CN116809267A - Method for automatically spraying large-sized workpiece - Google Patents
Method for automatically spraying large-sized workpiece Download PDFInfo
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- CN116809267A CN116809267A CN202310586219.3A CN202310586219A CN116809267A CN 116809267 A CN116809267 A CN 116809267A CN 202310586219 A CN202310586219 A CN 202310586219A CN 116809267 A CN116809267 A CN 116809267A
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- 238000005507 spraying Methods 0.000 title claims abstract description 119
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000013439 planning Methods 0.000 claims abstract description 33
- 239000007921 spray Substances 0.000 claims abstract description 7
- 230000033001 locomotion Effects 0.000 claims description 40
- 230000005540 biological transmission Effects 0.000 claims description 15
- 238000006073 displacement reaction Methods 0.000 claims description 15
- 230000003014 reinforcing effect Effects 0.000 claims description 11
- 239000004576 sand Substances 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 238000007781 pre-processing Methods 0.000 claims description 3
- 230000026676 system process Effects 0.000 claims description 3
- 238000013316 zoning Methods 0.000 claims 1
- 239000007769 metal material Substances 0.000 abstract description 2
- 238000004381 surface treatment Methods 0.000 abstract description 2
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 208000034699 Vitreous floaters Diseases 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000009194 climbing Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
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Abstract
The invention relates to the field of multi-step metal material surface treatment, in particular to a method for automatically spraying a large workpiece, which is used for automatically spraying the large workpiece. A method for automatically spraying a large workpiece includes the steps of firstly, scanning a workpiece to be processed through three-dimensional laser scanning equipment to obtain three-dimensional coordinates of each point on the surface of the workpiece to be processed; and carrying out model reconstruction and path planning on the obtained three-dimensional coordinates through a control system, and controlling an execution system to spray the workpiece to be processed according to the planned path through the control system. The three-dimensional laser scanning equipment emits an infrared laser beam to the surface of a workpiece to be processed, the scattered infrared laser beam returns to the three-dimensional laser scanning equipment, the three-dimensional coordinates of each point on the surface of an object are determined according to the angle of light wave reflection, and then the obtained data are subjected to analysis, splicing, denoising and thinning pretreatment.
Description
Technical Field
The invention relates to the field of multi-step metal material surface treatment, in particular to a method for automatically spraying a large-sized workpiece.
Background
At present, the spraying work for large complex workpieces is completed manually. However, in the present day where automation is used in most processes, if a large workpiece is still sprayed manually, this becomes a bottleneck in the whole process. And the efficiency of manual spraying is low, the spraying quality is also unstable, and the spraying work generally has great harm to the body of constructors. When the treatment grade reaches the Sa2.5 grade, a skilled artificial work unit average efficiency is about 15-20m 2 And/h, the working efficiency is low and the spraying quality is unstable. A large amount of floaters can be generated in the working space in the spraying process, and the sensitive parts such as respiratory tract, eyes and the like of a constructor can be greatly injured.
The existing automatic spraying equipment is divided into two types, one type is aimed at small-sized workpieces, and the automatic spraying work of the workpieces can be completed through a three-dimensional model or a demonstrator; another type is that for large workpieces, the robots adopt gantry truss crown blocks or wall climbing type to spray the workpieces, but the robots throw away the workpieces to be operated manually.
Therefore, the existing automatic spraying equipment cannot meet the automatic spraying work of large complex workpieces, and a spraying method capable of automatically spraying the large complex workpieces is needed, so that the automation of the spraying work is improved, and the working efficiency is improved.
Disclosure of Invention
The invention aims to provide a method for automatically spraying large-sized workpieces, which solves the problems of high cost, low efficiency and harm to the bodies of workers caused by manual participation in the prior art.
