CN117226458B - Intelligent assembly device and assembly method for coaxial thermocouple - Google Patents
Intelligent assembly device and assembly method for coaxial thermocouple Download PDFInfo
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Abstract
The invention belongs to the field of sensor manufacturing, and discloses an intelligent assembly device and an intelligent assembly method for a coaxial thermocouple. The electrode wire feeding mechanism, the electrode tube clamping and three-degree-of-freedom adjusting mechanism, the electrode wire drawing mechanism, the vertical camera adjusting mechanism and the horizontal camera adjusting mechanism are fixed on the mounting bottom plate of the assembly device; the vertical camera adjusting mechanism shoots the electrode tube from top to bottom, the horizontal camera adjusting mechanism shoots the electrode wire from left to right, and the position image is transmitted to the intelligent coaxial centering control system; according to the assembly method, an intelligent coaxial centering control system is used for centering the electrode tube and the electrode wire, the electrode wire feeding mechanism is controlled to enable the sharpened part at the front end of the electrode wire to penetrate out of the electrode tube from front to back, the electrode wire drawing mechanism continues to stretch the electrode wire, the electrode wire is not sharpened part of the electrode wire is in interference fit with the electrode tube, and finally the electrode wire is fixed in the electrode tube, so that the assembly is completed. The assembly device and the assembly method realize coaxial automatic assembly of the electrode tube and the electrode wire, and improve the efficiency and the qualification rate.
Description
Technical Field
The invention belongs to the field of sensor manufacturing, and particularly relates to an intelligent assembly device and an intelligent assembly method for a coaxial thermocouple.
Background
The coaxial thermocouple comprises an electrode wire and an electrode tube, is a temperature measuring sensor, measures temperature by using thermoelectric effect, and generates electromotive force when the temperatures at two ends of the coaxial thermocouple are different, wherein the electromotive force is proportional to the temperature difference. The coaxial thermocouple is simple, reliable and low in cost, and is widely applied to the technical fields of industrial manufacture, scientific research, aerospace and the like. Along with the development of manufacturing industry, the coaxial thermocouple is also improved in all directions, and from temperature sensing materials to manufacturing processes, advanced technology is continuously applied to the manufacture and processing of the coaxial thermocouple.
The coaxial thermocouple is mainly formed by coaxially assembling an electrode tube and an electrode wire (the surface of which is wrapped with an insulating paint layer), the two parts are insulated by the insulating paint layer on the surface of the electrode wire, a thermal joint between the electrode tube and the electrode wire on the end face of the assembly body forms a dynamic voltage signal after transient temperature change is sensed, and at the moment, the electrode tube, the electrode wire, the thermal joint and external equipment form a passage, and temperature measurement is carried out through electrical signal change. At present, the coaxial thermocouple is assembled mainly by adopting a manual mode, and a coiled electrode wire is straightened through a device and trimmed to a required length according to requirements; secondly, due to interference fit, the wire electrode is required to be subjected to diameter reduction operation through mechanical stretching deformation, so that the interference of the wire electrode and the electrode tube is reduced; then, manually aligning the cut electrode wire, pushing the electrode tube to enable the electrode wire to enter and tightly assemble the electrode wire; and finally, polishing the end face of the assembly structure, and finishing and forming by controlling the roughness, thereby completing the assembly of the coaxial thermocouple. The thermocouple can be manufactured by manually assembling, but the following problems exist:
(1) The uniformity of electrode wire diameter shrinkage is poor. In the manual assembly process, the electrode wire is required to be deformed and reduced, and the size consistency and the integrity of the electrode wire after the diameter reduction cannot be ensured by utilizing a mechanical means to carry out manual diameter reduction;
(2) The yield is low. In the process of manually pushing the electrode tube to assemble, the assembling force cannot be accurately grasped by a worker, so that an insulating layer on the surface of the electrode wire is easily damaged in the interference assembling process, the internal insulation of an assembling structure cannot be ensured, and defective products are generated;
(3) The manual assembly efficiency is low. Because the coaxial thermocouple assembly process is complex and precise, the coaxial thermocouple assembly process has higher requirements on experience and proficiency of staff, and cannot ensure assembly efficiency in the operation process.
Currently, development of an intelligent assembly device and an intelligent assembly method for a coaxial thermocouple are needed.
Disclosure of Invention
The invention aims to provide an intelligent assembly device for a coaxial thermocouple, and aims to provide an intelligent assembly method for the coaxial thermocouple, which is used for solving the technical problem that an electrode wire and an electrode tube need to be in interference fit during assembly of the thermocouple.
