CN116697972A - Ceramic product surface flatness detection method based on impedance control - Google Patents
Ceramic product surface flatness detection method based on impedance control Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/30—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring roughness or irregularity of surfaces
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Abstract
The application discloses a ceramic product surface flatness detection method based on impedance control, which comprises the following steps: constructing a force/gesture hybrid control system; the system comprises: impedance controller, gesture compliance controller, servo driver and six-dimensional force sensor; robot Z-axis force f measured by six-dimensional force sensor z ，f z Obtained by filtering the force With the expected force f d Performing difference to obtain a Z-axis force error; obtaining a Z-axis reference position through an impedance controller, and obtaining a joint angle theta of each motion of the robot through inverse kinematics; measuring moment M on X axis or Y axis of robot by six-dimensional force sensor xy And is obtained by moment filtering As input to a gesture compliance controller; the gesture compliance controller is used for controlling the rotation directions of X and Y axes of a tool coordinate system; θ and θ c And adding the signals to obtain the interaction force of the robot and the environment and the actual position in the environment. The beneficial effects are that: the method has wider applicability and higher precision in detecting the surface flatness of the ceramic product.
Description
Technical Field
The application relates to the field of defect detection, in particular to a ceramic product surface flatness detection method based on impedance control.
Background
The field of ceramic surface quality detection is still blank in the ceramic machinery industry in China. The surface quality detection of ceramics is one of the most important links in the ceramic production industry, and is still in a manual detection stage to a great extent in this aspect at home at present, so that the quality of ceramic detection is difficult to be well ensured.
In the detection of ceramic quality factors, flatness detection is very important, and the flatness of the ceramic directly relates to the decoration effect and the use effect. Most of traditional ceramic surface detection aims at a plane, and most of bathroom ceramic products have complex curved surfaces, and a model is difficult to accurately establish, so that a unified detection method is not available. With the rapid development of electronic technology and computer technology, robotics have been actively developed in recent decades and are increasingly used in many fields. Automated detection methods based on robots have become an inevitable trend for high quality production of ceramic articles.
The non-contact detection method based on the optical principle converts the characteristic point information into a digital signal, and obtains the flatness of the ceramic surface according to a specific flatness algorithm. However, the method has strict requirements on the light irradiation intensity, the irradiation angle and the like of the environment, and the ceramic product has low texture and smooth reflection, so the method also has requirements on the placement position of the ceramic product when being used. In summary, the non-contact detection method based on the optical principle has limited applicability to the detection of the surface flatness of ceramic products. The non-contact nondestructive testing method for the surface flatness of the ceramic tile has the advantages of simple system structure, strong practicability, high testing precision, realization of simultaneous detection of a plurality of samples and the like, can well solve the problems of inaccuracy, low efficiency and the like caused by manual detection of the surface quality of the ceramic tile, and can be a new testing method used in the production of ceramic tile industry.
Touch detection is commonly used for surface defect detection in the industries of steel, glass and the like, and whether a plane is flat or not is detected by observing the change of force information of a sensor. This method is generally aimed at flatness detection of a plane, and is not applicable to detection of a ceramic workpiece having a complicated shape. Aiming at ceramic workpieces with complex surface shapes, the existing robot detection process generally generates a robot detection program through off-line programming software. However, due to the positioning error and the machining error of the ceramic workpiece, the off-line program cannot be directly used, fine adjustment is required by workers according to the actual operation effect, and the adjustment process occupies most of the time of the whole detection process.
Constant contact force control is also commonly used in industrial grinding and polishing processes, which require strict adherence to a set reference trajectory. However, during the detection of the ceramic surface, due to the influence of the three-dimensional reconstruction accuracy, there must be an error between the preset reference trajectory and the actual trajectory of the ceramic workpiece surface, and the contact with the workpiece cannot be always ensured.