In order to achieve the above purpose, the technical solution adopted by the invention is as follows:
a method for automatically spraying a large workpiece includes the steps of firstly, scanning a workpiece to be processed through three-dimensional laser scanning equipment to obtain three-dimensional coordinates of each point on the surface of the workpiece to be processed; performing model reconstruction and path planning on the obtained three-dimensional coordinates through a control system, and controlling an execution system to spray a workpiece to be processed through the control system according to the planned path; the three-dimensional laser scanning equipment emits an infrared laser beam to the surface of a workpiece to be processed, returns to the three-dimensional laser scanning equipment after scattering, determines three-dimensional coordinates of each point on the surface of an object according to the angle of light wave reflection, and then carries out analysis, splicing, denoising and thinning pretreatment on the obtained data; the control system comprises a point cloud data modeling system and a track planning system; inputting the obtained three-dimensional coordinate data into a control system, and reconstructing the data to obtain a new three-dimensional model after the point cloud data modeling system processes the data; obtaining a motion path through a track planning system according to the new three-dimensional model, wherein the execution system comprises a gantry truss crown block and a mobile robot; comprising the following steps:
s1, moving a gantry truss crown block to a set initial position, and then fixing a workpiece to be processed;
s2, a worker is equipped with a three-dimensional laser scanning device to scan a workpiece to be processed in a region-by-region manner, so that a three-dimensional model of the workpiece is obtained;
s3, planning a path of the execution system according to the three-dimensional model obtained in the S2;
s3.1, according to the obtained three-dimensional model. The upper surface and the side surfaces are set as a first operation area, the lower surface is set as a second operation area, the gantry truss crown block is used for spraying the first operation area, and the mobile robot is used for spraying the second operation area;
s3.2, extracting typical components or abnormal components according to the three-dimensional model obtained by scanning, dividing the whole workpiece into individual components, and carrying out track planning by taking the individual components as units;
s3.3, according to the adjacent fastest scanning principle, sequentially scanning the typical curved surface; when the workpiece is complex, planning a track by adopting a particle swarm algorithm, and combining a 3-5-3 track planning algorithm to realize the traversal of the rapid spraying operation, so as to obtain the planning track of the complex workpiece;
s4, installing the mobile robot at the bottom of the workpiece, and enabling all parts of the mobile robot to be at a set initial position;
s5, inputting the track planning into a control system, and starting the robot to work according to the instruction;
s5.1, carrying out coordinate conversion on a coordinate system of track planning and a coordinate system of robot motion control, and unifying the coordinate systems;
s5.2, inputting a track planning result into a control system, and obtaining a corresponding control instruction set by the control system;
s5.3, the control system sends a control instruction to the execution system, and the execution system starts spraying operation;
s5.4, after the execution system receives the control instruction, the gantry truss crown block performs spraying operation on the first operation area according to the instruction, and the mobile robot performs spraying operation on the second operation area;
s6, after the spraying operation is completed, the execution system returns to the set initial position.
Further, the step S1 includes the steps of:
s1.1, a gantry truss crown block moves to one corner of a factory building, and the position is set as an initial position;
s1.2, conveying the workpiece to be processed to a designated position of a factory building, and supporting and fixing the workpiece.
Further, the step S2 includes:
s2.1, observing a workpiece to be processed, so as to ensure that complete scanning can be performed;
s2.2, performing initial calibration debugging and scanning parameter setting on the three-dimensional laser scanning equipment;
s2.3, dividing the area of the workpiece, and simultaneously scanning different areas by different workers to improve the scanning efficiency;
s2.4, after the scanning is completed, extracting all scanning data, checking the data quality, and rescanning unqualified data;
s2.5, preprocessing the scanned data to obtain point cloud data which can be used for model reconstruction;
s2.6, performing reverse modeling based on the point cloud data to obtain a three-dimensional model of the workpiece.
Further, the upper surface and the side face of the model are planned to be a first operation area, the lower surface is planned to be a second operation area according to the obtained three-dimensional model, and partition operation is realized through an execution system; the execution system comprises a gantry truss crown block and a mobile robot; the gantry truss crown block and the first spraying mechanical arm auxiliary nozzle can finish spraying operation on a first operation area; the mobile robot comprises a ground rail, a mobile frame, a telescopic arm and a second spraying mechanical arm; the movable frame is connected to a ground rail, and the ground rail can enable the movable frame 7 to move in a first direction; the telescopic arm is fixed on the movable frame, and the second spraying mechanical arm is fixed on the telescopic arm and can move in a second direction; the second spraying mechanical arm is hinged with a nozzle, the spraying mechanical arm can enable the nozzle to move in a third direction, and spraying operation on a second operation area can be completed.
Further, the gantry truss crown block comprises a base, a supporting plate and a cross beam, wherein the supporting plate is connected to the base, and the cross beam is connected between the two supporting plates; the base is provided with a first track which is matched with the supporting plate and can enable the supporting plate to move in a first direction; the support plate is provided with a second track, and two ends of the cross beam are provided with sliding bodies which are matched with the second track, so that the cross beam can move in a second direction; the beam is provided with a third track, the first spraying mechanical arm is connected with the third track, the first spraying mechanical arm can move in a third direction, the base, the supporting plate and the beam are all provided with motion sensors, and the motion sensors are connected with the control system.
Further, the first spraying mechanical arm is a six-degree-of-freedom serial mechanical arm and comprises a base, a fixed rod, a secondary telescopic rod, a first hinge, a second hinge and a first fixed piece; the fixed rod is connected to the base and can rotate in the horizontal direction of the base; the secondary telescopic rod is connected to the fixed rod and can move in the vertical direction; the first hinge piece is hinged on the secondary telescopic rod and can rotate on the secondary telescopic rod; the second hinge member is connected to the first hinge member, and the second hinge member is rotatable relative to the first hinge member; the first fixing piece is connected to the second hinge piece, and the first fixing piece can rotate on the second hinge piece; the first fixing piece is connected with a nozzle, the nozzle can rotate on the first fixing piece, and the nozzle is communicated with the sand supply system through a pipeline; an anti-collision sensor and a motion sensor are embedded in the first spraying mechanical arm, the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor can feed back the relative position and pose information of each part of the first spraying mechanical arm; the anti-collision sensor can prevent the first spraying mechanical arm from collision.
