CN115854946A - Sawtooth image pickup device applied to automatic circular saw blade tooth grinding machine and application method thereof - Google Patents
Sawtooth image pickup device applied to automatic circular saw blade tooth grinding machine and application method thereof Download PDFInfo
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Abstract
The invention relates to a sawtooth camera shooting device applied to an automatic tooth grinding machine of a circular saw blade and a using method thereof, wherein the device comprises a high-pressure air cavity, a circumferential air curtain block, a light supplementing lamp bead hole, a camera fixing through hole, a vacuum extraction pipe, a high-pressure air blowing pipe, a connecting rod, a return spring and a positioning coil; when in use, the two sets of devices are respectively arranged at two sides of the grinding wheel and work according to the following procedures: the method comprises the following steps of sawtooth shooting and parameter calculation, sawtooth abrasion calculation, sawtooth parameter type selection evaluation, sawtooth parameter optimization, sawtooth grinding precision verification and saw blade flatness evaluation. The device has the characteristics of high liquid discharge reliability, no damage to the saw blade, simple and stable structure and good popularization, and the using method of the device has the capability of realizing saw tooth abrasion detection, saw tooth profile optimization and saw blade flatness detection on line in a full-automatic manner; the device is additionally arranged on the automatic gear grinding machine, and the grinding precision and the intelligent degree of the automatic gear grinding machine can be greatly enhanced by using the method.
Description
Technical Field
The invention relates to a sawtooth camera device, in particular to a sawtooth camera device applied to an automatic circular saw blade gear grinding machine and a using method thereof.
Background
In the actual work of manufacturing industry, it is often necessary to cut materials such as plates, cast iron, glass, stone, plastics, etc. The cutting process is a basic operation in the manufacturing industry, like turning, milling, planing, grinding, and clamping. Circular saw blades (simply "saw blades") are common tools used in cutting operations. The saw blade consists of a central matrix and outer edge sawteeth. In operation, the blade rotates at high speed and the material is cut by the teeth at the edge of the blade.
The automatic gear grinding machine is a common device in the related industries of circular saw blade production and use, and can utilize a grinding wheel as a grinding tool to process the tooth profile of a saw blade. The gear grinding machine follows the whole life cycle of the saw blade: when the saw blade is produced, the last procedure is tooth punching, namely, grinding the saw teeth with certain shapes at the edge of the saw blade; after the saw blade is used for a period of time, the saw teeth at the edge of the saw blade can become dull, and an automatic gear grinding machine is needed to grind the saw teeth at the moment so as to keep the saw teeth sharp.
The saw teeth of the circular saw blade have various shapes, including circular arc teeth, wolf teeth, triangular teeth, high and low teeth, chamfer teeth and the like. The saw tooth parameters of each saw tooth profile are very important, because the saw tooth parameters are directly related to performance indexes such as the service life of the saw blade, the cutting efficiency, the cutting precision, the cutting energy consumption and the like.
The automatic gear grinding machine on the market can not carry out online real-time detection on tooth profile parameters in the process of grinding the saw teeth: because the sawtooth coping process can give off a large amount of heat, for avoiding the high temperature that the heat leads to causing the injury to the saw blade, generally can use cooling liquid such as saponin liquid to dispel the heat to it, therefore all can cover or remain a large amount of cooling liquid everywhere of saw blade among the coping process, lead to detection methods such as laser, image all can not detect sawtooth profile of tooth parameter accurately. At present, the conventional method is that after the saw teeth are polished, the circular saw blade is detached, and then off-line measurement is carried out by using tools such as an image detector, a three-coordinate measuring instrument and the like.
Because the tooth profile parameters of the sawteeth cannot be detected on line in real time, closed-loop feedback control cannot be formed in the process of grinding the sawteeth of the automatic gear grinding machine, which means that the automatic gear grinding machine cannot carry out self-adaptive gear grinding adjustment (such as adjustment of gear grinding feed amount, gear grinding feed speed and the like) according to the actual condition of the circular saw blade, and therefore the grinding precision of the sawteeth cannot be guaranteed.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides the sawtooth shooting device applied to the automatic tooth grinding machine of the circular saw blade and the using method thereof.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a sawtooth camera applied to an automatic tooth grinding machine of a circular saw blade comprises a high-pressure air cavity, a circumferential air curtain block, a light supplementing lamp bead hole, a camera fixing through hole, a vacuum extraction pipe, a high-pressure air blowing pipe, a connecting rod, a return spring and a positioning coil, wherein the high-pressure air cavity is communicated with the circumferential air curtain block; the vacuum extraction pipe and the high-pressure air blowing pipe penetrate through the high-pressure air cavity and the circumferential air curtain block and are respectively arranged on two sides of the camera fixing through hole; the connecting rod is arranged above the high-pressure air cavity, and two ends of the connecting rod are respectively fixed with the fixed vacuum extraction pipe and the high-pressure air blowing pipe in an interference fit mode; the return spring is arranged in the upper cavity wall of the high-pressure air cavity and is coaxially arranged with the vacuum extraction pipe; the positioning coil is arranged in the upper cavity wall of the high-pressure air cavity and is coaxially arranged with the high-pressure air blowing pipe;
an annular cavity surrounding the camera fixing through hole is formed in the center of the high-pressure air cavity, and air inlet holes are formed in two side wall surfaces of the high-pressure air cavity respectively; the upper half part of the circumferential air curtain block is provided with a plurality of cylindrical through holes which are distributed around the periphery of the camera fixing through hole, and the cylindrical through holes are communicated with the annular cavity of the high-pressure air cavity; the lower half part of the circumferential air curtain block is provided with an annular through hole, and the cross section of the annular through hole is of an inclined structure.
