CN116372305A - Extensible automatic solder coating system and method - Google Patents
Extensible automatic solder coating system and method Download PDFInfo
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- CN116372305A CN116372305A CN202310216338.XA CN202310216338A CN116372305A CN 116372305 A CN116372305 A CN 116372305A CN 202310216338 A CN202310216338 A CN 202310216338A CN 116372305 A CN116372305 A CN 116372305A
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- 239000011248 coating agent Substances 0.000 title claims abstract description 99
- 229910000679 solder Inorganic materials 0.000 title claims abstract description 81
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
- B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
- B05C5/0208—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work for applying liquid or other fluent material to separate articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
- B23K3/082—Flux dispensers; Apparatus for applying flux
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
- B25J11/0075—Manipulators for painting or coating
Abstract
The invention discloses an extensible automatic solder coating system, which comprises: the formula file manufacturing system is used for manufacturing independent solder coating track programs for various types of workpieces through an off-line programming technology; the automatic brazing filler metal coating device is used for selecting a formula file according to the model of a workpiece to be processed and coating brazing filler metal on the workpiece; visual correction mechanism extends and sets up on automatic solder coating device for mechanism of real-time correction solder coating orbit: the visual deviation correcting mechanism comprises a visual deviation correcting system, and is used for identifying pose deviation between a workpiece and a reference model in a formula file and carrying out online deviation correction on the automatic solder coating device. The process formula of each model of blade is manufactured by adopting an off-line programming technology, proper solder coating tracks are ensured for each blade, a vision correction mechanism is matched for assistance, the defect of the off-line programming technology compared with the on-line programming technology is overcome, and the high efficiency and the accuracy of automatic solder coating work are improved by correcting the position and the pose in real time.
Description
Technical Field
The invention relates to the technical field of aeroengine manufacturing, in particular to an extensible automatic solder coating system and method.
Background
The aero-engine completes compression and expansion of gas by virtue of the blades, and generates strong power to drive the aircraft to work forward with the highest efficiency. The quality of the blade is directly related to the power conversion efficiency of the aero-engine, and the welded aero-blade is widely applied due to the characteristics of simple structure, convenient design, lower cost and the like, and the quality of the solder coating directly influences the quality of the blade by taking welding as a combination mode, so that the performance of the engine is influenced. At present, the welding type blades in China are various in types, most of the welding type blades adopt a manual solder coating mode, the method is low in efficiency, high in labor intensity and unstable in quality, development of aviation industry is restrained, the automatic solder coating workstation for the blades solves the problems caused by manual solder coating, the solder coating efficiency is improved, the solder coating quality is ensured, and the welding type blade can be compatible with solder coating processes of various types of blades.
The intelligent automatic silica gel coating system and method for the tenons of the compressor blades of the aero-engine with the application number of CN202010795883.5 comprise the following steps: the device comprises a blade placing die, a first mechanical arm, a blade type recognition device, a blade gesture recognition device, a second mechanical arm and a control system, wherein the control system is respectively connected with the first mechanical arm, the blade type recognition device, the blade gesture recognition device, the second mechanical arm and the dispensing device through signals.
According to the scheme, the double manipulators are adopted to simulate manual gluing actions, and meanwhile, the double manipulators are combined with visual recognition means, so that functions of automatic recognition, positioning, coating and the like of a blade tenon silica gel coating process are realized, the gluing efficiency can be improved, the coating quality is ensured, and the movement flow of the manipulators is realized by depending on programming; in the prior art: the on-line teaching programming efficiency is low, the occupied time is long, the repeatability is poor, and the production requirement is difficult to adapt; the accuracy of teaching programming depends on the experience of an operator too much, and high-accuracy production tasks are difficult to finish; on-line teaching sometimes makes it difficult to find teaching points, so that the processing requirement of complex part tracks is difficult to complete; the teaching programming occupies a production line, and can greatly influence the production efficiency when the production line is stopped for modifying products or debugging new products in the face of huge production pressure or various small-batch production.
In summary, in most industrial robot applications, the robot motion is specified by pre-teaching and off-line programming, and the machining process simply repeats the pre-set motion. However, when the working environment or the position and size of the workpiece are changed, the robot operates according to the previously defined actions, and the quality is affected by the error.