The intelligent assembly device of the coaxial thermocouple is characterized by comprising a mechanical device and an intelligent coaxial centering control system;
the electrode wire feeding mechanism, the electrode tube clamping and three-degree-of-freedom adjusting mechanism and the electrode wire drawing mechanism are fixed on the mounting bottom plate of the mechanical device; the electrode wire feeding mechanism clamps and moves the electrode wire, the electrode tube clamps and the three-degree-of-freedom adjusting mechanism clamps and adjusts the position of the electrode tube, and the electrode wire drawing mechanism stretches the electrode wire; the mounting bottom plate of the mechanical device is also fixedly provided with a vertical camera adjusting mechanism and a horizontal camera adjusting mechanism, the vertical camera adjusting mechanism shoots an electrode tube from top to bottom, the position image of the electrode tube is transmitted to the intelligent coaxial centering control system, the horizontal camera adjusting mechanism shoots an electrode wire from left to right, and the position image of the electrode wire is transmitted to the intelligent coaxial centering control system;
the intelligent coaxial centering control system is arranged on the control computer and is connected with and controls the wire electrode wire feeding mechanism, the electrode tube clamping and three-degree-of-freedom adjusting mechanism and the wire electrode wire drawing mechanism in a wired or wireless mode.
Further, the mounting bottom plate is a flat plate, and a plurality of countersunk head screw holes are formed in the upper surface of the mounting bottom plate and are used for correspondingly mounting the wire electrode wire feeding mechanism, the vertical camera adjusting mechanism, the electrode tube clamping and three-degree-of-freedom adjusting mechanism, the wire electrode wire drawing mechanism and the horizontal camera adjusting mechanism.
Further, the wire electrode feeding mechanism comprises a linear guide rail, a clamping seat is clamped on the linear guide rail, a right-angle bracket I is fixed on the clamping seat, a pneumatic clamping jaw mechanism I is fixed on the right-angle bracket I and comprises a pneumatic clamping jaw I, a pneumatic finger I and a pneumatic finger II which are fixed on the pneumatic clamping jaw I, a V-shaped positioning groove is formed in the pneumatic finger I, a corresponding arc-shaped groove is formed in the pneumatic finger II, and the pneumatic clamping jaw I synchronously controls the pneumatic finger I and the pneumatic finger II and mutually cooperates with each other to clamp an electrode wire through the V-shaped positioning groove and the arc-shaped groove; the driving motor I drives the clamping seat to drive the electrode wire to move forwards, and the sharpened part of the front end of the electrode wire passes through the electrode tube from front to back;
air is supplied to the pneumatic clamping jaw I through an air compressor; the clamping force of the pneumatic clamping jaw I is adjusted by controlling the air path pressure through an air valve.
Further, the vertical camera adjusting mechanism comprises a vertical rod I fixed on the upper surface of the mounting bottom plate through a horizontal base angle, a horizontal rod fixed on the side surface of the vertical rod I through the vertical base angle, and a vertical camera vertically fixed at the front end of the horizontal rod, wherein the vertical camera shoots an electrode tube from top to bottom; the horizontal base angle of the vertical rod I and the vertical base angle of the horizontal rod are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the vertical camera.
Further, the electrode tube clamping and three-degree-of-freedom adjusting mechanism comprises a three-degree-of-freedom sliding table and a pneumatic clamping jaw mechanism II which is fixed on the three-degree-of-freedom sliding table through a right-angle bracket II; the three-degree-of-freedom sliding table has X, Y, Z degrees of freedom in three directions, so that the position of the electrode tube is adjusted; the pneumatic clamping jaw mechanism II comprises a pneumatic clamping jaw II, a pneumatic finger III and a pneumatic finger IV which are fixed on the pneumatic clamping jaw II, wherein a V-shaped positioning groove is formed in the pneumatic finger III, a corresponding arc-shaped groove is formed in the pneumatic finger IV, and the pneumatic clamping jaw II synchronously controls the pneumatic finger III and the pneumatic finger IV to mutually cooperate with each other to clamp an electrode tube through the V-shaped positioning groove and the arc-shaped groove;
air is supplied to the pneumatic clamping jaw II through an air compressor; the clamping force of the pneumatic clamping jaw II is adjusted by controlling the air path pressure through an air valve.
Further, the wire electrode drawing mechanism comprises a screw rod, an electric clamping jaw support is arranged on the screw rod, an electric clamping jaw is fixed on the electric clamping jaw support, the electric clamping jaw clamps the sharpened part of the front end of the wire electrode, a driving motor II drives the screw rod, the wire electrode is stretched continuously, the part of the wire electrode, which is not sharpened, is in interference fit with the electrode tube, and finally the wire electrode is fixed in the electrode tube.
Further, the horizontal camera adjusting mechanism comprises a vertical rod II fixed on the upper surface of the mounting bottom plate through a horizontal bottom angle, a horizontal bracket fixed on the side surface of the vertical rod II through the vertical bottom angle, and a horizontal camera horizontally fixed on the upper surface of the horizontal bracket, wherein the horizontal camera shoots electrode wires from left to right; the horizontal bottom angle of the vertical rod II and the vertical bottom angle of the horizontal bracket are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the horizontal camera; the distance between the shooting position of the horizontal camera and the distance from the electrode wire is 55-75mm.