Preferably, the high-pressure air cavity and the circumferential air curtain block are two cylinders with the same diameter at the bottom surface and are coaxially arranged.
Preferably, the light supplementing lamp bead holes are formed in the surface of the bottom of the circumferential air curtain block and evenly distributed around the outer side of the circumference of the camera fixing through hole.
Preferably, the bottom of the high pressure gas blowing pipe is 0.5 mm to 1 mm higher than the bottom of the vacuum extraction pipe.
Preferably, a layer of metal outer pipe is sleeved outside the high-pressure air blowing pipe at the part corresponding to the positioning coil, and the height of the metal outer pipe is equal to that of the positioning coil.
Preferably, the bottom of the vacuum extraction pipe is provided with an extraction port, the extraction port is step-shaped, the extraction port comprises a first step line and a second step line, and the width values of the first step line and the second step line are equal; the width of the first step line and the second step line is 1 mm to 3 mm.
The invention also provides a use method of the sawtooth camera applied to the automatic circular saw blade gear grinding machine, wherein two sets of sawtooth camera are respectively arranged on two sides of the grinding wheel and work according to the following procedures: the method comprises the following steps of (1) sawtooth shooting and parameter calculation, sawtooth abrasion calculation, sawtooth parameter type selection evaluation, sawtooth parameter optimization, sawtooth grinding precision verification and saw blade flatness evaluation;
sawtooth shooting and parameter calculation: respectively shooting the sawteeth before and after grinding and calculating tooth profile parameters, wherein the tooth profile parameter calculation process comprises the steps of identifying the edges of the sawteeth, extracting the characteristic points of the sawteeth and calculating the tooth profile parameters;
and (3) calculating the sawtooth abrasion: subtracting the standard tooth profile from the tooth profile before grinding to calculate the wear values of three parameters of a front angle, a rear angle and a tooth back of the sawtooth before grinding;
and (3) sawtooth parameter type selection evaluation: using a Support Vector Machine (SVM) model, taking three parameters of a front angle average wear value, a rear angle average wear value and a tooth back average wear value as input parameters of the SVM model, and taking proper sawtooth parameter selection and improper sawtooth parameter selection as output parameters of the SVM model so as to judge whether the sawtooth parameters are suitable for the working condition of the saw blade;
and (3) sawtooth parameter optimization: adjusting the average wear value of a front angle, the average wear value of a rear angle and the average wear value of a tooth back of the tooth profile parameter to be polished;
checking the grinding precision of the saw teeth: carrying out subtraction calculation on the standard tooth profile and the tooth profile after grinding to calculate the grinding error of the tooth profile parameter of the sawtooth;
saw blade flatness evaluation: and calculating the planeness of different saw teeth on the same saw blade after grinding according to the two parameters of the tooth width and the tooth depth after grinding, and further judging whether the saw blade after grinding is qualified.
Preferably, the sawtooth edge is identified, and an algorithm including canny operator detection is used for extracting the line of the most edge of the sawtooth; extracting sawtooth feature points, namely extracting five feature points which are easily identified through an image; calculating sawtooth parameters, namely calculating five parameters of a back angle alpha, a front angle gamma, a tooth back Rb, a tooth width T and a tooth depth H through five characteristic points;
and (3) calculating the wear of the sawteeth, namely subtracting the front angle parameter, the rear angle parameter and the tooth back parameter of each sawtooth before grinding from the front angle parameter, the rear angle parameter and the tooth back parameter of the standard tooth form, and then averaging the front angle difference, the rear angle difference and the tooth back difference of all the obtained sawteeth respectively to obtain a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb, which represent how much the front angle parameter, the rear angle parameter and the tooth back parameter are respectively worn in the previous cutting operation of the circular saw blade.
Preferably, the SVM model is represented as follows:
T
w x+b＝0
in the formula, x represents an input parameter of an SVM model, w represents a normal vector of a classification hyperplane, T represents the transposition of the vector, and b represents the offset of the hyperplane relative to an original point; wherein, the input parameter x is three parameters of a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb;
supposing that the output parameter of the SVM model is y, the value of the output parameter y is only two states, using y = +1 to indicate that the sawtooth parameter selection is proper, and using y = -1 to indicate that the sawtooth parameter selection is improper;
obtaining data (x, y) of each circular saw blade, and obtaining a sample set for training the SVM model by using a plurality of circular saw blades of the same type, wherein the sample set is represented by { (x) 1 ,y 1 ),(x 2 ,y 2 ),…,(x i ,y i ) }, wherein: x is the number of i ∈R d ，y i E { +1, -1} is a class label, i =1,2, \8230, n;
after the SVM model is trained to be mature through the sample set, the SVM model can be used for judging whether the sawtooth parameter selection is proper or not, namely three parameters including the front angle average wear value delta gamma, the rear angle average wear value delta alpha and the tooth back average wear value delta Rb are input into the SVM model, and then whether the sawtooth parameter of the circular saw blade is matched with the field working condition or not is obtained, namely whether the sawtooth parameter selection is proper or not is judged.