For planar ceramic detection, the normal vector direction of each point on the surface of the workpiece is consistent, and under the condition that the tangential moving speed of a six-dimensional force sensor probe at the tail end of the mechanical arm is constant, only the contact force between the sensor and the workpiece is required to be controlled to be constant. For curved ceramic detection, the normal direction of each point on the ceramic curved surface changes with the change of curvature. The direction of the relative velocity should be maintained at the tangent plane of each contact point on the surface of the ceramic workpiece so that the control system will normally apply the desired contact force at the contact point of the workpiece during the surface inspection process. The controller is required to calculate the normal direction of the detected ceramic workpiece surface according to the track detected by the robot or the force information of the sensor, and adjust the direction of the probe of the force sensor to be consistent with the normal direction of the ceramic product surface.
Disclosure of Invention
In order to solve the problem that the flatness problem caused by the fact that a robot cannot be guaranteed to normally contact a workpiece due to irregular change of curvature on a complex curved surface, the application provides a ceramic product surface flatness detection method based on impedance control, which specifically comprises the following steps:
s1, constructing a force/gesture hybrid control system; the hybrid control system includes: impedance controller, gesture compliance controller, servo driver and six-dimensional force sensor;
s2, measuring Z-axis force f of the robot through a six-dimensional force sensor z ，f z Obtained by filtering the force With the expected force f d Difference is made to obtain Z-axis force error e f ＝f d -f; wherein e f As input to an impedance controller, the impedance controller is used for controlling the Z direction of the robot tool coordinate system;
s3, obtaining a Z-axis reference position through an impedance controller, and obtaining a joint angle theta of each motion of the robot through inverse kinematics;
s4, measuring moment M of the robot on X axis or Y axis through six-dimensional force sensor xy And is obtained by moment filtering
S5、As input to the attitude compliance controller, the attitude compliance controller adjusts the angle theta of each motion joint of the robot c The method comprises the steps of carrying out a first treatment on the surface of the The gesture compliance controller is used for controlling the rotation directions of X and Y axes of a tool coordinate system;
s6, θ and θ c Addition as servo driverFinally obtaining the interaction force f of the robot and the environment s And the actual location Θ in the environment.
The beneficial effects provided by the application are as follows: the surface flatness detection method can adapt to curved surfaces and adjust the gesture of the mechanical arm to ensure that the contact state of the mechanical arm in normal contact with the workpiece is wider in applicability and higher in accuracy for the surface flatness detection of ceramic products.
Drawings
FIG. 1 is a schematic diagram of a force/attitude hybrid control system of the present application;
FIG. 2 is a schematic of a preprogrammed path;
FIG. 3 is a simplified diagram of the mechanical arm end effector sanding head under different attitudes.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present application more apparent, embodiments of the present application will be further described with reference to the accompanying drawings.
The application provides a ceramic product surface flatness detection method based on impedance control, which specifically comprises the following steps:
s1, constructing a force/gesture hybrid control system; the hybrid control system includes: impedance controller, gesture compliance controller, servo driver and six-dimensional force sensor;
s2, measuring Z-axis force f of the robot through a six-dimensional force sensor z ，f z Obtained by filtering the force With the expected force f d Difference is made to obtain Z-axis force error e f ＝f d -f; wherein e f As input to an impedance controller, the impedance controller is used for controlling the Z direction of the robot tool coordinate system;
s3, obtaining a Z-axis reference position through an impedance controller, and obtaining a joint angle theta of each motion of the robot through inverse kinematics;
s4, measuring the robot through six-dimensional force sensorMoment M obtained on X-axis or Y-axis xy And is obtained by moment filtering
S5、As input to the attitude compliance controller, the attitude compliance controller adjusts the angle theta of each motion joint of the robot c The method comprises the steps of carrying out a first treatment on the surface of the The gesture compliance controller is used for controlling the rotation directions of X and Y axes of a tool coordinate system;
s6, θ and θ c The addition is used as the input of a servo driver, and finally the interaction force f of the robot and the environment is obtained s And the actual location Θ in the environment.
In step S1, the impedance controller adopts an impedance control model with zero steady-state error of the contact force, and the following formula is adopted:
wherein x is,And->The actual position, the speed and the acceleration of the tail end of the mechanical arm are respectively; x is x d 、/>And->The expected position, speed and acceleration of the end of the mechanical arm respectively; f (f) d Is the desired contact force; f is the actual contact force; m is the mass of the end effector of the mechanical arm, and B is the damping coefficient.