The invention relates to an intelligent assembly method of a coaxial thermocouple, which comprises the following steps:
s81, mounting the electrode wire on an electrode wire feeding mechanism, enabling a sharpened part at the front end of the electrode wire to face an electrode tube, controlling a pneumatic clamping jaw I by an intelligent coaxial centering control system, and clamping the electrode wire by a pneumatic finger I and a pneumatic finger II;
s82, mounting the electrode tube on an electrode tube clamping and three-degree-of-freedom adjusting mechanism, controlling a pneumatic clamping jaw II by an intelligent coaxial centering control system, and clamping the electrode tube by a pneumatic finger III and a pneumatic finger IV;
s83, the vertical camera adjusting mechanism shoots the electrode tube from top to bottom, and transmits a position image of the electrode tube to the intelligent coaxial centering control system, and the horizontal camera adjusting mechanism shoots the electrode wire from left to right, and transmits a position image of the electrode wire to the intelligent coaxial centering control system;
s84, the intelligent coaxial centering control system calculates the relative position relation between the electrode tube and the electrode wire by utilizing an industrial camera self-adaptive coaxial centering algorithm, and feeds back the information of the relative position to the electrode tube clamping and three-degree-of-freedom adjusting mechanism;
s85, adjusting the position of the electrode tube in the X, Y, Z directions by the electrode tube clamping and three-degree-of-freedom adjusting mechanism until visual centering of the electrode tube and the electrode wire is achieved;
s86, the intelligent coaxial centering control system controls the wire electrode feeding mechanism to enable the sharpened part of the front end of the wire electrode to penetrate out of the electrode tube from front to back;
s87, controlling the wire electrode wire drawing mechanism to continuously stretch the wire electrode by the intelligent coaxial centering control system, performing interference fit on the part of the wire electrode, which is not sharpened, and the electrode tube, and finally fixing the wire electrode in the electrode tube to complete assembly of the wire electrode and the electrode tube.
Further, the industrial camera self-adaptive coaxial centering algorithm comprises the following steps:
s91, bilateral filtering is carried out on the position image of the electrode tube and the position image of the electrode wire, noise is removed, and an electrode tube contour image and an electrode wire contour image are obtained;
s92, performing image binarization on the electrode tube contour image and the electrode wire contour image to obtain an electrode tube binary contour image and an electrode wire binary contour image;
s93, performing sub-pixel edge perception calculation on the electrode tube binary contour image and the electrode wire binary contour image by adopting an edge contour extraction algorithm, and performing sub-pixel edge contour extraction;
s94, respectively calculating outline circumscribed rectangles of electrode tube sub-pixel edge outlines, wherein the outline circumscribed rectangles of electrode wire sub-pixel edge outlines comprise upper left corner coordinates of the circumscribed rectangles and widths and heights of the rectangles;
s95, respectively extracting the central line of the outline circumscribed rectangle of the electrode tube sub-pixel edge outline and the central line of the outline circumscribed rectangle of the electrode wire sub-pixel edge outline;
and S96, calculating the relative positions of the electrode tube and the electrode wire.
Further, the edge contour extraction algorithm calculates 4 edge parameters required for detecting an edge according to the rotation invariance of the moment, and the 4 edge parameters comprise the following contents:
binary contour imageMoment->The expression is as follows:
，
wherein,for image points->Gray value at>Is->Complex conjugate of (a);an n-order m-degree polynomial of the moment in a unit circle of a polar coordinate system;
under discrete conditions, binary profile imagesMoment->The definition in the unit circle is as follows:
，
moment (V)Rotate->The angular relationship function is defined as follows:
，
before the ideal step model of the sub-pixel edge rotates, gray values at two sides of a straight line L in a unit circle are respectively as followsAndwherein->For gray step difference, the length of the line segment from the origin to the straight line L in the unit circle is +.>，/>For line segment->And->An included angle of the shaft;
after the sub-pixel edge ideal step model rotates, obtaining according to different orders of Zernike moments after rotation、/>、/>The following formula is shown:
，
wherein,is->2 nd order constant term of->Is->1 st order item of (2)>Is->Item 1 st order after rotation, +.>Is the real part of the 1 st order term, +.>An imaginary part that is a 1 st order term;
the judgment condition of the edge point is thatWherein->For a preset +.>Threshold of->For a predetermined line segment->A threshold value of (2); the formula for calculating the sub-pixel edge detection is as follows:
，
wherein,the coordinate value of the sub-pixel of the edge is N, and the size of the template adopted in the edge detection is N;
further, the method for calculating the relative positions of the electrode tube and the electrode wire is as follows:
vertical relative height of electrode tube and wireThe calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube is circumscribed by the ordinate of the upper left corner coordinate of the rectangle, ">The outline of the electrode tube is circumscribed by a rectangular height, < >>Circumscribing the outline of the wire electrode with the ordinate of the upper left corner coordinate of the rectangle +>The outline of the electrode wire is externally connected with the height of the rectangle;
horizontal relative height of electrode tube and wireThe calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube is circumscribed by the abscissa of the upper left corner coordinates of the rectangle, ">The outline of the electrode tube is circumscribed by the width of the rectangle, < >>The outline of the wire electrode is circumscribed by the abscissa of the upper left corner coordinates of the rectangle, ">The outline of the electrode wire is circumscribed by the width of the rectangle.