Further, a displacement sensor is arranged on the ground rail and is connected with a control system; the ground rail comprises a guide rail supporting wheel and a rail set, and the guide rail supporting wheel is fixed at the bottom of the rail set; the track set comprises a first guide rail and a second guide rail; the second guide rail is fixed on the top of the first guide rail; the first guide rail is provided with a first chute and a second chute, the first chute is positioned at the inner side, the second chute is positioned at the outer side, and the first chute is provided with a rack; the ground rail is formed by splicing a plurality of sections of rail groups, and two adjacent sections of rail groups are fixedly connected through a connecting rod; each section of track group comprises two first guide rails which are fixedly connected through a fixing plate; the top of the second guide rail is arc-shaped.
Further, a displacement sensor is arranged on the movable frame and is connected with a control system, and the position of the movable frame can be known through the control system; the movable frame comprises a motor, a cover plate and a bottom plate; the motor is fixed on the bottom plate, the movable end of the motor is connected with a transmission shaft, the two ends of the transmission shaft are connected with hubs, and the hubs are matched with the second guide rail; the bottom plate is fixed on the transmission shaft through the connecting column, the transmission shaft is provided with a fixed column, and the cover plate is fixedly connected to the fixed column; one side of the hub is provided with a gear, the other side of the hub is provided with a pulley, and the gear and the pulley are fixed on a transmission shaft through a connecting piece; the gear is meshed with the rack, and the pulley is matched with the second chute.
Further, a displacement sensor is arranged on the telescopic arm and is connected with a control system, and the extension length of the telescopic arm can be known through the control system; the telescopic arm is fixed on the cover plate through a connecting plate and comprises a hydraulic push rod, a reinforcing plate, a variable amplitude plate and a primary telescopic rod; the amplitude board is fixed on the primary telescopic rod; one end of the hydraulic push rod is hinged on the connecting plate, and the other end of the hydraulic push rod is hinged on the amplitude board; one side of the reinforcing plate is hinged with the connecting plate, and the other side of the reinforcing plate is fixed on the primary telescopic rod; the one-level telescopic rod is internally provided with a second-level telescopic rod, a third-level telescopic rod and a fourth-level telescopic rod, and the fourth-level telescopic rod is connected with idler wheels through a supporting rod.
Further, the second spraying mechanical arm comprises a third hinging piece, a fourth hinging piece and a second fixing piece, the first hinging piece is connected to the fourth-stage telescopic rod through a telescopic piece, the second hinging piece is hinged to the first hinging piece, the fixing piece is fixed to the second hinging piece, the nozzle is hinged to the fixing piece, and the nozzle is communicated with the sand supply system through a pipeline; an anti-collision sensor and a motion sensor are embedded in the second spraying mechanical arm, the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor can feed back the relative position and pose information of each part of the second spraying mechanical arm; the anti-collision sensor can prevent the second spraying mechanical arm from collision.
By adopting the technical scheme, the invention has the beneficial technical effects that:
according to the invention, automatic spraying operation of large complex workpieces can be completed, model reconstruction of the workpieces is carried out through three-dimensional laser scanning, deviation between a real object and a processing drawing caused by workpiece processing is avoided, an accurate three-dimensional model of the real object is provided, according to the model, full-coverage automatic spraying operation on the surfaces of the workpieces can be completed through an execution system, the working efficiency is greatly improved, the labor cost is reduced, and the labor intensity of workers and the harm to the health of the workers are reduced.
Drawings
FIG. 1 is a flow chart of a method for automatically spraying a large workpiece.
FIG. 2 is a schematic diagram of an implementation system.
Fig. 3 is a schematic view of a first spray robot.
Fig. 4 is a schematic view of a ground rail.
Fig. 5 is a schematic diagram of the connection of the ground rail and the movable frame.
Fig. 6 is a schematic view of a second spray robot.
Detailed Description
Example 1
As shown in FIG. 1, in the method for automatically spraying a large workpiece, a three-dimensional laser scanning device is used for scanning the workpiece to be processed to obtain three-dimensional coordinates of each point on the surface of the workpiece to be processed; performing model reconstruction and path planning on the obtained three-dimensional coordinates through a control system, and controlling an execution system 1 to spray a workpiece to be processed according to the planned path through the control system; the three-dimensional laser scanning equipment emits an infrared laser beam to the surface of a workpiece to be processed, returns to the three-dimensional laser scanning equipment after scattering, determines three-dimensional coordinates of each point on the surface of an object according to the angle of light wave reflection, and then carries out analysis, splicing, denoising and thinning pretreatment on the obtained data; the control system comprises a point cloud data modeling system and a track planning system; inputting the obtained three-dimensional coordinate data into a control system, and reconstructing the data to obtain a new three-dimensional model after the point cloud data modeling system processes the data; the motion path is obtained through a track planning system according to the new three-dimensional model, and the execution system 1 comprises a gantry truss crown block 3 and a mobile robot 2; comprising the following steps:
s1, moving a gantry truss crown block 3 to a set initial position, and then fixing a workpiece to be processed;
s1.1, a gantry truss crown block moves to one corner of a factory building, and the position is set as an initial position;
s1.2, conveying the workpiece to be processed to a designated position of a factory building, and supporting and fixing the workpiece.