In the impedance controller, a PD control method is adopted to increase damping itemsTo adjust the damping coefficient B and thereby balance the system oscillations caused by the end effector mass M of the robotic arm.
The control rate of the PD control method is as follows:
wherein b kp B for contact force error gain kd For differential gain of contact force error, the impedance controller adjusts the damping term according to the contact force error
The attitude compliance controller controls the rotational direction of the X and Y axes of the tool coordinate system, wherein the attitude adjustment angle θ y The formula is as follows:
wherein S is the S parameter of the impedance model, K is the rigidity coefficient of the robot, M y Is the moment along the Y axis of the friction force generated when the mechanical arm end effector moves downwards.
The gesture compliance controller controls the rotation direction of the X axis of the tool coordinate system, wherein the gesture adjustment angle theta x The formula is as follows:
M x is the moment along the X axis of the friction force generated when the mechanical arm end effector moves downwards.
The following describes the detailed steps of the method, taking a seven degree of freedom mechanical arm to detect a ceramic workpiece as an example.
First is a preprogrammed path. The pre-programmed path is a series of path points preset according to the three-dimensional reconstruction result, and the pre-programmed path is used as a reference path for a subsequent control strategy. No precise three-dimensional model of the workpiece is required for programming during the programming of the preprogrammed path, but rather a simple two-dimensional planar path (e.g., a series of straight line segments), as shown in fig. 2.
The constant force impedance control of the normal direction ensures the constant contact in the detection process, and the gesture compliance control ensures the normal contact with the workpiece. Each path point in the path contains the position and pose of the tool coordinate system in the robot base coordinate system, which can be generally described using a homogeneous transformation matrix.
In the subsequent experimental process, firstly, a flaw area to be detected is obtained through a three-dimensional reconstruction method, a plurality of key path points of square voxels of 10mm x 10mm are selected around flaws, and the linear interpolation is carried out on the positions and the postures between the starting point and the end point between every two adjacent key path points.
For the starting point X in a path s And endpoint X e ：
For X s And X e The two points are directly subjected to linear interpolation in Euclidean space to obtain the position of the intermediate path point:
where n is the number of interpolation points between two points.
Due to the path-starting-point attitude R s And end point pose R e Given by the rotation matrix, no direct linear interpolation is possible, where the slave R is first found s Rotated to target attitude R e Is a rotation matrix of (a)
Then, Δr is converted into a rotation vector representation (axis angle representation), and linear interpolation is performed:
v＝mtov(ΔR)(1-4)
in the expression, mtov rotation matrix to rotation vector conversion scheme, vtom is rotation vector to rotation matrix conversion scheme, v is rotation vector equivalent to Δr, and n is the number of interpolation points between two points.
Next, the present application relates to the design of the impedance controller.
The motion of the robot can be divided into free space motion and limited space motion according to whether the end effector is in contact with the environment during the motion of the robot.
In free space, the robot is not in contact with the environment, no interaction force is generated, and the robot is mainly in position control.
When contact occurs between the end effector and the workpiece, the movement is position constrained, creating an interaction force between the robot and the environment. Into a confined space, the robot at this point needs force control.
Impedance control is a control method applicable to free space and limited space, and is one of the most important methods for realizing contact control between a robot and an environment. The dynamic and static response characteristics of the mechanical arm under the action of external force are adjusted by changing the equivalent inertia, damping or rigidity parameters of the robot system.
The impedance control is decoupled in each direction axis of the rectangular coordinate system.
Considering that impedance control is performed in only one dimension of space,
the expected impedance equation can be written as:
wherein M is mass, B is damping, and K is stiffness. x is,And->Respectively the actual position, speed and acceleration of the tail end of the mechanical arm, x d 、/>And->The desired position, velocity and acceleration of the robot arm tip, respectively. e=x-x d A position correction amount indicating impedance control, e f ＝f d -f represents the force error between the desired contact force and the actual contact force.
The contact force between the robot arm tip and the ceramic is reduced to f=k e (x e -x), wherein K e Representing the ambient stiffness. The actual position of the tail end of the mechanical arm is
When the mechanical arm is in a stable stateIts contact force steady state error can be expressed as:
according to formulas (1-8), the steady state error of the contact force is proportional to the stiffness parameter of the impedance model, and the larger the stiffness parameter is, the larger the stiffness parameter is accompanied by the steady state error of the contact force.