Disclosure of Invention
In order to make up for the defects of online teaching in actual production, the invention provides an extensible automatic solder coating system, an offline programming technology is adopted, a three-dimensional model is built for a robot and parts by means of related offline programming software, a simulation situation consistent with a real environment is created in a computer interface, a model processing path is operated and processed by a corresponding algorithm in a mode of combining text programming and graphic programming, a program for controlling the robot to run is written according to a result of track programming under the condition that the robot is offline, so that an overall process formula of solder coating of workpieces (aviation blades) of the model is obtained, the formula creation and induction arrangement of the blades of each model are realized, and in the follow-up work, the efficient implementation of the solder coating process can be realized by only calling the process formula corresponding to the blade model.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
an expandable automated brazing filler metal coating system comprising:
the formula file manufacturing system is used for manufacturing independent solder coating track programs for various types of workpieces through an off-line programming technology;
the automatic brazing filler metal coating device is used for selecting a formula file according to the model of a workpiece to be processed and coating brazing filler metal on the workpiece;
visual correction mechanism extends and sets up on automatic solder coating device for mechanism of real-time correction solder coating orbit:
the visual deviation correcting mechanism comprises a visual deviation correcting system, and is used for identifying pose deviation between a workpiece and a reference model in a formula file and carrying out online deviation correction on the automatic solder coating device. As described in the background art, the online programming technology has a plurality of defects in actual production, so that the process formula of each type of blade is manufactured by adopting the offline programming technology, the proper solder coating track is ensured for each type of blade, the visual correction mechanism is matched for assistance, the defects of the offline programming technology compared with the online programming technology are overcome, and the high efficiency and the accuracy of the automatic solder coating work are improved by correcting the pose in real time.
Preferably, the automatic solder coating device comprises a machine table provided with an upper computer, wherein the machine table is provided with a dispensing mechanism and an execution robot; the machine table is also provided with a workpiece conveying mechanism; the execution robot comprises a workpiece clamp. The upper computer is used as a computer for directly sending out control commands, and other mechanisms such as a dispensing mechanism, an execution robot and the like can be controlled through software; the dispensing mechanism is a solder supply mechanism in solder coating work, the executing robot is an executing mechanism for clamping a workpiece to reach a preset position and waiting for solder coating, the dispensing mechanism and the executing robot are matched to carry out solder coating work, and the workpiece to be processed is clamped through the workpiece clamp to realize accurate positioning. The workpiece conveying mechanism is used for conveying the workpieces on the upper line and the lower line, and ensures that the flow machining work is normally carried out.
Preferably, the workpiece conveying mechanism comprises a feeding disc and a discharging conveying belt. The feeding disc is used for placing blades to be processed, and has universality, namely, is compatible with various blades; and the blanking conveyer belt is used for placing and transporting the processing blades.
Preferably, the formula file manufacturing system comprises a dispensing mechanism model database and a workpiece model database, and the steps of generating a robot solder coating track program by the formula file manufacturing system are as follows:
s1a: retrieving a reference model corresponding to a workpiece to be processed from a workpiece model database, and assembling the reference model to a virtual drill coating workstation in cooperation with a preset workpiece clamp model;
s1b: synchronously installing calibration equipment with the S1a, and completing the calibration of a workpiece coordinate system in a tool coordinate system;
s2: performing off-line track programming through a virtual drill coating workstation;
s3: performing simulation test on the track obtained in the step S2;
s4: after S3 and S1b are completed, performing real machine operation and process parameter adjustment;
s5: whether the test equipment meets the preset solder coating effect or not, and if not, returning to the step S4; if yes, entering S6;
s6: and the software in the upper computer arranged in the automatic solder coating device creates and stores the formula file of the model of the processing workpiece.
It should be noted that the processing before blade welding mainly comprises the important technological processes of blanking, precise milling, rough and precise polishing of molded surface and the like. The method reduces the difficulty and cost of formula multiplexing by optimizing the original design steps. Track establishment is realized through the steps S1a, S2 and S3; and the calibration of the coordinate system of each mechanism is realized through the S1b, wherein in the step S1b, a calibration rod 8 arranged on the machine table is included and used for calibrating the coordinate system of the tool by the robot. And carrying out real machine operation test according to the track establishment data and the coordinate system calibration result, thereby obtaining the solder coating track formula corresponding to each model of workpiece.
Preferably, the vision correction mechanism comprises a fixed tool and a workpiece surface data acquisition assembly arranged on the fixed tool, and the workpiece surface data acquisition assembly comprises a vision scanner and a driving motor for driving the vision scanner to run on the fixed tool. The vision correcting mechanism controls the vision correcting mechanism by the vision correcting system to realize secondary positioning and real-time pose correcting work of the workpiece, and the driving motor drives the vision scanner to move in a certain range on the guide rail of the fixed tool so as to follow the coordinates of the workpiece when the position is adjusted.