S2, a worker is equipped with a three-dimensional laser scanning device to scan a workpiece to be processed in a region-by-region manner, so that a three-dimensional model of the workpiece is obtained;
s2.1, observing a workpiece to be processed, so as to ensure that complete scanning can be performed;
s2.2, performing initial calibration debugging and scanning parameter setting on the three-dimensional laser scanning equipment;
s2.3, dividing the area of the workpiece, and simultaneously scanning different areas by different workers to improve the scanning efficiency;
s2.4, after the scanning is completed, extracting all scanning data, checking the data quality, and rescanning unqualified data;
s2.5, preprocessing the scanned data to obtain point cloud data which can be used for model reconstruction;
s2.6, performing reverse modeling based on the point cloud data to obtain a three-dimensional model of the workpiece.
S3, planning a path of the execution system 1 according to the three-dimensional model obtained in the S2;
s3.1, according to the obtained three-dimensional model. The upper surface and the side surfaces are set as a first operation area, the lower surface is set as a second operation area, a gantry truss crown block 3 is used for spraying the first operation area, when a workpiece to be processed has the second operation area, a mobile robot 2 is arranged at the bottom of the workpiece to be processed, and the second operation area is sprayed by the mobile robot 2;
s3.2, extracting typical components or abnormal components according to the three-dimensional model obtained by scanning, dividing the whole workpiece into individual components, and carrying out track planning by taking the individual components as units;
s3.3, according to the adjacent fastest scanning principle, sequentially scanning the typical curved surface; when the workpiece is complex, planning a track by adopting a particle swarm algorithm, and combining a 3-5-3 track planning algorithm to realize the traversal of the rapid spraying operation, so as to obtain the planning track of the complex workpiece;
s4, installing the mobile robot 2 at the bottom of the workpiece, and enabling all parts of the mobile robot 2 to be at a set initial position;
s5, inputting the track planning into a control system, and starting the robot to work according to the instruction;
s5.1, carrying out coordinate conversion on a coordinate system of track planning and a coordinate system of robot motion control, and unifying the coordinate systems;
s5.2, inputting a track planning result into a control system, and obtaining a corresponding control instruction set by the control system;
s5.3, the control system sends a control instruction to the execution system 1, and the execution system 1 starts spraying operation;
s5.4, after the execution system 1 receives the control instruction, the gantry truss crown block 3 performs spraying operation on the first operation area according to the instruction, and the mobile robot 2 performs spraying operation on the second operation area;
s6, after the spraying operation is completed, the execution system 1 returns to the set initial position.
As shown in fig. 2, according to the obtained three-dimensional model, the upper surface and the side surface of the model are planned as a first working area, the lower surface is planned as a second working area, and the partition operation is realized by the execution system 1; the execution system 1 comprises a mobile robot 2 and a gantry truss crown block 3; the gantry truss crown block 3 is provided with a first spraying mechanical arm 4, the first spraying mechanical arm 4 is provided with a nozzle 5, and the spraying operation of a first operation area can be completed by the gantry truss crown block 3 and the first spraying mechanical arm 4 in an auxiliary mode; the mobile robot 2 comprises a ground rail 6, a mobile frame 7, a telescopic arm 8 and a second spraying mechanical arm 9; the movable frame 7 is connected to the ground rail 6, and the ground rail 6 can enable the movable frame 7 to move in a first direction; the telescopic arm 8 is fixed on the movable frame 7, and the second spraying mechanical arm 9 is fixed on the telescopic arm 8, so that the second spraying mechanical arm 9 can move in a third direction; the second spraying mechanical arm 9 is hinged with the nozzle 5, and can enable the nozzle 5 to move in a second direction, so that spraying operation on a second operation area can be completed. The first spraying mechanical arm 4 moves in three mutually perpendicular directions through the gantry truss crown block 3, and the nozzle 5 performs all-round spraying operation on a large workpiece through the interaction of rotation and movement of the first spraying mechanical arm 4. The ground rail 6 realizes the movement of the nozzle 5 in the front-back direction, the telescopic arm 8 can assist the movement of the nozzle 5 in the left-right direction, the second spraying mechanical arm 9 assists the nozzle 5 to realize the movement and rotation in the up-down direction, and the bottom and the side of a large-sized workpiece can be automatically sprayed in an omnibearing dead-angle-free manner.
The gantry truss crown block 3 comprises a base 31, a supporting plate 32 and a cross beam 33, wherein the supporting plate 32 is connected to the base 31, and the cross beam 33 is connected between the two supporting plates 32; the base 31 is provided with a first rail 311, and the first rail 311 is matched with the support plate 32 and can enable the support plate 32 to move in a first direction; the support plate 32 is provided with a second track 321, and two ends of the cross beam 33 are provided with sliding bodies which are matched with the second track 321, so that the cross beam 33 can move in a second direction; the beam 33 is provided with a third rail 331, and the first spraying mechanical arm 4 is connected with the third rail 331, so that the first spraying mechanical arm 4 can move in a third direction. The first direction is the front-back direction of the first track 311, the second direction is the up-down direction of the second track 321, and the third direction is the left-right direction of the third track 331. The base 31, the support plate 32 and the cross beam are all provided with motion sensors, and the motion sensors are connected with a control system.
