing the blade, wherein the blade material box 6 is placed on the workbench 12; the cooperative mechanical arm 7 is connected with the mechanical arm controller 4; an end effector 9 is mounted on the cooperative mechanical arm 7; the camera 5 is used for collecting images of the blade to be measured; the camera 5 and the mechanical arm controller 4 are both connected with the client computer 1, and the client computer 1 is connected with the server 3 through the switch 2. Specifically, the mechanical arm controller 4 is connected with the client computer 1 through a network cable, the camera 5 is connected with the client computer 1 through a USB interface, finally, the control of the cooperative mechanical arm 7 and the camera 5 is realized through the client computer 1, the end effector 9 at the end of the cooperative mechanical arm 7 sequentially carries out three operations of grabbing, surface quality obtaining and identifying and blade replacing on the blade, the corresponding position calibration matching is completed according to the blade material box 6, and further, the scheme automation is realized.
In the present embodiment, the automatic measuring device further comprises a teach pendant 8, and the teach pendant 8 is in control connection with the cooperative mechanical arm 7. Through the teaching of the demonstrator 8 operation interface or dragging, the user can control each joint of the cooperative mechanical arm 7 to rotate, and the completion of the track motion of each angle posture in the motion space is ensured.
As shown in fig. 3, the joints of the cooperative mechanical arm 7 include, from bottom to top, a base 701, a shoulder 702, an elbow 703, a first wrist 704, a second wrist 705, and a third wrist 706 in this order, forming six joints; arm tube connections are used between the shoulder 702 and the elbow 703, and between the elbow 703 and the first wrist 704.
As shown in fig. 1, a desk 11 is placed on one side of the workbench 8, the arm controller 4 is disposed on the desk 11, a display is placed on the desk 11, and the display is connected to the client computer 1; the camera 5 is mounted on the workbench 12 through a camera mounting bracket 13, and the mechanical arm main control case 10 prevents the host of the client computer 1 from being placed below the desk 11 at the lower part of the workbench 8.
In this embodiment, an auxiliary light source (not shown) is disposed on the worktable 12, such as white light or ultraviolet light at an inclination angle, for increasing the display effect of the blade surface in the photographed image, adjusting the tone of the image, determining the contrast of the image, increasing the success rate of identifying the defects on the blade surface, and avoiding the occurrence of problems such as light reflection.
A plurality of blank spaces are arranged in the blade material box 6 and are used for vertically inserting the blades to be detected into the blank spaces; a plurality of blank spaces are distributed in a rectangular array mode, matrix distribution is adopted, and track planning of the cooperation mechanical arm 7 is facilitated.
On the other hand, the embodiment further provides a use method of the automatic measuring device, which includes the following steps:
planning a space track: collecting position information, size information and safety distance of an object placed on the workbench 1, inputting the position information, size information and safety distance into a control system of the cooperative mechanical arm 7, and judging an object interference area and information of each surface when the cooperative mechanical arm 7 moves;
building a database: constructing different databases for each blade to be tested, wherein the databases comprise the size of the blade material box 6, the space interval of the inner vacancy of the blade material box 6 and the surface attribute information of the blade to be tested; establishing a lightweight database for the information of the motion track of the cooperative mechanical arm 7, and carrying out one-to-one corresponding matching on each blade to be detected and the corresponding track information; after the trajectory planning is finished, the user only needs to select the corresponding blade model to finish the surface quality detection of the corresponding type of blade, so that the method is convenient and quick;
detecting defects of the blade: the detection process comprises the steps of collecting images of the leaves to be detected, processing the collected images, extracting features and judging algorithms; the method comprises the steps that a CNN (Convolutional Neural Networks) Convolutional Neural Network and an RPN (Region probable Network) Network structure are used, an algorithm model is established according to blade flaws, the detection accuracy and the generalization of the algorithm are continuously improved through updating and iteration, a blade real-time monitoring model is established, and the detection result of whether defects exist on the surface of the blade and the specific defect types is generated;
and (3) result feedback: and after comparing with the blade model to be detected, feeding back the state of the blade in the detection process in real time and prompting the error type of the defects on the surface of the blade. The system can gather the detection results for many times, and finally feed back the detection results to the process through data analysis and comparison to complete the closed loop of the detection process.