Preferably, the sawtooth parameter is optimized, if the SVM model determines that the sawtooth parameter selection is not appropriate, the sawtooth parameter to be ground is adjusted, and the specific adjustment principle is as follows: firstly, adjusting three parameters of a front angle, a rear angle and a tooth back of a standard tooth form, then subtracting the adjusted standard tooth form parameter from the tooth form parameter before grinding, finally judging whether the average wear value of the front angle, the average wear value of the rear angle and the average wear value of the tooth back after adjustment are equal, if so, finishing the adjustment, otherwise, repeating the steps;
verifying the grinding precision of the sawteeth, namely subtracting the actual front angle, rear angle and tooth back parameter values of the grinded sawteeth from the front angle, rear angle and tooth back parameter values of the standard tooth shape to verify whether the grinding of the automatic tooth grinding machine to the sawteeth is accurate or not; setting a threshold value, and if the error of a certain parameter of any saw tooth on any circular saw blade exceeds 2%, requiring intervention of an operator to further examine the saw blade;
and evaluating the saw blade planeness, namely judging whether the circular saw blade planeness is qualified or not by adopting two parameters of the tooth width T and the tooth depth H on the circular saw blade according to deviation values of the tooth width T and the tooth depth H of all the sawteeth on the circular saw blade, wherein a judgment threshold value is determined by three parameters of the diameter of the circular saw blade, the number of the sawteeth and an allowable planeness error range, the deviation values of the tooth width T of all the sawteeth are within +/-1%, and the deviation values of the tooth depth H of all the sawteeth are within +/-2.4%, otherwise, requiring the intervention of an operator to further examine the saw blade.
The invention has the beneficial effects that:
(1) The working reliability is high: through the triple liquid drainage structure design of outer side liquid drainage, inner side liquid blowing and central liquid pumping, the complete drainage of the cooling liquid in the area to be detected is ensured, and the detection precision is further ensured;
(2) No damage to the saw blade: because the liquid drainage and blowing processes are completed by gas, the liquid pumping process is vacuum-absorbed, and no part is collided with the saw blade in the whole process, the damage such as scratch and the like to the surface of the saw blade can not be caused;
(3) The popularization is good: the invention has simple structure and low cost, and the required gas source, the vacuum pump and the like are also all stock equipment in a saw blade manufacturer, so the invention has better popularization;
(4) The detectable parameters are many: by the device and the using method of the device, the sawtooth abrasion detection, the sawtooth tooth profile optimization and the saw blade flatness detection can be fully automatically completed, and the processes are all completed on line in the process of grinding the teeth of the circular saw blade, so that the process of grinding the teeth of the circular saw blade cannot be interrupted;
(5) The device provided by the invention can be used as an important component of an automatic gear grinding machine, lays a foundation for increasing closed-loop feedback control of the automatic gear grinding machine, and can improve the grinding precision of the automatic gear grinding machine on the saw teeth; the use method of the device provided by the invention can greatly enhance the intelligence of the automatic tooth grinding machine of the circular saw blade.
Drawings
FIG. 1 is a schematic diagram of a partial cross-sectional structure of the present invention;
FIG. 2 is a schematic diagram of a partial cross-sectional structure of the present invention;
FIG. 3 is a cross-sectional view of the present invention;
FIG. 4 is a functional diagram of the present invention;
FIG. 5 is a schematic view of the bottom of the vacuum extractor tube of the present invention;
FIG. 6 is a schematic diagram of a method of calculating a sawtooth parameter scale of the present invention;
FIG. 7 is a schematic view of the arrangement of the present invention in actual use;
FIG. 8 is a flow chart of a method of use of the apparatus of the present invention;
FIG. 9 is a schematic diagram of a sawtooth parameter calculation method based on image recognition according to the present invention;
illustration of the drawings: 1. the device comprises a high-pressure air cavity, a 1a high-pressure air cavity air inlet hole, a 2 circumferential air curtain block, a 2a cylindrical through hole, a 2b annular through hole, a 3 supplementary light lamp bead hole, a 4 camera fixing through hole, a 5 vacuum extraction pipe, a 5a extraction port, a 5b first step line, a 5c second step line, a 6 high-pressure air blowing pipe, a 6a metal outer pipe, a 7 connecting rod, a 8 return spring, a 9 positioning coil, a 10 integral assembly body of the device, a 11 circular saw blade, a 12 and a grinding wheel.
Detailed Description
The invention will be further described with reference to the following figures and specific examples, but the scope of the invention is not limited thereto.