As shown in fig. 3, the first spraying mechanical arm 4 is a six-degree-of-freedom serial mechanical arm, and includes a base 41, a fixed rod 42, a secondary telescopic rod 43, a first hinge 44, a second hinge 45, and a first fixing member 46; the fixed rod 42 is connected to the base 41, and the fixed rod 42 can rotate in the horizontal direction of the base 41; the secondary telescopic rod 43 is connected to the fixed rod 42, and the secondary telescopic rod 43 can move in the vertical direction; the first hinge 44 is hinged on the secondary telescopic rod 43, the first hinge 44 being rotatable on the secondary telescopic rod 43; the second hinge 45 is connected to the first hinge 44, the second hinge 45 being rotatable relative to the first hinge 44; the first fixing member 46 is connected to the second hinge member 45, and the first fixing member 46 is rotatable on the second hinge member 45; the first fixing piece 46 is connected with a nozzle 5, the nozzle 5 can rotate on the first fixing piece 46, and the nozzle 5 is communicated with the sand supply system through a pipeline. An anti-collision sensor and a motion sensor are embedded in the first spraying mechanical arm 4, the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor can feed back the relative position and pose information of each part of the first spraying mechanical arm 4; the collision prevention sensor can prevent the first spraying robot 4 from collision.
As shown in fig. 4, the ground rail 6 is provided with a displacement sensor, and the displacement sensor is connected with a control system; the ground rail 6 comprises a guide rail supporting wheel 61 and a rail group; the guide rail supporting wheels 61 are fixed at the bottom of the track group; the track set comprises a first rail 62 and a second rail 63; the second guide rail 63 is fixed on the top of the first guide rail 62, and the guide rail supporting wheel 61 is fixed on the bottom of the first guide rail 62; the ground rail 6 is formed by splicing a plurality of track groups, and two adjacent track groups are fixedly connected through a connecting rod 64; the two first guide rails 62 are connected through a fixing plate 60; the first guide rail 62 is provided with a first chute 65 and a second chute 66, the first chute 65 is located on the inner side, the second chute 66 is located on the outer side, and a rack 67 is arranged on the first chute 65. The top of the second guide rail 63 is arc-shaped, and the steel grit will not pile up after falling on the surface, but will fall on the surface of the first guide rail 62, so that the falling steel grit will not affect the walking function of the ground rail 6. The support wheels raise the ground rail 6 so that the falling steel grit can accumulate on the ground without affecting the normal operation of the ground rail 6. The ground rail 6 is spliced by a plurality of sections, so that the ground rail can be conveniently transported and quickly installed, each section of ground rail 6 is connected through the connecting rod, and the connecting rod is fixed through the groove, so that the connection precision and connection stability can be improved.
As shown in fig. 5, the moving frame 7 is provided with a displacement sensor, the displacement sensor is connected with a control system, and the position of the moving frame 7 can be known through the control system; the moving frame 7 comprises a motor 71, a cover plate 72 and a bottom plate 73; the motor 71 is fixed on the bottom plate 73, the movable end of the motor 71 is connected with a transmission shaft 74, two ends of the transmission shaft 74 are connected with hubs 75, and the hubs 75 are matched with the second guide rail 63; the bottom plate 73 is fixed on the transmission shaft 74 through a connecting column 76, a fixed column 77 is arranged on the transmission shaft 74, and the cover plate 72 is connected to the fixed column 77; gears 78 and pulleys 79 are arranged on two sides of the hub 75, and the gears 78 and the pulleys 79 are fixed on the transmission shaft 74 through connecting pieces 80; the gear 78 engages with the rack 67 and the pulley 79 is adapted to the second chute 66. The connecting member 80 is provided with a reinforcing plate 70, and two gears 78 or two pulleys 79 are connected to two sides of the reinforcing plate 70. The gear 78, the pulley 79 and the hub 75 hug the ground rail 6 from three directions, so that stability of the movable frame 7 during movement is guaranteed, and rollover is effectively prevented. The meshing of the gear 78 and the rack 67 not only effectively prevents slipping, but also improves the movement precision of the movable frame 7, thereby realizing high-precision navigation positioning.