The intelligent assembly device and the assembly method of the coaxial thermocouple can be used for carrying out self-adaptive intelligent centering on the electrode tube and the electrode wire by combining the self-adaptive coaxial centering algorithm of the industrial camera and the edge contour extraction algorithm, thereby reducing the manual assembly error, the labor cost and unstable product performance caused by manual work; the coaxial automatic assembly of the electrode wire and the electrode tube is realized, and the efficiency and the qualification rate of the automatic assembly are improved.
Drawings
FIG. 1 is a schematic view of the automated assembly device for coaxial thermocouples of the present invention;
FIG. 2 is a schematic view of the mounting base plate structure in the automatic assembly automation device of the coaxial thermocouple of the present invention;
FIG. 3 is a schematic view of a wire electrode feeding mechanism in the automatic assembly and automation device of the coaxial thermocouple of the present invention;
FIG. 4 is a schematic view of a vertical camera adjustment mechanism in the automatic coaxial thermocouple assembly automation device of the present invention;
FIG. 5 is a schematic view of the electrode tube clamping and three degree of freedom adjustment mechanism in the automatic assembly device of the coaxial thermocouple of the present invention;
FIG. 6 is a schematic diagram of a pneumatic clamping jaw mechanism II in the automatic coaxial thermocouple assembly automation device;
FIG. 7 is a schematic diagram of a wire electrode drawing mechanism in the automatic assembly automation device of the coaxial thermocouple;
FIG. 8 is a schematic view of a horizontal camera adjustment mechanism in the automatic coaxial thermocouple assembly automation device of the present invention;
FIG. 9 is a schematic flow chart of an automated method for assembling a coaxial thermocouple in accordance with the present invention;
FIG. 10 is a flow chart of an industrial camera adaptive coaxial centering algorithm employed in the automated method for automatic assembly of coaxial thermocouples of the present invention;
FIG. 11a is a schematic diagram of a sub-pixel edge ideal step model (before rotation) employed in the automated method for automated assembly of coaxial thermocouples of the present invention;
FIG. 11b is a schematic diagram of a sub-pixel edge ideal step model (after rotation) used in the automated method for automated assembly of coaxial thermocouples of the present invention.
In the figure, 1. Mounting a bottom plate; 2. a wire electrode feeding mechanism; 3. a vertical camera adjustment mechanism; 4. electrode tube clamping and three-degree-of-freedom adjusting mechanisms; 5. an electrode wire drawing mechanism; 6. a horizontal camera adjustment mechanism; 7. an electrode wire; 8. an electrode tube;
201. a driving motor I; 202. a clamping seat; 203. a right-angle bracket I; 204. pneumatic clamping jaw I; 205. pneumatic finger I; 206. pneumatic finger II;
301. a horizontal bar; 302. a vertical rod I; 303. a vertical camera;
401. a right-angle bracket II; 402. pneumatic clamping jaw II; 403. pneumatic finger III; 404. pneumatic finger IV; 405. three-degree-of-freedom sliding table;
501. a driving motor II; 502. an electric clamping jaw bracket; 503. an electric clamping jaw;
601. a horizontal bracket; 602. a vertical rod II; 603. a horizontal camera.
Detailed Description
The invention is described in detail below with reference to the drawings and examples.
Example 1:
as shown in fig. 1, the intelligent assembly device for the coaxial thermocouple of the embodiment comprises a mechanical device and an intelligent coaxial centering control system;
a wire electrode feeding mechanism (2), an electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) and a wire electrode wire drawing mechanism (5) are fixed on an installation bottom plate (1) of the mechanical device; the wire feeding mechanism (2) clamps and moves the wire electrode (7), the wire electrode clamping and three-degree-of-freedom adjusting mechanism (4) clamps and adjusts the position of the wire electrode (8), and the wire electrode wire drawing mechanism (5) stretches the wire electrode (7); a vertical camera adjusting mechanism (3) and a horizontal camera adjusting mechanism (6) are also fixed on a mounting bottom plate (1) of the mechanical device, the vertical camera adjusting mechanism (3) shoots an electrode tube (8) from top to bottom, position images of the electrode tube (8) are transmitted to an intelligent coaxial centering control system, the horizontal camera adjusting mechanism (6) shoots an electrode wire (7) from left to right, and position images of the electrode wire (7) are transmitted to the intelligent coaxial centering control system;
the intelligent coaxial centering control system is arranged on the control computer and is connected with and controls the wire electrode wire feeding mechanism (2), the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) and the wire electrode wire drawing mechanism (5) in a wired or wireless mode.
Further, as shown in fig. 2, the mounting base plate (1) is a flat plate, and a plurality of countersunk screw holes are formed in the upper surface of the mounting base plate and are used for correspondingly mounting the wire electrode wire feeding mechanism (2), the vertical camera adjusting mechanism (3), the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4), the wire electrode wire drawing mechanism (5) and the horizontal camera adjusting mechanism (6).