Referring to fig. 1-3, the sawtooth camera applied to the automatic tooth grinding machine of the circular saw blade comprises a high-pressure air cavity 1, a circumference air curtain block 2, a light-compensating lamp bead hole 3, a camera fixing through hole 4, a vacuum extraction pipe 5, a high-pressure air blowing pipe 6, a connecting rod 7, a return spring 8 and a positioning coil 9.
The high-pressure air cavity 1 and the circumferential air curtain block 2 are both cylindrical, and a cylindrical camera fixing through hole 4 is formed in the centers of the high-pressure air cavity and the circumferential air curtain block; meanwhile, the diameter of the bottom surface of the high-pressure air cavity 1 is the same as that of the bottom surface of the circumferential air curtain block 2, and the high-pressure air cavity and the circumferential air curtain block are coaxially arranged. An annular cavity surrounding the camera fixing through hole 4 is arranged in the center of the high-pressure air cavity 1, and air inlet holes (high-pressure air cavity air inlet holes) 1a are respectively formed in two side wall surfaces of the high-pressure air cavity 1; the upper half part of the circumferential air curtain block 2 is provided with a plurality of cylindrical through holes 2a which are distributed around the periphery of the camera fixing through hole 4, and the cylindrical through holes are communicated with the annular cavity of the high-pressure air cavity; the lower half part of the circumferential air curtain block 2 is provided with an annular through hole 2b, and the section of the annular through hole is inclined so as to facilitate the gas to be obliquely sprayed outwards; 2 bottom surfaces of circumference air curtain piece encircle camera fixed through hole 4 circumference outsides evenly distributed a plurality of light filling lamp pearl hole 3, and the mountable camera light filling lamp is convenient for shoot clear image.
In the invention, a vacuum extraction pipe 5 and a high-pressure air blowing pipe 6 both penetrate through a high-pressure air cavity 1 and a circumferential air curtain block 2, and are respectively arranged at two sides of a camera fixing through hole 4 on the same straight line, and simultaneously, the bottom of the high-pressure air blowing pipe 6 is 0.5 mm to 1 mm higher than the bottom of the vacuum extraction pipe 5; the connecting rod 7 is fixed above the high-pressure air cavity 1, and the vacuum extraction pipe 5 and the high-pressure air blowing pipe 6 are respectively fixed by fixing holes on two sides of the connecting rod in an interference fit mode; the return spring 8 is arranged in the upper cavity wall of the high-pressure air cavity 1 and is coaxially arranged with the vacuum extraction pipe 5; the positioning coil 9 is arranged in the upper cavity wall of the high-pressure air cavity 1 and is coaxially arranged with the high-pressure air blowing 6 pipe; the high-pressure gas blowing pipe 6 is made of non-metal materials, a layer of metal outer pipe 6a is sleeved outside the high-pressure gas blowing pipe 6 at the part corresponding to the positioning coil 9, and the height of the metal outer pipe 6a is equal to that of the positioning coil 9; in the initial state, the positioning coil 9 is flush with the metal outer tube 6 a.
The device is driven by a motor, and the motor is controlled by a controller.
When the device works, the bottom of the vacuum extraction pipe needs to be close to the circular saw blade as much as possible, but the bottom of the vacuum extraction pipe cannot touch the circular saw blade, because the circular saw blade needs to rotate continuously during sawtooth grinding, if the bottom of the vacuum extraction pipe touches the circular saw blade, the surface of the circular saw blade can be scratched. The invention solves the problem of how to position between the device and the circular saw blade by the design of the connecting rod, the return spring and the positioning coil, and the specific flow is as follows:
firstly, the device of the invention continuously approaches to the circular saw blade, when the bottom of the vacuum extraction pipe 5 contacts the circular saw blade, the vacuum extraction pipe 5 can be pushed upwards, the return spring 8 can be compressed at the moment, and the high-pressure air blowing pipe 6 is fixed with the vacuum extraction pipe 5 through the connecting rod 7, so that the high-pressure air blowing pipe 6 can also be synchronously pushed upwards, and the bottom of the high-pressure air blowing pipe is prevented from being abutted against and damaging the surface of the circular saw blade.
Then, the metal outer tube 6a outside the high pressure gas blowing tube 6 is pushed up at this time, and a misalignment occurs between the metal outer tube and the positioning coil 9, so that the self inductance value of the positioning coil 9 is changed. The detection circuit (e.g. an ac bridge) can detect a change in the self-inductance of the positioning coil, and the controller stops the drive motor immediately after reading the signal value of the detection circuit, i.e. stops the device of the invention from approaching further towards the circular saw blade.
Finally, the controller drives the motor to rotate reversely, namely, the device is driven to move in the direction far away from the circular saw blade, meanwhile, the controller synchronously detects the self-inductance value of the positioning coil, and when the self-inductance value recovers to the original value, the driving motor is immediately stopped. To this end, the positioning between the apparatus of the present invention and the circular saw blade is completed with the bottom of the vacuum take-off tube approaching the circular saw blade but not abutting the circular saw blade.