Referring to fig. 4 to 6, when the object interference area is judged when the cooperative mechanical arm 7 moves, and when the object interference area enters the interference area in the two-point movement posture process of the cooperative mechanical arm 7, the new posture is automatically added to avoid the interference area; when the two postures of the same plane enter an interference region in the motion process, adding new sites to enable the cooperative mechanical arm 7 to reach the target pose in a progressive mode; when the two postures of different planes enter the interference area in the motion process, the two postures of different planes move to the coincident angle position of the two planes outside the interference area, then the posture of the same plane is judged, and finally the target posture is reached, so that obstacle avoidance is completed.
In this embodiment, when a lightweight database is created for information on a movement trajectory of the cooperative arm 7, if the cooperative arm 7 supports a drag teaching function, a current position and posture is recorded by dragging, and an automatic obstacle avoidance function is used as a supplement.
Referring to fig. 7, when the cooperative mechanical arm 7 starts from an initial pose and moves to a first blade grabbing pose, a signal is sent to the end effector 9, the end effector 9 clamps the blades, the cooperative mechanical arm 7 moves to a next pose again, image data acquisition of the surface quality of the blades is completed in a shooting area of the camera 5, the blades are placed back to an original vacancy of the original blade material box 6, the end effector 9 releases the blades, the cooperative mechanical arm 7 carries out grabbing shooting of the next blade until surface data of all the blades on the material tray are obtained, and the cooperative mechanical arm 7 returns to the set finishing pose.
The working principle of the invention is as follows:
by adopting the automatic measuring device provided by the invention, the blade material box 6 is placed in the corresponding station, the cooperative mechanical arm 7 and the end effector 9 are in coordination, the path track of the cooperative mechanical arm 7 is planned, the ordered grabbing of the blades in the blade material box 6 is realized, the camera 5 is arranged at the fixed station, the cooperative mechanical arm 6 clamps the blades to the corresponding detection station and moves according to the designed posture, the image acquisition of the surface quality of the blades is completed, and the defect detection is completed through the artificial intelligence algorithm.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents made by the contents of the present specification and drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. An automated measuring device for blade surface defect detection, characterized by comprising a worktable (12), and a cooperating mechanical arm (7) and a camera (5) mounted on the worktable (12); the blade material box is characterized by further comprising a blade material box (6) for containing blades, wherein the blade material box (6) is placed on the workbench (12);
the cooperative mechanical arm (7) is connected with the mechanical arm controller (4); an end effector (9) is arranged on the cooperative mechanical arm (7); the camera (5) is used for collecting an image of the blade to be measured; the camera (5) and the mechanical arm controller (4) are both connected with the client computer (1), and the client computer (1) is connected with the server (3) through the switch (2).
2. An automated measuring device for blade surface defect inspection according to claim 1, characterized by further comprising a teach pendant (8), the teach pendant (8) being in control connection with the cooperating robotic arm (7).
3. An automated measuring device for blade surface defect inspection according to claim 1, characterized in that the joints of the cooperating robotic arm (7) comprise, from bottom to top, a base (701), a shoulder (702), an elbow (703), a first wrist (704), a second wrist (705) and a third wrist (706), forming six joints; arm tube connections are used between the shoulder (702) and the elbow (703), and between the elbow (703) and the first wrist (704).
4. The automatic measuring device for blade surface defect detection as claimed in claim 1, wherein a desk (11) is placed on one side of the workbench (8), the arm controller (4) is arranged on the desk (11), a display is placed on the desk (11), and the display is connected to the client computer (1); the camera (5) is arranged on the workbench (12) through a camera mounting frame (13).