Further, as shown in fig. 3, the wire feeding mechanism (2) comprises a linear guide rail, a clamping seat (202) is clamped on the linear guide rail, a right-angle bracket I (203) is fixed on the clamping seat (202), a pneumatic clamping jaw mechanism I is fixed on the right-angle bracket I (203), the pneumatic clamping jaw mechanism I comprises a pneumatic clamping jaw I (204), a pneumatic finger I (205) and a pneumatic finger II (206) which are fixed on the pneumatic clamping jaw I (204), a V-shaped positioning groove is formed in the pneumatic finger I (205), a corresponding arc-shaped groove is formed in the pneumatic finger II (206), the pneumatic clamping jaw I (204) synchronously controls the pneumatic finger I (205) and the pneumatic finger II (206) to mutually match and clamp the wire electrode (7) through the V-shaped positioning groove and the arc-shaped groove; the driving motor I (201) drives the clamping seat (202) to drive the electrode wire (7) to move forwards, and the sharpened part of the front end of the electrode wire (7) passes through the electrode tube (8) from front to back;
air is supplied to the pneumatic clamping jaw I (204) through an air compressor; the clamping force of the pneumatic clamping jaw I (204) is adjusted by controlling the air path pressure through an air valve.
Further, as shown in fig. 4, the vertical camera adjusting mechanism (3) comprises a vertical rod i (302) fixed on the upper surface of the mounting base plate (1) through a horizontal base angle, a horizontal rod (301) fixed on the side surface of the vertical rod i (302) through a vertical base angle, and a vertical camera (303) vertically fixed on the front end of the horizontal rod (301), wherein the vertical camera (303) shoots the electrode tube (8) from top to bottom; the horizontal bottom angle of the vertical rod I (302) and the vertical bottom angle of the horizontal rod (301) are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the vertical camera (303).
Further, as shown in fig. 5 and 6, the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) comprises a three-degree-of-freedom sliding table (405) and a pneumatic clamping jaw mechanism II fixed on the three-degree-of-freedom sliding table (405) through a right-angle bracket II (401); the three-degree-of-freedom sliding table (405) has X, Y, Z three-direction degrees of freedom, so that the position adjustment of the electrode tube (8) is realized; the pneumatic clamping jaw mechanism II comprises a pneumatic clamping jaw II (402), a pneumatic finger III (403) and a pneumatic finger IV (404) which are fixed on the pneumatic clamping jaw II (402), a V-shaped positioning groove is formed in the pneumatic finger III (403), a corresponding arc-shaped groove is formed in the pneumatic finger IV (404), the pneumatic clamping jaw II (402) synchronously controls the pneumatic finger III (403) and the pneumatic finger IV (404), and the electrode tube (8) is clamped through the V-shaped positioning groove and the arc-shaped groove in a matched mode;
air is supplied to the pneumatic clamping jaw II (402) through an air compressor; the clamping force of the pneumatic clamping jaw II (402) is adjusted by controlling the air path pressure through an air valve.
Further, as shown in fig. 7, the wire drawing mechanism (5) comprises a screw, an electric clamping jaw bracket (502) is mounted on the screw, an electric clamping jaw (503) is fixed on the electric clamping jaw bracket (502), the electric clamping jaw (503) clamps the sharpened part of the front end of the wire electrode (7), a driving motor II (501) drives the screw, the wire electrode (7) is stretched again, the part of the wire electrode (7) which is not sharpened is in interference fit with the electrode tube (8), and finally the wire electrode (7) is fixed in the electrode tube (8).
Further, as shown in fig. 8, the horizontal camera adjusting mechanism (6) comprises a vertical rod ii (602) fixed on the upper surface of the mounting base plate (1) through a horizontal base angle, a horizontal bracket (601) fixed on the side surface of the vertical rod ii (602) through the vertical base angle, and a horizontal camera (603) horizontally fixed on the upper surface of the horizontal bracket (601), wherein the horizontal camera (603) shoots the wire electrode (7) from left to right; the horizontal bottom angle of the vertical rod II (602) and the vertical bottom angle of the horizontal bracket (601) are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the horizontal camera (603); the distance between the shooting position of the horizontal camera (603) and the distance from the electrode wire (7) is 55-75mm.