As shown in figure 4, the cooling liquid of the automatic gear grinding machine is completely excluded from the visual field of the camera through the design of a triple liquid drainage structure. The detailed design concept and working mode are shown in the following figures:
first, the outer annular curtain of gas removes the cooling fluid. High-pressure gas (high-pressure gas) 1 enters the annular cavity from the air inlet hole of the high-pressure gas cavity, then enters the annular through hole through the cylindrical through hole in the circumferential gas curtain block, finally forms a circumferential annular gas curtain, and is obliquely downwards and outwards sprayed to prevent cooling liquid of the automatic gear grinding machine from entering the vision field of the camera.
Secondly, the high-pressure air blowing pipe blows air directionally. The annular air curtain is not sufficient to completely exclude the coolant, and especially, the coolant droplets adhered to the surface of the circular saw blade pass through the annular air curtain as the circular saw blade rotates. At the moment, a high-pressure air blowing pipe is used for blowing air reversely outwards along the advancing direction of the circular saw blade, and cooling liquid drops brought in by the circular saw blade are blown out. The direction of the air blown out by the high-pressure air blowing pipe is consistent with the direction of the air of the annular air curtain to form resultant force, and the direction of the resultant force is opposite to the advancing direction of the circular saw blade to obtain the optimal removing effect.
Finally, a vacuum extraction tube extracts the droplets. After directional blowing of the high-pressure blowing pipe, basically no cooling liquid drops exist. However, in case a little liquid drops leak from the camera fixing through hole, for example, the present invention is provided with a vacuum extraction tube. The air suction direction of the vacuum suction pipe is consistent with the moving direction of the circular saw blade so as to obtain the optimal liquid suction effect.
According to the invention, through the triple liquid drainage structure design of outer side liquid drainage, inner side liquid blowing and central liquid pumping, the complete drainage of cooling liquid in the area to be detected is ensured, and the detection precision of the camera on the sawtooth is further ensured; meanwhile, in the liquid discharging, liquid blowing and liquid extracting processes, no part is abutted against the saw blade in the whole process, so that the surface of the saw blade cannot be scratched and the like; the device provided by the invention can be used as an important component of the automatic gear grinding machine, lays a foundation for increasing closed-loop feedback control of the automatic gear grinding machine, and can improve the grinding precision of the automatic gear grinding machine on the saw teeth.
Referring to fig. 5, the vacuum extraction pipe of the present invention is provided at the bottom thereof with an extraction port 5a, the extraction port 5a having a stepped shape including a first step line 5b and a second step line 5c. The first step line and the second step line shown in fig. 5 are equal in width and can range from 1 mm to 3 mm to accommodate most saw tooth sizes. In the present invention, the first step line and the second step line are arranged to provide a ruler for an image processing process, so as to facilitate the image processing to calculate saw tooth parameters and a saw blade distance more accurately, and the specific principle is as shown in fig. 6.
The left half of fig. 6 is a picture taken by the camera in the device of the present invention, and since the second step line at the bottom of the vacuum extraction tube is closer to the camera than the first step line, the width of the second step line is greater than the width of the first step line in the field of view of the camera. Since the four parameters of the actual first step line width value, the actual second step line width value, the actual first step line height difference, the actual second step line height difference, and the actual first step line height difference between the first step line and the circular saw blade are known, as shown in the right half of fig. 6, the height value between the camera and the second step line (shown by the dotted line in the right half of fig. 6) can be obtained according to the geometric relationship, and thus the distance value between the camera and the circular saw blade can also be obtained. Further, an actual value of the sawtooth profile can be obtained by conversion based on the actual width value of the first step line, the width value of the first step line in the visual field, and the numerical value of the sawtooth profile in the visual field.
Referring to fig. 7, the device of the present invention may be used in combination with two devices, and after the positioning between the device of the present invention 10 and the circular saw blade 11 is completed, one device of the present invention 10 is disposed before the grinding wheel 12, and one device of the present invention 10 is disposed after the grinding wheel, wherein one device is disposed before the grinding wheel to photograph the saw tooth parameters before the grinding wheel, and the other device is disposed after the grinding wheel to photograph the saw tooth parameters after the grinding wheel.
Referring to fig. 8, in the method for using the sawtooth camera applied to the automatic circular saw blade tooth grinding machine, two sets of sawtooth camera are respectively installed on two sides of the grinding wheel, and the method works according to the following procedures: the method comprises the following steps of (1) sawtooth shooting and parameter calculation, sawtooth abrasion calculation, sawtooth parameter type selection evaluation, sawtooth parameter optimization, sawtooth grinding precision verification and saw blade flatness evaluation; to complete a comprehensive evaluation of the circular saw blade and the saw teeth.
The step of sawtooth shooting and parameter calculation comprises the steps of shooting and tooth profile parameter calculation of sawteeth before and after grinding respectively. FIG. 9 is a sawtooth parameter calculation method based on image recognition, which comprises three steps of sawtooth edge recognition, sawtooth feature point extraction and sawtooth parameter calculation. The step of identifying the jagged edge is shown in fig. 9a, and an algorithm such as canny operator detection can be used to extract the line of the most jagged edge. The extraction of the sawtooth feature points is shown in fig. 9b, and five feature points such as ABCDE in the figure are extracted. In the above feature points, the point a is the highest point as well as the point B, which is the point where the two straight lines intersect; point E is the lowest point; the point C and the point D are the intersection points of the two lines, and the curvature of the circular arc has sudden change; therefore, the above five points are easily recognized by the image. And a sawtooth parameter calculating step, namely calculating five parameters of a back angle alpha, a front angle gamma, a tooth back Rb, a tooth width T and a tooth depth H through the five characteristic points ABCDE.