Preferably, the machine is further provided with a secondary positioning assembly, and the secondary positioning assembly comprises a clamping table. The workpiece is temporarily clamped and placed by the secondary positioning assembly through the clamping table, so that the grabbing gesture of the robot is conveniently adjusted after the workpiece is grabbed from the feeding disc.
Preferably, the workflow of the visual correction system is as follows:
s1: the execution robot grabs the workpiece to reach the position corresponding to the vision correction device;
s2: the visual deviation correcting device scans the workpiece and then calculates pose deviation;
s3: the execution robot adjusts the grabbing gesture according to the gesture deviation data provided by the S2.
Preferably, the vision scanner includes a camera a and a camera B disposed opposite to each other up and down, and the pose deviation resolving section includes the steps of:
s1: determining a transformation relation from the camera B to the camera A by adopting a double-camera calibration method;
s2: the point cloud data collected by the camera A and the camera B are subjected to downsampling and denoising;
s3: determining the transformation relation from the camera A to the execution robot base by adopting a hand eye calibration method;
s4: and carrying out nearest neighbor iteration solution on the transformed point cloud data and the reference model to calculate the conversion relation between the reference model and the tested workpiece, and obtaining pose deviation.
In robotic applications, the motion and trajectory of the robot are specified by pre-teaching and off-line programming, with the process simply repeating the pre-set. However, in an actual working environment, errors in size and shape of a workpiece model are generated in manufacturing the workpiece, in addition, errors in position are generated in clamping the workpiece by the robot, and if the robot still executes according to the previously set actions and tracks, errors are further generated, so that the product quality is affected. Therefore, the visual deviation correcting system is used for controlling the visual deviation correcting mechanism to conduct point-to-point comparison deviation correcting on the actual position of the workpiece and the position of the reference model, and accurate execution of the formula generated in the off-line programming mode is ensured.
Further, the point cloud data collected by the camera A and the camera B are stored by adopting a data structure of octree so as to perform downsampling and normal calculation; extracting geometric features of each point in the point cloud data by using a fast feature point histogram descriptor algorithm; after roughly aligning the point cloud data collected by the camera A with the point cloud data collected by the camera B by using a fast global alignment (FGR: fast Global Registration) algorithm, finely aligning the point cloud data collected by the camera A with the point cloud data collected by the camera B by using an iterative closest point (ICP: iterative closest point) algorithm. The fast feature point histogram descriptor algorithm (FPFH: fast Point Feature Histogram) has advantages for dense point feature computation; in the case of three-dimensional point cloud matching (Point cloud registration), it is common practice to first make a rough match based on features and RANSAC, and then make a round of fine matching. One feature that is often used for coarse matching is the FPFH feature, while the ICP method is generally used for fine matching.
The invention also discloses a working method of the extensible automatic solder coating system, which is characterized by comprising the following steps of:
s1: loading a formula file corresponding to a workpiece to be processed by the automatic solder coating device;
s2: the workpiece clamp arranged on the execution robot clamps the workpiece to be processed for secondary positioning;
s3: the execution robot clamps the workpiece to the vision correction device to perform vision correction;
s4: executing the robot to clamp the workpiece and automatically coating the brazing filler metal;
s5: the execution robot clamps the workpiece to a blanking conveyor belt of the workpiece conveying mechanism and then puts down the workpiece.
According to the method, the secondary positioning mechanism assists the execution robot to carry out accurate clamping and positioning of the workpiece, follow-up solder coating work is guaranteed to be carried out according to a preset formula, and a vision correction system is assisted in actual processing to carry out real-time pose correction, so that accurate and efficient solder coating of all types of blades is guaranteed.
Therefore, the invention has the following beneficial effects: (1) Under the condition that the robot is offline, programming a program for controlling the robot to run according to a track planning result, so that an overall process formula of the brazing filler metal coating for the workpieces (aviation blades) of the model is obtained, the formula creation and the induction arrangement of the blades of each model are realized, and in the follow-up work, the efficient performance of the brazing filler metal coating process can be realized only by calling the process formula corresponding to the model of the blade; (2) Carrying out real machine operation test on the workpieces of each model according to the track establishment data and the coordinate system calibration result, thereby obtaining solder coating track formulas corresponding to the workpieces of each model, and establishing a formula database to facilitate subsequent processing; (3) And the vision correction system is used for controlling the vision correction mechanism to perform point-to-point comparison correction on the actual position of the workpiece and the reference model position, so that the accurate execution of the formula generated in the off-line programming mode is ensured.
Drawings
Fig. 1 is a schematic structural view of the present invention.