As shown in fig. 6, the telescopic arm 8 is provided with a displacement sensor, the displacement sensor is connected with a control system, and the extension length of the telescopic arm 8 can be known through the control system; the telescopic arm 8 is fixed on the cover plate 72 through a connecting plate 81, and the telescopic arm 8 comprises a hydraulic push rod 82, a reinforcing plate 83, a luffing plate 84 and a primary telescopic rod 85; the amplitude changing plate 84 is fixed on the primary telescopic rod 85; one end of the hydraulic push rod 82 is hinged on the connecting plate 81, and the other end is hinged on the amplitude board 84; one side of the reinforcing plate 83 is hinged with the connecting plate 81, and the other side of the reinforcing plate is fixed on the primary telescopic rod 85; a second-stage telescopic rod 86, a third-stage telescopic rod 87 and a fourth-stage telescopic rod 88 are arranged in the first-stage telescopic rod 85, and the fourth-stage telescopic rod 88 is connected with a roller 90 through a supporting rod 89. The telescopic arm 8 is formed by integral machining, and is high in strength and bending resistance. The telescopic boom 8 is connected with a control system, the control system can control the hydraulic push rod 82 to push out the telescopic rod of each stage, and the roller 90 can enable movement to be smoother.
The second spraying mechanical arm 9 comprises a third hinge member 91, a fourth hinge member 92 and a second fixing member 93, wherein the third hinge member 91 is connected to the fourth-stage telescopic rod 88 through a telescopic member 94, the fourth hinge member 92 is hinged to the third hinge member 91, and the telescopic member 94 enables the nozzle 5 to move up and down. The second spraying mechanical arm 9 enables the nozzle 5 to perform all-round dead-angle-free spraying operation on the bottom and the side surface of the large-sized workpiece under the cooperation of rotation and movement. An anti-collision sensor and a motion sensor are embedded in the second spraying mechanical arm 9, the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor can feed back the relative position and pose information of each part of the second spraying mechanical arm 9; the collision prevention sensor can prevent the collision of the second painting robot 9.
Example 2
When the workpiece to be processed needs to be sprayed on the lower surface, such as spraying the automobile body, the gantry truss crown block 3 is moved to one corner of a factory building, so that the gantry truss crown block 3 is located at an initial position. The three-dimensional model is prevented from being different from the solid shape by observing the automobile body. And then, the worker scans the entity or the three-dimensional model of the automobile body through the three-dimensional laser scanning equipment to obtain the three-dimensional coordinates of each point on the surface of the automobile body. And then, carrying out data processing on the obtained coordinates and reconstructing the model, and when unqualified data is found in the data processing process, carrying out scanning again to obtain a reconstructed new three-dimensional model. After the new three-dimensional model is obtained, the upper surface and the side surface of the automobile body are defined as a first working area by the control system, and the lower surface is defined as a second working area. The mobile robot 2 is arranged at the bottom of the automobile body, and then the movement route of the gantry truss crown block 3 and the mobile robot 2 is planned according to the division of the operation area, so that the comprehensive spraying of the automobile body is realized.
Example 3
When the workpiece to be processed does not need to be sprayed on the lower surface, such as a barrel-shaped part, only the outer surface of the part is required to be sprayed. Firstly, the gantry truss crown block 3 is moved to one corner of a factory building, so that the gantry truss crown block 3 is located at an initial position. The part is observed, and the three-dimensional model is prevented from being different from the solid shape. And then, the worker scans the entity or the three-dimensional model of the part through the three-dimensional laser scanning equipment to obtain the three-dimensional coordinates of each point on the surface of the part. And then, carrying out data processing on the obtained coordinates and reconstructing the model, and when unqualified data is found in the data processing process, carrying out scanning again to obtain a reconstructed new three-dimensional model. After a new three-dimensional model is obtained, the side surface of the part is sprayed through a control system, and then the movement route of the gantry truss crown block 3 is planned, so that the comprehensive spraying of the part is realized.
It should be understood that the above description is not intended to limit the invention to the particular embodiments disclosed, but to limit the invention to the particular embodiments disclosed, and that the invention is not limited to the particular embodiments disclosed, but is intended to cover modifications, adaptations, additions and alternatives falling within the spirit and scope of the invention.
Claims (10)
1. A method for automatically spraying a large workpiece is characterized in that a three-dimensional laser scanning device is used for scanning a workpiece to be processed to obtain three-dimensional coordinates of each point on the surface of the workpiece to be processed; carrying out model reconstruction and path planning on the obtained three-dimensional coordinates through a control system, and controlling an execution system (1) to spray a workpiece to be processed according to the planned path through the control system; the three-dimensional laser scanning equipment emits an infrared laser beam to the surface of a workpiece to be processed, returns to the three-dimensional laser scanning equipment after scattering, determines three-dimensional coordinates of each point on the surface of an object according to the angle of light wave reflection, and then carries out analysis, splicing, denoising and thinning pretreatment on the obtained data; the control system comprises a point cloud data modeling system and a track planning system; inputting the obtained three-dimensional coordinate data into a control system, and reconstructing the data to obtain a new three-dimensional model after the point cloud data modeling system processes the data; and dividing an operation area according to the obtained new three-dimensional model, obtaining a motion path of an execution system through a track planning system according to the division of the operation area, and realizing the spraying of the workpiece to be processed, wherein the execution system (1) comprises a gantry truss crown block (3) and a mobile robot (2).