The sawtooth wear calculation is to calculate the subtraction of the standard tooth form and the tooth form before grinding so as to calculate the wear values of three parameters of the front angle, the rear angle and the tooth back of the sawtooth before grinding; specifically, three parameters of a front angle, a back angle and a tooth back of a standard tooth form (initial parameter values are input by an operator on a touch screen of a gear grinding machine) are respectively subtracted from the three parameters of the front angle, the back angle and the tooth back of each sawtooth before grinding, then the obtained front angle difference, back angle difference and tooth back difference of all the sawteeth are respectively averaged, and the obtained front angle average wear value delta gamma, back angle average wear value delta alpha and tooth back average wear value delta Rb represent how much the three parameters of the front angle, the back angle and the tooth back of the circular saw blade are respectively worn in the previous cutting operation.
The sawtooth parameter model selection evaluation means that a Support Vector Machine (SVM) model is used, three parameters of a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb are used as input parameters of the SVM model, sawtooth parameter model selection is proper, and sawtooth parameter model selection is improper to be used as output parameters of the SVM model (namely, the SVM model is used for carrying out secondary classification), so that whether sawtooth parameters are suitable for the working condition of a saw blade or not is judged.
The mathematical principle of the SVM model of the present invention is as follows:
the essence of the SVM model is to find a hyperplane in the multidimensional space that separates data (especially non-linear data) at maximum intervals to achieve data classification. The hyperplane equation can be written as follows:
w T x+b＝0 (1)
in the above formula, x represents an input parameter of the SVM model, w represents a normal vector of the classification hyperplane, T represents a transposition of the vector, and b represents a deviation of the hyperplane from an origin. The input parameter x is three parameters of a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb. Assuming that an output parameter of the SVM model is y, in the invention, the value of the output parameter y is only two states, wherein y = +1 represents that the sawtooth parameter selection is proper, and y = -1 represents that the sawtooth parameter selection is improper.
One data (x, y) can be obtained for each circular saw blade, so that a sample set for training the SVM model can be obtained by using a large number of circular saw blades of the same type, and the sample set can be expressed as { (x) 1 ,y 1 ),(x 2 ,y 2 ),…,(x i ,y i ) }, in which: x is the number of i ∈R d ，y i E { +1, -1} is the class label, i =1,2, \8230, n.
After the SVM model is trained to be mature through the sample set, the SVM model can be used for judging whether the sawtooth parameter selection is proper or not, namely three parameters including the front angle average wear value delta gamma, the rear angle average wear value delta alpha and the tooth back average wear value delta Rb are input into the SVM model, and then the SVM model can inform an operator whether the sawtooth parameter of the circular saw blade is matched with the field working condition or not, namely whether the sawtooth parameter selection is proper or not.
The sawtooth parameter optimization means that if the SVM model judges that the sawtooth parameter selection is not proper, tooth profile parameters of the sawtooth to be ground are adjusted, and particularly three parameters of a front angle, a rear angle and a tooth back of the sawtooth are adjusted. The specific adjustment principle is as follows: firstly, adjusting three parameters of a front angle, a rear angle and a tooth back of a standard tooth form, then subtracting the adjusted standard tooth form parameter from the tooth form parameter before grinding, finally judging whether the average wear value of the front angle, the average wear value of the rear angle and the average wear value of the tooth back after adjustment are equal, if so, finishing the adjustment, otherwise, repeating the steps.
The verification of the grinding precision of the sawtooth refers to subtraction calculation of a standard tooth form and a tooth form after grinding so as to calculate the grinding error of a sawtooth tooth form parameter. Specifically, subtraction is carried out on three parameters of an actual front angle, a real back angle and a tooth back of the sawteeth after grinding and three parameters of a front angle, a real back angle and a tooth back of a standard tooth shape so as to verify whether the grinding of the sawteeth by the automatic tooth grinding machine is accurate or not. A threshold value may be set that requires operator intervention to further audit the saw blade if any one of the saw teeth on any circular saw blade has a parameter error of more than 2%.
The saw blade flatness evaluation refers to calculating the flatness of different saw teeth on the same saw blade after grinding according to two parameters of the tooth width and the tooth depth after grinding, and the specific saw blade flatness evaluation basis is as follows: when the circular saw blade is good in flatness, each saw tooth is required to be equally large in the visual field of the camera; when the circular saw blade is warped, the saw teeth warped upwards (close to the camera) are larger in the visual field of the camera, and the saw teeth concaved downwards (far from the camera) are smaller in the visual field of the camera. In practical operation, the present invention uses two parameters of the tooth width T and the tooth depth H in fig. 8, and determines whether the flatness of the circular saw blade is qualified according to the deviation values of the tooth width T and the tooth depth H of all the sawteeth on the circular saw blade, and the determination threshold is determined by three parameters of the diameter of the circular saw blade, the number of sawteeth, and the allowable range of the allowable flatness error, such as the circular saw blade with the diameter of 300 mm, the number of sawteeth of 100 teeth, and the allowable range of the flatness error of ± 10 wires, the tooth width T of the circular saw blade is 9.42 mm, and the tooth depth H of the circular saw blade is 4.24 mm, and the deviation values of the tooth widths T of all the sawteeth should be within ± 1% (i.e., the maximum and minimum tooth widths taken within the view field of the camera are smaller than the average tooth width, and the deviation should be controlled within 1%), and the deviation values of the tooth depths H of all the sawteeth should be within ± 2.4%, otherwise, the operation worker should be required to further examine the sawblade.