Fig. 2 is a flowchart of the operation of the automatic solder coating apparatus of fig. 1.
Fig. 3 is a flow chart of the fabrication of a solder track.
Fig. 4 is a schematic creation of a recipe file.
Fig. 5 is a schematic diagram of the distribution of a recipe file.
Fig. 6 is a flow chart of the operation of the braze formulation.
FIG. 7 is a diagram of an upper computer monitor interface.
Fig. 8 is a flowchart of the operation of the visual deviation correcting device.
Fig. 9 is an algorithm process diagram of the visual deviation correcting system.
Fig. 10 is a process diagram of the hand-eye calibration method in example 3.
FIG. 11 is a schematic diagram of the relationship between the center of a fitted circle and the center of a calibration sphere.
FIG. 12 is a schematic diagram of a coordinate system location in a simulation environment.
In the figure: 100 camera coordinate system, 200 workpiece coordinate system, 300 flange plate coordinate system, 400 robot base coordinate system, 1 automatic solder coating device, 11 machines, 2 dispensing mechanism, 3 execution robot, 31 work piece holder, 32, flange plate, 5 unloading conveyer belt, 6 secondary positioning assembly, 61 clamping table, 7 vision correction mechanism, 71 camera A, 72 camera B, 73 driving motor, 74, fixed frock, 8 calibration pole, 101 work piece.
Detailed Description
The invention is further described below with reference to the drawings and detailed description. Examples of the embodiments are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements throughout or elements having like or similar functionality. The embodiments described below by referring to the drawings are illustrative and intended to explain the present invention and should not be construed as limiting the invention.
Example 1
As shown in fig. 1, an expandable automated brazing filler metal coating system comprising:
the formula file manufacturing system is used for manufacturing independent solder coating track programs for various types of workpieces through an off-line programming technology;
the automatic brazing filler metal coating device 1 selects a formula file according to the model of a workpiece to be processed and performs brazing filler metal coating on the workpiece;
the visual correction mechanism 7 is arranged on the automatic solder coating device in an expanding way and used for correcting the solder coating track in real time:
the visual deviation correcting mechanism comprises a visual deviation correcting system, and is used for identifying pose deviation between a workpiece and a reference model in a formula file and carrying out online deviation correction on the automatic solder coating device. The automatic solder coating device comprises a machine table 11 provided with an upper computer, wherein the machine table is provided with a dispensing mechanism 2 and an execution robot 3; the machine table is also provided with a workpiece conveying mechanism; the actuator robot is connected to a work holder 31 via a flange 32. The workpiece conveying mechanism comprises a feeding disc and a discharging conveying belt 5.
As described in the background art, the online programming technology has a plurality of defects in actual production, so that the process formula of each type of blade is manufactured by adopting the offline programming technology, the proper solder coating track is ensured for each type of blade, the visual correction mechanism is matched for assistance, the defects of the offline programming technology compared with the online programming technology are overcome, and the high efficiency and the accuracy of the automatic solder coating work are improved by correcting the pose in real time.
The working flow of the automatic solder coating device is shown in fig. 2, the upper computer is used as a computer for directly sending out control commands, and other mechanisms such as a dispensing mechanism, an execution robot and the like can be controlled through software; the dispensing mechanism is a solder supply mechanism in solder coating work, the executing robot is an executing mechanism for clamping a workpiece to reach a preset position and waiting for solder coating, the dispensing mechanism and the executing robot are matched to carry out solder coating work, and the workpiece to be processed is clamped through the workpiece clamp to realize accurate positioning. The workpiece conveying mechanism is used for conveying the workpieces on the upper line and the lower line, and ensures that the flow machining work is normally carried out. The feeding disc is used for placing blades to be processed, and has universality, namely, is compatible with various blades; and the blanking conveyer belt is used for placing and transporting the processing blades. Wherein the execution robot is a six-axis robot. The blanking conveyer belt adopts a belt conveying mechanism. The dispensing mechanism is used for storing a container of brazing filler metal and comprises a discharge hole of the brazing filler metal.
The operation of the scalable automated solder coating system in this embodiment includes the steps of:
s1: loading a formula file corresponding to a workpiece to be processed by the automatic solder coating device;
s2: the workpiece clamp arranged on the execution robot clamps the workpiece to be processed for secondary positioning;
s3: the execution robot clamps the workpiece to the vision correction device to perform vision correction;
s4: executing the robot to clamp the workpiece and automatically coating the brazing filler metal;
s5: the execution robot clamps the workpiece to a blanking conveyor belt of the workpiece conveying mechanism and then puts down the workpiece.