2. A method for automatically spraying large workpieces according to claim 1, comprising the specific steps of:
s1, moving a gantry truss crown block (3) to a set initial position, and then fixing a workpiece to be processed;
s2, a worker is equipped with a three-dimensional laser scanning device to scan a workpiece to be processed in a region-by-region manner, so that a three-dimensional model of the workpiece is obtained;
s3, planning a path of the execution system (1) according to the three-dimensional model obtained in the S2;
s3.1, setting the upper surface and the side surface as a first operation area according to the obtained three-dimensional model, setting the lower surface as a second operation area, spraying the first operation area by a gantry truss crown block (3), and spraying the second operation area by a mobile robot (2);
s3.2, extracting typical components or abnormal components according to the three-dimensional model obtained by scanning, dividing the whole workpiece into individual components, and carrying out track planning by taking the individual components as units;
s3.3, according to the adjacent fastest scanning principle, sequentially scanning the typical curved surface; when the workpiece is complex, planning a track by adopting a particle swarm algorithm, and realizing traversal of the rapid spraying operation by combining a 3-5-3 track planning algorithm to obtain a planned track of the workpiece;
s4, installing the mobile robot (2) at the bottom of the workpiece, and enabling all parts of the mobile robot (2) to be at a set initial position;
s5, inputting the track planning into a control system, and starting the robot to work according to the instruction;
s5.1, carrying out coordinate conversion on a coordinate system of track planning and a coordinate system of robot motion control, and unifying the coordinate systems;
s5.2, inputting a track planning result into a control system, and obtaining a corresponding control instruction set by the control system;
s5.3, the control system sends a control instruction to the execution system (1), and the execution system (1) starts spraying operation;
s5.4, after the execution system (1) receives the control instruction, the gantry truss crown block (3) performs spraying operation on the first operation area according to the instruction, and the mobile robot (2) performs spraying operation on the second operation area;
s6, after the spraying operation is completed, the execution system (1) returns to the set initial position.
3. A method of automatically spraying large workpieces according to claim 1, wherein S1 comprises the steps of:
s1.1, a gantry truss crown block moves to one corner of a factory building, and the position is set as an initial position;
s1.2, conveying the workpiece to be processed to a designated position of a factory building, and supporting and fixing the workpiece.
The step S2 comprises the following steps:
s2.1, observing a workpiece to be processed, and ensuring complete scanning;
s2.2, performing initial calibration debugging and scanning parameter setting on the three-dimensional laser scanning equipment;
s2.3, dividing the area of the workpiece, and simultaneously scanning different areas by different workers to improve the scanning efficiency;
s2.4, after the scanning is completed, extracting all scanning data, checking the data quality, and rescanning unqualified data;
s2.5, preprocessing the scanned data to obtain point cloud data for model reconstruction;
s2.6, performing reverse modeling based on the point cloud data to obtain a three-dimensional model of the workpiece.
4. A method for automatically spraying large-scale workpieces according to claim 1, characterized in that the zoning operation is carried out by an execution system (1); the gantry truss crown block (3) is provided with a first spraying mechanical arm (4), the first spraying mechanical arm (4) is provided with a nozzle (5), and the gantry truss crown block (3) and the first spraying mechanical arm (4) assist the nozzle (5) to finish spraying operation on a first operation area; the mobile robot (2) comprises a ground rail (6), a mobile frame (7), a telescopic arm (8) and a second spraying mechanical arm (9); the movable frame (7) is connected to the ground rail (6), and the movable frame (7) moves on the ground rail (6) along a first direction; the telescopic arm (8) is fixed on the movable frame (7), the second spraying mechanical arm (9) is fixed on the telescopic arm (8), and the second spraying mechanical arm (9) moves on the telescopic arm (8) along a second direction; and the second spraying mechanical arm (9) is hinged with a nozzle (5), and the second spraying mechanical arm (9) enables the nozzle (5) to move in a third direction.
5. A method for automatically spraying large-scale workpieces according to claim 4, characterized in that the gantry truss crown block (3) comprises a base (31), support plates (32) and a beam (33), wherein the support plates (32) are connected to the base (31), and the beam (33) is connected between the two support plates (32); the base (31) is provided with a first track (311), the first track (311) is matched with the supporting plate (32), and the supporting plate (32) moves on the base (31) along a first direction; the support plate (32) is provided with a second track (321), sliding bodies are arranged at two ends of the cross beam (33) and are matched with the second track (321), and the cross beam (33) moves on the support plate (32) along a second direction; be equipped with third track (331) on crossbeam (33), first spraying arm (4) are connected with third track (331), and first spraying arm (4) are along the third direction removal on crossbeam (33), all be equipped with motion sensor on base (31), backup pad (32) and the crossbeam (33), motion sensor is connected with control system.