As shown in fig. 9, the intelligent assembly method of the coaxial thermocouple of the present embodiment includes the following steps:
s81, mounting the electrode wire (7) on the electrode wire feeding mechanism (2), enabling a sharpened part of the front end of the electrode wire (7) to face the electrode tube (8), controlling the pneumatic clamping jaw I (204) by the intelligent coaxial centering control system, and clamping the electrode wire (7) by the pneumatic finger I (205) and the pneumatic finger II (206);
s82, installing the electrode tube (8) on an electrode tube clamping and three-degree-of-freedom adjusting mechanism (4), controlling a pneumatic clamping jaw II (402) by an intelligent coaxial centering control system, and clamping the electrode tube (8) by a pneumatic finger III (403) and a pneumatic finger IV (404);
s83, the vertical camera adjusting mechanism (3) shoots the electrode tube (8) from top to bottom, and transmits a position image of the electrode tube (8) to the intelligent coaxial centering control system, the horizontal camera adjusting mechanism (6) shoots the electrode wire (7) from left to right, and transmits a position image of the electrode wire (7) to the intelligent coaxial centering control system;
s84, calculating the relative position relation between the electrode tube (8) and the electrode wire (7) by using an industrial camera self-adaptive coaxial centering algorithm by using the intelligent coaxial centering control system, and feeding back the information of the relative position to the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4);
s85, adjusting the position of the electrode tube (8) in the X, Y, Z three directions by the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) until visual centering of the electrode tube (8) and the electrode wire (7) is achieved;
s86, the intelligent coaxial centering control system controls the wire electrode feeding mechanism (2) to enable the sharpened part of the front end of the wire electrode (7) to penetrate out of the electrode tube (8) from front to back;
s87, controlling the wire electrode wire drawing mechanism (5) to continuously stretch the wire electrode (7) by the intelligent coaxial centering control system, enabling the part, which is not sharpened, of the wire electrode (7) to be in interference fit with the electrode tube, and finally fixing the wire electrode (7) in the electrode tube (8) to complete assembly of the wire electrode (7) and the electrode tube (8).
Further, as shown in fig. 10, the industrial camera adaptive coaxial centering algorithm includes the following steps:
s91, bilateral filtering is carried out on the position image of the electrode tube (8) and the position image of the electrode wire (7), noise is removed, and an outline image of the electrode tube (8) and an outline image of the electrode wire (7) are obtained;
s92, performing image binarization on the contour image of the electrode tube (8) and the contour image of the electrode wire (7) to obtain a binary contour image of the electrode tube (8) and a binary contour image of the electrode wire (7);
s93, performing sub-pixel edge perception calculation on the electrode tube (8) binary contour image and the electrode wire (7) binary contour image by adopting an edge contour extraction algorithm, and performing sub-pixel edge contour extraction;
s94, respectively calculating outline circumscribed rectangles of the edge outlines of the sub-pixels of the electrode tube (8), wherein the outline circumscribed rectangles of the edge outlines of the sub-pixels of the electrode wire (7) comprise upper left corner coordinates of the circumscribed rectangles and width and height of the rectangles;
s95, respectively extracting the central line of the outline circumscribed rectangle of the sub-pixel edge outline of the electrode tube (8) and the central line of the outline circumscribed rectangle of the sub-pixel edge outline of the electrode wire (7);
s96, calculating the relative positions of the electrode tube (8) and the electrode wire (7).
Further, the edge contour extraction algorithm calculates 4 edge parameters required for detecting an edge according to the rotation invariance of the moment, and the 4 edge parameters comprise the following contents:
binary contour imageMoment->The expression is as follows:
，
wherein,for image points->Gray value at>Is->Complex conjugate of (a);an n-order m-degree polynomial of the moment in a unit circle of a polar coordinate system;
under discrete conditions, binary profile imagesMoment->The definition in the unit circle is as follows:
，
moment (V)Rotate->The angular relationship function is defined as follows:
，
as shown in FIG. 11a, the gray values on both sides of the straight line L in a unit circle before the sub-pixel edge ideal step model rotates are respectivelyAnd->Wherein->For gray step difference, the length of the line segment from the origin to the straight line L in the unit circle is +.>，/>For line segment->And->An included angle of the shaft;
as shown in FIG. 11b, after the sub-pixel edge ideal step model rotates, the sub-pixel edge ideal step model is obtained according to the Zernike moments of different orders after rotation、/>、/>The following formula is shown:
，
wherein,is->2 nd order constant term of->Is->1 st order item of (2)>Is->Item 1 st order after rotation, +.>Is the real part of the 1 st order term, +.>An imaginary part that is a 1 st order term;
the judgment condition of the edge point is thatWherein->For a preset +.>Threshold of->For a predetermined line segment->A threshold value of (2); the formula for calculating the sub-pixel edge detection is as follows:
，
wherein,the coordinate value of the sub-pixel of the edge is N, and the size of the template adopted in the edge detection is N;
further, the relative position calculation method of the electrode tube (8) and the electrode wire (7) is as follows:
vertical relative height of electrode tube (8) and electrode wire (7)The calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube (8) is circumscribed by the ordinate of the upper left corner coordinate of the rectangle, +.>The outline of the electrode tube (8) is circumscribed by a rectangular height +.>The outline of the electrode wire (7) is circumscribed with the ordinate of the upper left corner coordinate of the rectangle, +.>The outline of the electrode wire (7) is externally connected with the height of the rectangle;
horizontal relative height of electrode tube (8) and electrode wire (7)The calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube (8) is circumscribed with the abscissa of the upper left corner coordinate of the rectangle, +.>The outline of the electrode tube (8) is circumscribed by the width of the rectangle, < >>The outline of the electrode wire (7) is circumscribed with the abscissa of the upper left corner coordinate of the rectangle, +.>The outline of the electrode wire (7) is circumscribed by the width of the rectangle.