The sawtooth camera device applied to the automatic gear grinding machine has the characteristics of high liquid discharge reliability, no damage to a saw blade, simple and stable structure and good popularization. Therefore, the device is additionally arranged on the automatic gear grinding machine, and the grinding precision and the intelligent degree of the automatic gear grinding machine can be greatly enhanced by using the method.
The foregoing detailed description is intended to illustrate and not limit the invention, which is intended to be within the spirit and scope of the appended claims, and any changes and modifications that fall within the true spirit and scope of the invention are intended to be covered by the following claims.
Claims (10)
1. The utility model provides a be applied to sawtooth camera device of automatic gear grinding machine of saw blade which characterized in that: the sawtooth camera device comprises a high-pressure air cavity, a circumferential air curtain block, a light-compensating lamp bead hole, a camera fixing through hole, a vacuum extraction pipe, a high-pressure air blowing pipe, a connecting rod, a return spring and a positioning coil, wherein the high-pressure air cavity is communicated with the circumferential air curtain block, the camera fixing through hole is formed in the center positions of the high-pressure air cavity and the circumferential air curtain block, and the light-compensating lamp bead hole is formed in the bottom of the circumferential air curtain block; the vacuum extraction pipe and the high-pressure air blowing pipe penetrate through the high-pressure air cavity and the circumferential air curtain block and are respectively arranged on two sides of the camera fixing through hole; the connecting rod is arranged above the high-pressure air cavity, and two ends of the connecting rod are respectively fixed with the fixed vacuum extraction pipe and the high-pressure air blowing pipe in an interference fit mode; the return spring is arranged in the upper cavity wall of the high-pressure air cavity and is coaxially arranged with the vacuum extraction pipe; the positioning coil is arranged in the upper cavity wall of the high-pressure air cavity and is coaxially arranged with the high-pressure air blowing pipe;
an annular cavity surrounding the camera fixing through hole is formed in the center of the high-pressure air cavity, and air inlet holes are formed in two side wall surfaces of the high-pressure air cavity respectively; the upper half part of the circumferential air curtain block is provided with a plurality of cylindrical through holes which are distributed around the periphery of the camera fixing through hole, and the cylindrical through holes are communicated with the annular cavity of the high-pressure air cavity; the lower half part of the circumferential air curtain block is provided with an annular through hole, and the cross section of the annular through hole is of an inclined structure.
2. The saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 1, wherein: the high-pressure air cavity and the circumferential air curtain block are two cylinders with the same diameter at the bottom and are coaxially arranged.
3. The saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 1, wherein: the light filling lamp pearl hole sets up on circumference air curtain piece bottom surface, and encircles camera fixed through hole circumference outside evenly distributed.
4. The saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 1, wherein: the bottom of the high-pressure air blowing pipe is 0.5 mm to 1 mm higher than the bottom of the vacuum extraction pipe.
5. The saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 1, wherein: and a layer of metal outer pipe is sleeved outside the high-pressure air blowing pipe at the part corresponding to the positioning coil, and the height of the metal outer pipe is equal to that of the positioning coil.
6. The saw-tooth imaging apparatus for a circular saw blade automatic gear grinding machine as claimed in claim 1, wherein: the bottom of the vacuum extraction pipe is provided with an extraction port, the extraction port is step-shaped, the extraction port comprises a first step line and a second step line, and the width values of the first step line and the second step line are equal; the width of the first step line and the second step line is 1 mm to 3 mm.
7. The use method of the saw-tooth camera device applied to the automatic circular saw blade gear grinding machine, which is characterized in that: two sets of sawtooth image pick-up devices are respectively arranged on two sides of the grinding wheel and work according to the following procedures: the method comprises the following steps of (1) sawtooth shooting and parameter calculation, sawtooth abrasion calculation, sawtooth parameter type selection evaluation, sawtooth parameter optimization, sawtooth grinding precision verification and saw blade flatness evaluation;
sawtooth shooting and parameter calculation: respectively shooting the sawteeth before and after grinding and calculating tooth profile parameters, wherein the tooth profile parameter calculation process comprises the steps of identifying the edges of the sawteeth, extracting the characteristic points of the sawteeth and calculating the tooth profile parameters;
and (3) calculating the sawtooth abrasion: subtracting the standard tooth form and the tooth form before grinding to calculate the wear values of three parameters of a front angle, a rear angle and a tooth back of the sawtooth before grinding;
and (3) sawtooth parameter type selection evaluation: using a Support Vector Machine (SVM) model, taking three parameters of a front angle average wear value, a rear angle average wear value and a tooth back average wear value as input parameters of the SVM model, and taking proper sawtooth parameter selection and improper sawtooth parameter selection as output parameters of the SVM model so as to judge whether the sawtooth parameters are suitable for the working condition of the saw blade;
and (3) sawtooth parameter optimization: adjusting the average wear value of a front angle, the average wear value of a rear angle and the average wear value of a tooth back of the tooth profile parameter to be polished;
checking the grinding precision of the saw teeth: carrying out subtraction calculation on the standard tooth profile and the tooth profile after grinding to calculate the grinding error of the tooth profile parameter of the sawtooth;
saw blade flatness evaluation: and calculating the planeness of different saw teeth on the same saw blade after grinding according to the two parameters of the tooth width and the tooth depth after grinding, and further judging whether the saw blade after grinding is qualified.