6. The method for automatically spraying a large workpiece according to claim 4, wherein the first spraying mechanical arm (4) is a six-degree-of-freedom serial mechanical arm and comprises a base (41), a fixed rod (42), a secondary telescopic rod (43), a first hinge (44), a second hinge (45) and a first fixed member (46); the fixed rod (42) is connected to the base (41), and the fixed rod (42) rotates in the horizontal direction of the base (41); the secondary telescopic rod (43) is connected to the fixed rod (42), and the secondary telescopic rod (43) moves in the vertical direction; the first hinge (44) is hinged on the secondary telescopic rod (43), and the first hinge (44) rotates on the secondary telescopic rod (43); the second hinge piece (45) is hinged on the first hinge piece (44), the first fixing piece (46) is hinged on the second hinge piece (45), the first fixing piece (46) is hinged with a nozzle (5), and the nozzle (5) is communicated with the sand supply system through a pipeline; an anti-collision sensor and a motion sensor are embedded in the first spraying mechanical arm (4), the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor feeds back the relative position and pose information of each part of the first spraying mechanical arm (4); the anti-collision sensor prevents the first spraying mechanical arm (4) from collision.
7. The method for automatically spraying large-scale workpieces according to claim 4, wherein the ground rail (6) is provided with a displacement sensor, and the displacement sensor is connected with a control system; the ground rail (6) comprises a guide rail supporting wheel (61) and a rail set, and the guide rail supporting wheel (61) is fixed at the bottom of the rail set; the track set comprises a first guide rail (62) and a second guide rail (63); the second guide rail (63) is fixed on the top of the first guide rail (62); the first guide rail (62) is provided with a first sliding groove (65) and a second sliding groove (66), the first sliding groove (65) is positioned on the inner side, the second sliding groove (66) is positioned on the outer side, and the first sliding groove (65) is provided with a rack (67); the ground rail (6) is formed by splicing a plurality of sections of rail groups, and two adjacent sections of rail groups are fixedly connected through a connecting rod (64); each section of track group comprises two first guide rails (62), and the two first guide rails (62) are fixedly connected through a fixing plate (60); the top of the second guide rail (63) is arc-shaped.
8. The method for automatically spraying large-scale workpieces according to claim 4, wherein the movable frame (7) is provided with a displacement sensor, the displacement sensor is connected with a control system, and the position of the movable frame (7) is known through the control system; the movable frame (7) comprises a motor (71), a cover plate (72) and a bottom plate (73); the motor (71) is fixed on the bottom plate (73), the movable end of the motor (71) is connected with a transmission shaft (74), two ends of the transmission shaft (74) are connected with hubs (75), and the hubs (75) are matched with the second guide rail (63); the bottom plate (73) is fixed on the transmission shaft (74) through the connecting column (76), the transmission shaft (74) is provided with the fixing column (77), and the cover plate (72) is fixedly connected to the fixing column (77); one side of the hub (75) is provided with a gear (78), the other side is provided with a pulley (79), and the gear (78) and the pulley (79) are fixed on the transmission shaft (74) through a connecting piece; the gear (78) is meshed with the rack, and the pulley (79) is matched with the second sliding groove (66).
9. The method for automatically spraying large-scale workpieces according to claim 8, wherein the telescopic arm (8) is provided with a displacement sensor, the displacement sensor is connected with a control system, and the extension length of the telescopic arm (8) is known through the control system; the telescopic arm (8) is fixed on the cover plate (72) through a connecting plate (81), and the telescopic arm (8) comprises a hydraulic push rod (82), a reinforcing plate (83), a luffing plate (84) and a primary telescopic rod (85); the amplitude changing plate (84) is fixed on the primary telescopic rod (85); one end of the hydraulic push rod (82) is hinged on the connecting plate (81), and the other end of the hydraulic push rod is hinged on the amplitude plate (84); one side of the reinforcing plate (83) is hinged with the connecting plate (81), and the other side of the reinforcing plate is fixed on the primary telescopic rod (85); be equipped with second grade telescopic link (86), tertiary telescopic link (87) and fourth grade telescopic link (88) in one-level telescopic link (85), fourth grade telescopic link (88) are connected with gyro wheel (90) through bracing piece (89).
10. A method for automatically spraying large workpieces according to claim 9, characterized in that the second spraying robot comprises a third hinge (91), a fourth hinge (92) and a second fixing member (93), the third hinge (91) is connected to the four-stage telescopic rod (88) by means of a telescopic member (94), the fourth hinge (92) is hinged to the third hinge (91), the second fixing member (93) is fixed to the fourth hinge (92), and the nozzle (5) is connected to the second fixing member (93). An anti-collision sensor and a motion sensor are embedded in the second spraying mechanical arm (9), the anti-collision sensor and the motion sensor are both connected with a control system, and the motion sensor feeds back the relative position and pose information of each part of the second spraying mechanical arm (9); the anti-collision sensor prevents the second spraying mechanical arm (9) from collision.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310586219.3A CN116809267A (en) | 2023-05-22 | 2023-05-22 | Method for automatically spraying large-sized workpiece |
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| CN202310586219.3A CN116809267A (en) | 2023-05-22 | 2023-05-22 | Method for automatically spraying large-sized workpiece |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118080205A (en) * | 2024-04-24 | 2024-05-28 | 四川吉埃智能科技有限公司 | Automatic spraying method and system based on vision |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118080205A (en) * | 2024-04-24 | 2024-05-28 | 四川吉埃智能科技有限公司 | Automatic spraying method and system based on vision |
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