Thus, by designing the stiffness parameter k=0 of the impedance model, the steady state error of the contact force tends to be 0 in theory. The impedance control model with zero contact force steady state error can be expressed as:
to obtain e ss =0, introducing adaptive variable impedance control to compensate for time varying errors.
The mass coefficient of the impedance model is prone to system oscillations, so the damping coefficient is typically adjusted to ensure stability. And dynamically adjusting the damping coefficient of the impedance model on line according to the contact force error and the first-order differential thereof, and establishing the control rate of the damping and the contact force deviation by utilizing the thought of the PD controller.
The control rate of the PD controller can be expressed as:
wherein b kp B for contact force error gain kd For differential gain of contact force error, the variable impedance controller adjusts damping term according to contact force error
In the impedance controller, the damping parameters are adjusted by two contact gain error coefficients to achieve compliant contact between the robot and the environment.
To verify the effectiveness of the impedance controller of the present application, it was demonstrated by the second method of lyapunov.
The stability of the system is judged by the lispro stability criterion, the range of gain parameters is also determined, and the system is designed according to the progressive stability judgment theorem (the lispro second method).
Wherein e x ＝x-x d ，
Taking the Liapunov function
Its derivative is
According to the theory of the stability of the lisinov, the following 2 conditions are met. (1) Liapunov function(2) Time differentiation of the Liapunov function +.>The system is asymptotically stable. The parameters of the controller should have the following constraints:
putting a damping term of the gain increasing parameter into an impedance control model, wherein the formula (4-18) can be obtained through Laplace transformation:
Ms 2 α(s)+Bsα(s)+b kp δ(s)+b kd sδ(s)＝-δ(s)(1-16)
wherein δ(s) = -e f ，
For the followingA stable system, steady state error e ss Is defined based on the laplace transform. For its convergence determination, steady state error e ss The method can obtain the following steps:
when the input is a step function, it is in the form ofFrom equations (1-17) it can be derived:
so that
When t → infinity, f → f d When the contact force between the robot and the environment converges to a dynamic desired force. Even if F(s) is not a constant, the tracking error can be verified as 0 as in the experimental sine function.
Finally, the design of the gesture compliance controller in the application is realized.
The main function of the gesture compliance controller is to control the gesture of the sensor probe in real time in the detection process so that the direction of constant force control always coincides with the direction of the surface of the workpiece.
The workpiece forces applied by the sensor probe in different postures during the detection of the robot are analyzed, as shown in fig. 3. In the position shown on the left side of fig. 3, the sanding head moves downwards to generate an upward oblique friction force f, which generates a moment +m along the Y-axis y In order to achieve the posture sensor probe shown in the middle of fig. 3, the posture angle required to be adjusted in the positive Y-axis direction is θ y By using a robot impedance control method, the moment M is used for controlling the impedance of the robot y Obtaining the attitude adjustment angle theta y ：
When the sensor probe is in the state shown on the right side of fig. 3 during the detection process, the sensor probe receives the extrusion force n and the friction force f of the ceramic workpiece, and generates a moment-M along the Y axis y The same relationship between the attitude adjustment angle and the moment can be obtained.
The attitude control method of the sensor probe along the X-axis direction is as follows:
therefore, in the detection process, the constant force impedance controller is used for controlling the axial force of the sensor probe to be constant, the impedance compliance control is used for adjusting the posture of the sensor probe in real time according to moment information, and the proper impedance parameters are adjusted, so that the axial direction of the sensor probe is along the normal direction of the surface of the workpiece, and the contact force is kept constant. The gesture compliance is a dynamic adjustment process, and in the detection process, the gesture compliance controller dynamically adjusts the gesture of the mechanical arm in real time according to the moment information of the sensor.