8. The use method of the saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 7, wherein: identifying the sawtooth edge, and extracting the line of the most edge of the sawtooth by using an algorithm including canny operator detection; extracting sawtooth feature points, namely extracting five feature points which are easily identified through images; calculating sawtooth parameters, namely calculating five parameters of a back angle alpha, a front angle gamma, a tooth back Rb, a tooth width T and a tooth depth H through five characteristic points;
and (3) calculating the wear of the sawteeth, namely subtracting the front angle parameter, the rear angle parameter and the tooth back parameter of each sawtooth before grinding from the front angle parameter, the rear angle parameter and the tooth back parameter of the standard tooth form, and then averaging the front angle difference, the rear angle difference and the tooth back difference of all the obtained sawteeth respectively to obtain a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb, which represent how much the front angle parameter, the rear angle parameter and the tooth back parameter are respectively worn in the previous cutting operation of the circular saw blade.
9. The use of the saw-tooth imaging apparatus for a circular saw blade automatic gear grinding machine according to claim 8, wherein the SVM model is expressed as follows:
T
w x+b＝0
in the formula, x represents an input parameter of an SVM model, w represents a normal vector of a classification hyperplane, T represents the transposition of the vector, and b represents the offset of the hyperplane relative to an original point; the input parameter x is three parameters of a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb;
supposing that the output parameter of the SVM model is y, the value of the output parameter y is only two states, using y = +1 to indicate that the sawtooth parameter selection is proper, and using y = -1 to indicate that the sawtooth parameter selection is improper;
obtaining data (x, y) of each circular saw blade, and obtaining a sample set for training the SVM model by using a plurality of circular saw blades of the same type, wherein the sample set is expressed as { (x) 1 ,y 1 ),(x 2 ,y 2 ),…,(x i ,y i ) }, in which:
x i ∈R d ，y i e { +1, -1} is a category label, i =1,2, \8230, n;
after the SVM model is trained well through the sample set, the SVM model can be used for judging whether the sawtooth parameter selection is proper or not, namely three parameters of a front angle average wear value delta gamma, a rear angle average wear value delta alpha and a tooth back average wear value delta Rb are input into the SVM model, and then whether the sawtooth parameter of the circular saw blade is matched with the field working condition or not, namely whether the sawtooth parameter selection is proper or not is obtained.
10. The use method of the saw-tooth camera device applied to the automatic gear grinding machine of the circular saw blade as claimed in claim 9, wherein: and (3) sawtooth parameter optimization, if the SVM model judges that the sawtooth parameter selection is not proper, regulating the sawtooth tooth profile parameter to be polished, wherein the specific regulation principle is as follows: firstly, adjusting three parameters of a front angle, a rear angle and a tooth back of a standard tooth form, then subtracting the adjusted standard tooth form parameter from the tooth form parameter before grinding, finally judging whether the average wear value of the front angle, the average wear value of the rear angle and the average wear value of the tooth back after adjustment are equal, if so, finishing the adjustment, otherwise, repeating the steps;
verifying the grinding precision of the sawteeth, namely subtracting the actual front angle, rear angle and tooth back parameter values of the grinded sawteeth from the front angle, rear angle and tooth back parameter values of the standard tooth shape to verify whether the grinding of the automatic tooth grinding machine to the sawteeth is accurate or not; setting a threshold value, and if the error of a certain parameter of any saw tooth on any circular saw blade exceeds 2%, requiring intervention of an operator to further examine the saw blade;
and evaluating the saw blade planeness, namely judging whether the circular saw blade planeness is qualified or not by adopting two parameters of the tooth width T and the tooth depth H on the circular saw blade according to deviation values of the tooth width T and the tooth depth H of all the sawteeth on the circular saw blade, wherein a judgment threshold value is determined by three parameters of the diameter of the circular saw blade, the number of the sawteeth and an allowable planeness error range, the deviation values of the tooth width T of all the sawteeth are within +/-1%, and the deviation values of the tooth depth H of all the sawteeth are within +/-2.4%, otherwise, requiring the intervention of an operator to further examine the saw blade.
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| CN117808798B (en) * | 2024-02-29 | 2024-05-14 | 山东万利精密机械制造有限公司 | Visual acquisition and analysis method for intelligent manufacturing production data of circular sawing machine |
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