5. An automated measuring device for blade surface defect inspection according to claim 1, characterized in that an auxiliary light source is provided on the table (12).
6. The automatic measuring device for detecting the surface defects of the blades is characterized in that a plurality of blank spaces are arranged in the blade material box (6) and used for vertically inserting the blades to be detected into the blank spaces; the plurality of blank spaces are distributed in a rectangular array.
7. Use of an automated measuring device according to any one of claims 1 to 6, characterized in that it comprises the following processes:
planning a space track: the method comprises the steps of collecting position information, size information and safety distance of an object placed on a workbench (1), inputting the position information, size information and safety distance into a control system of a cooperative mechanical arm (7), and judging an object interference area and information of each surface when the cooperative mechanical arm (7) moves;
building a database: constructing different databases for each type of blade to be tested, wherein the databases comprise the size of a blade material box (6), the space interval of the inner vacancy of the blade material box (6) and the surface attribute information of the blade to be tested; establishing a lightweight database for the information of the motion track of the cooperative mechanical arm (7), and carrying out one-to-one corresponding matching on each blade to be detected and the corresponding track information;
detecting defects of the blade: the detection process comprises the steps of carrying out image acquisition on the blade to be detected, carrying out image processing, feature extraction and algorithm judgment on the acquired image; establishing an algorithm model aiming at blade flaws by using a CNN convolutional neural network and an RPN network structure, and establishing a blade real-time monitoring model through updating and iteration to generate a detection result of whether the surface of the blade has defects and specific defect types;
and (3) result feedback: and after comparing with the blade model to be detected, feeding back the state of the blade in the detection process in real time and prompting the error type of the defects on the surface of the blade.
8. The use method of the automatic measuring device according to claim 7, characterized in that when the interference area of the object is judged when the cooperative mechanical arm (7) moves, when the two-point movement attitude of the cooperative mechanical arm (7) enters the interference area, the new attitude is automatically added to avoid the interference area; when the two postures of the same plane enter an interference region in the motion process, a new locus is added, so that the cooperative mechanical arm (7) reaches the target pose in a progressive mode; when the two postures of different planes enter the interference area in the motion process, the two postures of different planes move to the coincident angle position of the two planes outside the interference area, then the posture of the same plane is judged, and finally the target posture is reached, so that obstacle avoidance is completed.
9. The use method of the automatic measuring device according to claim 7, wherein when the light database is established for the information of the movement track of the cooperative mechanical arm (7), if the cooperative mechanical arm (7) supports a drag teaching function, the current position and posture is recorded by dragging, and an automatic obstacle avoidance function is assisted.
10. The method of using an automated measurement device of claim 9, wherein the drag teaching tool operation is: the cooperative mechanical arm (7) starts from an initial pose and moves to a first blade grabbing pose, a signal is sent to the end effector (9), the end effector (9) clamps the blades, the cooperative mechanical arm (7) moves to the next pose again, image data collection of the surface quality of the blades is completed in a shooting area of the camera (5), then the blades are placed back to an original vacancy of the original blade material box (6), the end effector (9) loosens the blades, the cooperative mechanical arm (7) conducts grabbing shooting of the next blade until surface data of all the blades on the material tray are obtained, and the cooperative mechanical arm (7) returns to the set finishing pose.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211581400.7A CN115728313A (en) | 2022-12-09 | 2022-12-09 | Automatic measuring device for detecting surface defects of blade and using method |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211581400.7A CN115728313A (en) | 2022-12-09 | 2022-12-09 | Automatic measuring device for detecting surface defects of blade and using method |
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| CN115728313A true CN115728313A (en) | 2023-03-03 |
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| CN202211581400.7A Pending CN115728313A (en) | 2022-12-09 | 2022-12-09 | Automatic measuring device for detecting surface defects of blade and using method |
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- 2022-12-09 CN CN202211581400.7A patent/CN115728313A/en active Pending
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