The beneficial effects of the application are as follows:
1. compared with the existing non-contact detection method based on the optical principle, the method can solve the problems that the ceramic product is low in texture and smooth in reflection and is influenced by the illumination intensity, illumination angle and the like of the lamplight of the environment, and the method adopts a constant force detection controller for mixed control of force and gesture, a detection system can adapt to a curved surface and adjust the gesture of a mechanical arm to ensure that the contact state of the mechanical arm in normal contact with a workpiece is wider and higher in applicability to detection of the surface flatness of the ceramic product; 2. compared with the existing constant contact force control method, the method needs to strictly follow a set reference track, and due to the influence of three-dimensional reconstruction precision, an error exists between the preset reference track and an actual track on the surface of a ceramic workpiece, so that the contact with the workpiece cannot be always ensured, an accurate three-dimensional model of the workpiece is not required to be programmed in the process of planning a pre-programming path, but a simple two-dimensional plane path is adopted, the constant contact in the detection process is ensured through normal constant force impedance control, and the normal contact with the workpiece is ensured through gesture compliance control.
The foregoing description of the preferred embodiments of the application is not intended to limit the application to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the application are intended to be included within the scope of the application.
Claims (6)
1. A ceramic product surface flatness detection method based on impedance control is characterized by comprising the following steps: the method comprises the following steps:
s1, constructing a force/gesture hybrid control system; the hybrid control system includes: impedance controller, gesture compliance controller, servo driver and six-dimensional force sensor;
s2, measuring Z-axis force f of the robot through a six-dimensional force sensor z ，f z Obtained by filtering the force With the expected force f d Difference is made to obtain Z-axis force error e f ＝f d -f; wherein e f As input to an impedance controller, the impedance controller is used for controlling the Z direction of the robot tool coordinate system;
s3, obtaining a Z-axis reference position through an impedance controller, and obtaining a joint angle theta of each motion of the robot through inverse kinematics;
s4, measuring moment M of the robot on X axis or Y axis through six-dimensional force sensor xy And is obtained by moment filtering
S5、As input to the attitude compliance controller, the attitude compliance controller adjusts the angle theta of each motion joint of the robot c The method comprises the steps of carrying out a first treatment on the surface of the The gesture compliance controller is used for controlling the rotation directions of X and Y axes of a tool coordinate system;
s6, θ and θ c The addition is used as the input of a servo driver, and finally the interaction force f of the robot and the environment is obtained s And the actual location Θ in the environment.
2. The method for detecting the surface flatness of a ceramic product based on impedance control according to claim 1, characterized by comprising the steps of: in step S1, the impedance controller adopts an impedance control model with zero steady-state error of the contact force, and the following formula is adopted:
wherein x is,And->The actual position, the speed and the acceleration of the tail end of the mechanical arm are respectively; x is x d 、/>And->The expected position, speed and acceleration of the end of the mechanical arm respectively; f (f) d Is the desired contact force; f is the actual contact force; m is the mass of the end effector of the mechanical arm, and B is the damping coefficient.
3. The method for detecting the surface flatness of a ceramic product based on impedance control according to claim 2,the method is characterized in that: in the impedance controller, a PD control method is adopted to increase damping itemsTo adjust the damping coefficient B and thereby balance the system oscillations caused by the end effector mass M of the robotic arm.
4. A method for detecting the surface flatness of a ceramic product based on impedance control as claimed in claim 3, characterized by: the control rate of the PD control method is as follows:
wherein b kp B for contact force error gain kd For differential gain of contact force error, the impedance controller adjusts the damping term according to the contact force error
5. The method for detecting the surface flatness of a ceramic product based on impedance control according to claim 1, characterized by comprising the steps of: the attitude compliance controller controls the rotational direction of the X and Y axes of the tool coordinate system, wherein the attitude adjustment angle θ y The formula is as follows:
wherein S is the S parameter of the impedance model, K is the rigidity coefficient of the robot, M y Is the moment along the Y axis of the friction force generated when the mechanical arm end effector moves downwards.
6. The method for detecting the surface flatness of a ceramic product based on impedance control according to claim 5, characterized by comprising the steps of: the gesture compliance controlThe controller controls the rotation direction of the X axis of the tool coordinate system, wherein the attitude adjustment angle theta x The formula is as follows:
M x is the moment along the X axis of the friction force generated when the mechanical arm end effector moves downwards.
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