Example 2
In this embodiment, a method for preparing a recipe file is disclosed, the recipe file preparing system includes a model database of a dispensing mechanism and a model database of a workpiece, and the steps of generating a robot solder coating track program by the recipe file preparing system are as follows:
s1a: retrieving a reference model corresponding to a workpiece to be processed from a workpiece model database, and assembling the reference model to a virtual drill coating workstation in cooperation with a preset workpiece clamp model;
s1b: synchronously installing calibration equipment with the S1a, and completing the calibration of a workpiece coordinate system in a tool coordinate system;
s2: performing off-line track programming through a virtual drill coating workstation;
s3: performing simulation test on the track obtained in the step S2;
s4: after S3 and S1b are completed, performing real machine operation and process parameter adjustment;
s5: whether the test equipment meets the preset solder coating effect or not, and if not, returning to the step S4; if yes, entering S6;
s6: and the software in the upper computer arranged in the automatic solder coating device creates and stores the formula file of the model of the processing workpiece.
It should be noted that the processing before blade welding mainly comprises the important technological processes of blanking, precise milling, rough and precise polishing of molded surface and the like. The scheme gets rid of the constraint of high formula creation cost or low efficiency in the production field, and reduces the difficulty and cost of formula multiplexing. Track establishment is realized through the steps S1a, S2 and S3; and the calibration of the coordinate system of each mechanism is realized through the S1b, wherein in the step S1b, a calibration rod arranged on the machine table is included and used for calibrating the coordinate system of the tool by the robot. And carrying out real machine operation test according to the track establishment data and the coordinate system calibration result, thereby obtaining the solder coating track formula corresponding to each model of workpiece.
Specifically, the formula file mainly comprises a dispensing mechanism model, a reference model and a robot solder coating track program. Wherein the reference model is a three-dimensional model of the workpiece to be machined. The robot solder track program was created by off-line programming software RobotStudio, the flow of which is shown in fig. 3.
And packaging and uploading the manufactured solder track program to an ftp server in a zip format. The new creation of the recipe file is shown in fig. 4, a new button is clicked in the upper computer software recipe management interface, a new dialog box of the recipe is popped up, the information of the blade type, the fixture type and the dispensing head type is input, and after the browsing button is clicked, the track program package is selected from the ftp server, the creation of the recipe is clicked to be completed.
After the formula is created, the formula is issued as shown in fig. 5, after the formula to be issued is clicked, the issuing button is clicked, the upper computer sends the solder coating track file corresponding to the blade model to the robot end, and under normal conditions, after the workstation starting button is pressed, the workstation starts working. If different blades are to be replaced, the automatic processing can be started rapidly only by issuing a formula file of a corresponding model after replacing the corresponding clamp, so that the working efficiency of a workstation is greatly improved, and the good compatibility of the technical scheme for processing the blades of different models is reflected.
The formula operation flow of the solder coating is shown in fig. 6, and in the automatic operation process of the workstation, the upper computer of the workstation comprises a monitoring interface shown in fig. 7, so that the state of the operation process is monitored in real time, if an abnormality occurs, a protection measure can be immediately triggered, the safety of the whole workstation is improved, and the efficiency of an engineer for checking the abnormality is also improved.
Example 3
The embodiment discloses a specific implementation mode of a vision correction system: the vision correction mechanism comprises a fixed tool 74 and a workpiece surface data acquisition assembly arranged on the fixed tool, wherein the workpiece surface data acquisition assembly comprises a vision scanner and a driving motor 73 for driving the vision scanner to run on the fixed tool, and the driving motor is a stepping motor. The vision correcting mechanism controls the vision correcting mechanism by the vision correcting system to realize secondary positioning and real-time pose correcting work of the workpiece, and the driving motor drives the vision scanner to move in a certain range on the guide rail of the fixed tool so as to follow the coordinates of the workpiece when the position is adjusted. The solutions that are popular in the field of vision three-dimensional scanning and measurement can be broadly divided into structured light-based and laser-based solutions according to the working principle. According to different measurement requirements, the two modes have different applicable scenes. On the one hand, for metal objects with small size and high light reflection like blades, the measurement equipment based on blue light structured light can realize non-contact measurement, but the imaging effect is easily affected by the high light reflection metal surface. The surface of the workpiece is generally required to be pretreated, such as powder spraying or labeling, so as to ensure the measurement precision and stability.
In this embodiment, to aviation blade's size and high reflection of light characteristic, adopt 3D laser scanner can detect blade surface morphology well, compare blue light structure light detection scheme, can prevent the detection error that the surface reflection of light brought well and can carry out full-automatic online rectifying.