The foregoing examples merely represent exemplary embodiments of the present invention, which are described in more detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (6)
1. The intelligent coaxial thermocouple assembly device is characterized by comprising a mechanical device and an intelligent coaxial centering control system;
a wire electrode feeding mechanism (2), an electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) and a wire electrode wire drawing mechanism (5) are fixed on an installation bottom plate (1) of the mechanical device; the wire feeding mechanism (2) clamps and moves the wire electrode (7), the wire electrode clamping and three-degree-of-freedom adjusting mechanism (4) clamps and adjusts the position of the wire electrode (8), and the wire electrode wire drawing mechanism (5) stretches the wire electrode (7); a vertical camera adjusting mechanism (3) and a horizontal camera adjusting mechanism (6) are also fixed on a mounting bottom plate (1) of the mechanical device, the vertical camera adjusting mechanism (3) shoots an electrode tube (8) from top to bottom, position images of the electrode tube (8) are transmitted to an intelligent coaxial centering control system, the horizontal camera adjusting mechanism (6) shoots an electrode wire (7) from left to right, and position images of the electrode wire (7) are transmitted to the intelligent coaxial centering control system;
the intelligent coaxial centering control system is arranged on the control computer and is connected with and controls the wire electrode wire feeding mechanism (2), the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) and the wire electrode wire drawing mechanism (5) in a wired or wireless mode;
the mounting bottom plate (1) is a flat plate, and a plurality of countersunk head screw holes are formed in the upper surface of the mounting bottom plate and are used for correspondingly mounting the wire electrode wire feeding mechanism (2), the vertical camera adjusting mechanism (3), the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4), the wire electrode wire drawing mechanism (5) and the horizontal camera adjusting mechanism (6);
the wire electrode feeding mechanism (2) comprises a linear guide rail, a clamping seat (202) is clamped on the linear guide rail, a right-angle bracket I (203) is fixed on the clamping seat (202), a pneumatic clamping jaw mechanism I is fixed on the right-angle bracket I (203), the pneumatic clamping jaw mechanism I comprises a pneumatic clamping jaw I (204), a pneumatic finger I (205) and a pneumatic finger II (206) which are fixed on the pneumatic clamping jaw I (204), a V-shaped positioning groove is formed in the pneumatic finger I (205), a corresponding arc-shaped groove is formed in the pneumatic finger II (206), the pneumatic clamping jaw I (204) synchronously controls the pneumatic finger I (205) and the pneumatic finger II (206) to mutually cooperate to clamp the electrode wire (7) through the V-shaped positioning groove and the arc-shaped groove; the driving motor I (201) drives the clamping seat (202) to drive the electrode wire (7) to move forwards, and the sharpened part of the front end of the electrode wire (7) passes through the electrode tube (8) from front to back;
air is supplied to the pneumatic clamping jaw I (204) through an air compressor; the air valve is used for controlling the air pressure, so as to adjust the clamping force of the pneumatic clamping jaw I (204);
the vertical camera adjusting mechanism (3) comprises a vertical rod I (302) fixed on the upper surface of the mounting base plate (1) through a horizontal base angle, a horizontal rod (301) fixed on the side surface of the vertical rod I (302) through the vertical base angle, and a vertical camera (303) vertically fixed at the front end of the horizontal rod (301), wherein the vertical camera (303) shoots an electrode tube (8) from top to bottom; the horizontal bottom angle of the vertical rod I (302) and the vertical bottom angle of the horizontal rod (301) are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the vertical camera (303);
the wire electrode drawing mechanism (5) comprises a screw rod, an electric clamping jaw support (502) is arranged on the screw rod, an electric clamping jaw (503) is fixed on the electric clamping jaw support (502), the electric clamping jaw (503) clamps the sharpened part of the front end of the wire electrode (7), a driving motor II (501) drives the screw rod, the wire electrode (7) is stretched continuously, the part of the wire electrode (7) which is not sharpened is in interference fit with the electrode tube (8), and finally the wire electrode (7) is fixed in the electrode tube (8).
2. The intelligent assembly device for the coaxial thermocouple according to claim 1, wherein the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) comprises a three-degree-of-freedom sliding table (405) and a pneumatic clamping jaw mechanism II which is fixed on the three-degree-of-freedom sliding table (405) through a right-angle bracket II (401); the three-degree-of-freedom sliding table (405) has X, Y, Z three-direction degrees of freedom, so that the position adjustment of the electrode tube (8) is realized; the pneumatic clamping jaw mechanism II comprises a pneumatic clamping jaw II (402), a pneumatic finger III (403) and a pneumatic finger IV (404) which are fixed on the pneumatic clamping jaw II (402), a V-shaped positioning groove is formed in the pneumatic finger III (403), a corresponding arc-shaped groove is formed in the pneumatic finger IV (404), the pneumatic clamping jaw II (402) synchronously controls the pneumatic finger III (403) and the pneumatic finger IV (404), and the electrode tube (8) is clamped through the V-shaped positioning groove and the arc-shaped groove in a matched mode;
air is supplied to the pneumatic clamping jaw II (402) through an air compressor; the clamping force of the pneumatic clamping jaw II (402) is adjusted by controlling the air path pressure through an air valve.