The machine is also provided with a secondary positioning assembly 6 which comprises a clamping table 61. The workpiece is temporarily clamped and placed by the secondary positioning assembly through the clamping table, so that the grabbing gesture of the robot is conveniently adjusted after the workpiece is grabbed from the feeding disc.
As shown in fig. 8, the workflow of the visual correction system is as follows:
s1: the execution robot grabs the workpiece to reach the position corresponding to the vision correction device;
s2: the visual deviation correcting device scans the workpiece and then calculates pose deviation;
s3: the execution robot adjusts the grabbing gesture according to the gesture deviation data provided by the S2.
The visual scanner comprises a camera A71 and a camera B72 which are arranged up and down oppositely, the visual correction algorithm process of the pose deviation resolving part is shown in fig. 9, and the key steps are the transformation relation from the camera B to the camera A and the transformation relation from the camera A to the execution robot base. The method comprises the following steps:
s1: determining a transformation relation from the camera B to the camera A by adopting a double-camera calibration method;
s2: the point cloud data collected by the camera A and the camera B are subjected to downsampling and denoising;
s3: determining the transformation relation from the camera A to the execution robot base by adopting a hand eye calibration method;
s4: and carrying out nearest neighbor iteration solution on the transformed point cloud data and the reference model to calculate the conversion relation between the reference model and the tested workpiece, and obtaining pose deviation.
As shown in fig. 1, the camera a and the camera B in the vision correction mechanism are laser cameras, and are driven by a stepping motor to run on a fixed tool. In robotic applications, the motion and trajectory of the robot are specified by pre-teaching and off-line programming, with the process simply repeating the pre-set. However, in an actual working environment, errors in size and shape of a workpiece model are generated in manufacturing the workpiece, in addition, errors in position are generated in clamping the workpiece by the robot, and if the robot still executes according to the previously set actions and tracks, errors are further generated, so that the product quality is affected. Therefore, the visual deviation correcting system is used for controlling the visual deviation correcting mechanism to conduct point-to-point comparison deviation correcting on the actual position of the workpiece and the position of the reference model, and accurate execution of the formula generated in the off-line programming mode is ensured.
Specifically, the purpose of the dual camera calibration is to integrate the measurement data collected by the two cameras into a coordinate system, so that the measured object information can be obtained more comprehensively. Structurally, as shown in fig. 1, camera a and camera B satisfy correlation, and the y-axis is perpendicular to the light plane. Ideally, the transformation relationship camera1Tcamera2 between cameras can be expressed by expression (1).
However, in practice, there is some deviation in the position of the camera due to machining and installation errors of the camera fixture. To eliminate this deviation, a cube standard block is used for calibration.
The point cloud acquired by the camera A under the camera coordinate system is recorded as P= [ P ] 1 ,p 2 ,...,p n ]The point cloud matrix acquired by the camera B under the camera coordinate system is Q= [ Q ] 1 ,q 2 ,...,q n ]. Square standard block model point cloud m= [ M ] 1 ,m 2 ,...,m n ]. The following relationship is satisfied:
p T q ＝ p T m · m T q (2)
in the method, in the process of the invention, p T q representing the transformation relation from the camera1 coordinate system to the camera2 coordinate system, namely the result of the dual camera calibration, p T m representing the transformation relation from the camera1 coordinate system to the standard block model point cloud coordinate system, m T q and the transformation relation from the standard block model point cloud coordinate system to the camera2 coordinate system is represented.
p T m And solving coarse alignment and ICP alignment parts for solving and correcting the reference pose deviation. Storing P, M point cloud data in Octree (Octree) data structure for downsampling and normal computation, extracting the geometry of each point using FPFH algorithmAfter the feature, P, M is roughly aligned by using a fast global alignment (Fast Global Registration) algorithm, and P, M point clouds are closely overlapped by using an ICP alignment algorithm p T m . The same procedure can be achieved q T m Then calculate q T m Is inverse transformed to obtain m T q . According to (2) p T m And m T q is known, i.e. the transformation relation from the camera A coordinate system to the camera B coordinate system is solved p T q 。
In the case that no relative motion occurs between the two cameras, the results of the two camera calibration can be multiplexed all the time, which is saved in the upper computer program.
Specifically, the pose deviation calculation algorithm is as follows: as shown in fig. 12, a camera coordinate system 100, a work piece coordinate system 200, a flange plate coordinate system 300, and an execution robot base coordinate system 400 are first established on the device.
Recording that the laser camera collects the whole point cloud matrix form of the surface of the tested workpiece under the camera coordinate system as A l ＝[a 1 ,a 2 ,...,a n ]A is subjected to the following transformation:
A w ＝ w T f · f T b · b T l ·A l
wherein, the liquid crystal display device comprises a liquid crystal display device, f T b the transformation relation from the robot flange coordinate system to the robot base coordinate system is represented and can be obtained by the robot SDK. w T f The transformation relation from the workpiece coordinate system to the robot flange coordinate system is represented and can be obtained by the robot SDK. b T l The transformation relation from the robot base coordinate system to the camera coordinate system is represented and obtained by a hand-eye calibration method.
Through the transformation of the upper part, A w And representing a point cloud matrix of the surface of the measured workpiece under the workpiece coordinate system. With a point cloud matrix B referencing the workpiece in the working coordinate system w ＝[b 1 ,b 2 ,...,b n ]With point cloud A in the object coordinate system w 、B w 。
Stored in an Octree (Octree) data structureStore A w 、B w Downsampling and normal calculation are carried out on point cloud data, after geometrical characteristics of each point are extracted by using an FPFH algorithm, A is obtained by using a fast global alignment (Fast Global Registration) algorithm w 、B w Coarse alignment is achieved. After coarse alignment, pair A w 、B w An ICP alignment algorithm is used for achieving close coincidence of two point clouds. The point cloud A under the original workpiece coordinate system can be obtained through coarse alignment and ICP alignment algorithm w Sum point cloud B w The transformation relation between them, i.e. pose deviation B T A . After the pose deviation is calculated, the robot applies the transformation relation to the workpiece coordinate system B T A The pose of the actual workpiece is consistent with the pose of the reference workpiece in the simulation environment, so that deviation correction can be achieved, and the influence of errors on the product quality is avoided.
The hand-eye calibration method and the hand-eye calibration system mainly comprise an industrial six-axis robot, a line laser camera and a calibration ball. The robot wrist end is provided with a calibration ball, the calibration ball reaches the measuring range of the laser camera according to the planned path, the laser camera arranged on the fixed tool collects the coordinate value of the intersection line of the laser and the calibration ball under the camera coordinate system, and the automatic flow is shown in figure 10. Fitting a circle equation under the camera coordinate system (y-axis perpendicular to the light plane) is:
(x-x n ) 2 -(z-z n ) 2 ＝r 2
fitting the measurement data acquired by the line laser camera through a fitting equation to obtain the circle center O of the intersecting circular arc under the camera coordinate system n Radius r. FIG. 11 shows the relationship between the center of the fitted circle and the center of the calibration sphere.
Further find the spherical center P coordinate under the camera coordinate system as
x p ＝x n
z p ＝z n
Wherein: r is the radius of the calibration sphere; y is p Is determined from the position of the laser camera. The pose of the robot is changed to carry out multiple measurements, the calculated spherical center coordinates of the calibration sphere are integrated under a base coordinate system of the robot, and the transformation relation between the base coordinate system and the flange coordinate system is changed along with the change of the robot B T F Continuously changing but obtainable from a positive kinematic model of the robot. Then there is the following formula:
b T l ·C l ＝ b T f ·C f
in the method, in the process of the invention, b T l representing the transformation relation from the base coordinate system to the camera coordinate system, C l Representing the coordinates of the sphere center of the calibration sphere under the camera coordinate system, b T f representing the transformation relation from the base coordinate system to the flange coordinate system, C f And (5) representing the coordinates of the sphere center of the calibration sphere under the robot flange coordinate system. According to this equation, the problem can be expressed as an optimization problem:
a i representing the coordinates of the sphere center in the camera coordinate system, b i Representing the coordinates of the sphere center in the base coordinate system. The rotation relation R and the translation relation t, R and t can be solved through the transformation relation from the spherical center coordinate under the camera coordinate system of different robot pose and the robot base coordinate system to the flange coordinate system, and the hand-eye calibration result is obtained through the combination of the following components b T l 。
Claims (10)
1. An expandable automated brazing filler metal coating system, comprising:
the formula file manufacturing system is used for manufacturing independent solder coating track programs for various types of workpieces through an off-line programming technology;
the automatic brazing filler metal coating device is used for selecting a formula file according to the model of a workpiece to be processed and coating brazing filler metal on the workpiece;
visual correction mechanism extends and sets up on automatic solder coating device for mechanism of real-time correction solder coating orbit:
the visual deviation correcting mechanism comprises a visual deviation correcting system, and is used for identifying pose deviation between a workpiece and a reference model in a formula file and carrying out online deviation correction on the automatic solder coating device.
2. An expandable automatic solder coating system according to claim 1, wherein the automatic solder coating device comprises a machine table provided with an upper computer, and the machine table is provided with a dispensing mechanism and an execution robot; the machine table is also provided with a workpiece conveying mechanism; the execution robot comprises a workpiece clamp.
3. An expandable automated brazing filler metal coating system according to claim 2, wherein the workpiece transport mechanism comprises an upper tray and a lower belt.
4. An expandable automated solder coating system according to claim 1, wherein the recipe file creation system comprises a dispensing mechanism model database and a workpiece model database, the recipe file creation system generating a robotic solder coating track program comprising the steps of:
s1a: retrieving a reference model corresponding to a workpiece to be processed from a workpiece model database, and assembling the reference model to a virtual drill coating workstation in cooperation with a preset workpiece clamp model;
s1b: synchronously installing calibration equipment with the S1a, and completing the calibration of a workpiece coordinate system in a tool coordinate system;
s2: performing off-line track programming through a virtual drill coating workstation;
s3: performing simulation test on the track obtained in the step S2;
s4: after S3 and S1b are completed, performing real machine operation and process parameter adjustment;
s5: whether the test equipment meets the preset solder coating effect or not, and if not, returning to the step S4; if yes, entering S6;
s6: and the software in the upper computer arranged in the automatic solder coating device creates and stores the formula file of the model of the processing workpiece.
5. An expandable automated solder coating system according to any of claims 1-4, wherein the vision correction mechanism comprises a fixed tooling and a workpiece surface data acquisition assembly disposed on the fixed tooling, the workpiece surface data acquisition assembly comprising a vision scanner and a drive motor for driving the vision scanner to operate on the fixed tooling.
6. An expandable automated solder coating system according to claim 1, wherein the machine is further provided with a secondary positioning assembly comprising a clamping table.
7. An expandable automated solder coating system according to claim 5, wherein the workflow of the visual correction system is as follows:
s1: the execution robot grabs the workpiece to reach the position corresponding to the vision correction device;
s2: the visual deviation correcting device scans the workpiece and then calculates pose deviation;
s3: the execution robot adjusts the grabbing gesture according to the gesture deviation data provided by the S2.
8. An expandable automated brazing system according to claim 5, wherein the vision scanner comprises a camera a and a camera B disposed opposite each other up and down, the pose deviation resolving section comprising the steps of:
s1: determining a transformation relation from the camera B to the camera A by adopting a double-camera calibration method;
s2: the point cloud data collected by the camera A and the camera B are subjected to downsampling and denoising;
s3: determining the transformation relation from the camera A to the execution robot base by adopting a hand eye calibration method;
s4: and carrying out nearest neighbor iteration solution on the transformed point cloud data and the reference model to calculate the conversion relation between the reference model and the tested workpiece, and obtaining pose deviation.
9. The scalable automated brazing system according to claim 8, wherein the point cloud data collected by camera a and camera B is stored in octree data structures for downsampling and normal computation; extracting geometric features of each point in the point cloud data by using a fast feature point histogram descriptor algorithm; after roughly aligning the point cloud data collected by the camera A with the point cloud data collected by the camera B by using a rapid global alignment algorithm, finely aligning the point cloud data collected by the camera A with the point cloud data collected by the camera B by using an iterative nearest point algorithm.
10. A method of operating an expandable automated solder coating system according to any of claims 1-9, comprising the steps of:
s1: loading a formula file corresponding to a workpiece to be processed by the automatic solder coating device;
s2: the workpiece clamp arranged on the execution robot clamps the workpiece to be processed for secondary positioning;
s3: the execution robot clamps the workpiece to the vision correction device to perform vision correction;
s4: executing the robot to clamp the workpiece and automatically coating the brazing filler metal;
s5: the execution robot clamps the workpiece to a blanking conveyor belt of the workpiece conveying mechanism and then puts down the workpiece.
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| CN116871709A (en) * | 2023-09-08 | 2023-10-13 | 常州市鹏瑞自动化设备有限公司 | Method for cutting special-shaped round pipe fitting by laser |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116871709A (en) * | 2023-09-08 | 2023-10-13 | 常州市鹏瑞自动化设备有限公司 | Method for cutting special-shaped round pipe fitting by laser |
| CN116871709B (en) * | 2023-09-08 | 2023-12-08 | 常州市鹏瑞自动化设备有限公司 | Method for cutting special-shaped round pipe fitting by laser |
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