3. The intelligent coaxial thermocouple assembly device according to claim 1, wherein the horizontal camera adjusting mechanism (6) comprises a vertical rod II (602) fixed on the upper surface of the mounting base plate (1) through a horizontal base angle, a horizontal bracket (601) fixed on the side surface of the vertical rod II (602) through the vertical base angle, and a horizontal camera (603) horizontally fixed on the upper surface of the horizontal bracket (601), wherein the horizontal camera (603) shoots the wire electrode (7) from left to right; the horizontal bottom angle of the vertical rod II (602) and the vertical bottom angle of the horizontal bracket (601) are provided with waist-shaped holes, and after the screws are positioned, the waist-shaped holes slide along the screws to change the shooting position of the horizontal camera (603); the distance between the shooting position of the horizontal camera (603) and the distance from the electrode wire (7) is 55-75mm.
4. The intelligent assembly method of the coaxial thermocouple is used for the intelligent assembly device of the coaxial thermocouple of any one of claims 2-3, and is characterized by comprising the following steps:
s81, mounting the electrode wire (7) on the electrode wire feeding mechanism (2), enabling a sharpened part of the front end of the electrode wire (7) to face the electrode tube (8), controlling the pneumatic clamping jaw I (204) by the intelligent coaxial centering control system, and clamping the electrode wire (7) by the pneumatic finger I (205) and the pneumatic finger II (206);
s82, installing the electrode tube (8) on an electrode tube clamping and three-degree-of-freedom adjusting mechanism (4), controlling a pneumatic clamping jaw II (402) by an intelligent coaxial centering control system, and clamping the electrode tube (8) by a pneumatic finger III (403) and a pneumatic finger IV (404);
s83, the vertical camera adjusting mechanism (3) shoots the electrode tube (8) from top to bottom, and transmits a position image of the electrode tube (8) to the intelligent coaxial centering control system, the horizontal camera adjusting mechanism (6) shoots the electrode wire (7) from left to right, and transmits a position image of the electrode wire (7) to the intelligent coaxial centering control system;
s84, calculating the relative position relation between the electrode tube (8) and the electrode wire (7) by using an industrial camera self-adaptive coaxial centering algorithm by using the intelligent coaxial centering control system, and feeding back the information of the relative position to the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4);
s85, adjusting the position of the electrode tube (8) in the X, Y, Z three directions by the electrode tube clamping and three-degree-of-freedom adjusting mechanism (4) until visual centering of the electrode tube (8) and the electrode wire (7) is achieved;
s86, the intelligent coaxial centering control system controls the wire electrode feeding mechanism (2) to enable the sharpened part of the front end of the wire electrode (7) to penetrate out of the electrode tube (8) from front to back;
s87, controlling the wire electrode wire drawing mechanism (5) to continuously stretch the wire electrode (7) by the intelligent coaxial centering control system, enabling the part, which is not sharpened, of the wire electrode (7) to be in interference fit with the electrode tube, and finally fixing the wire electrode (7) in the electrode tube (8) to complete assembly of the wire electrode (7) and the electrode tube (8).
5. The intelligent assembly method of the coaxial thermocouple according to claim 4, wherein the adaptive coaxial centering algorithm of the industrial camera comprises the following steps:
s91, bilateral filtering is carried out on the position image of the electrode tube (8) and the position image of the electrode wire (7), noise is removed, and an outline image of the electrode tube (8) and an outline image of the electrode wire (7) are obtained;
s92, performing image binarization on the contour image of the electrode tube (8) and the contour image of the electrode wire (7) to obtain a binary contour image of the electrode tube (8) and a binary contour image of the electrode wire (7);
s93, performing sub-pixel edge perception calculation on the electrode tube (8) binary contour image and the electrode wire (7) binary contour image by adopting an edge contour extraction algorithm, and performing sub-pixel edge contour extraction;
s94, respectively calculating outline circumscribed rectangles of the edge outlines of the sub-pixels of the electrode tube (8), wherein the outline circumscribed rectangles of the edge outlines of the sub-pixels of the electrode wire (7) comprise upper left corner coordinates of the circumscribed rectangles and width and height of the rectangles;
s95, respectively extracting the central line of the outline circumscribed rectangle of the sub-pixel edge outline of the electrode tube (8) and the central line of the outline circumscribed rectangle of the sub-pixel edge outline of the electrode wire (7);
s96, calculating the relative positions of the electrode tube (8) and the electrode wire (7).
6. The intelligent assembly method of the coaxial thermocouple according to claim 5, wherein the edge profile extraction algorithm calculates 4 edge parameters required for detecting the edge according to the rotational invariance of the moment, and the method comprises the following steps:
binary contour imageMoment->The expression is as follows:
，
wherein,for image points->Gray value at>Is->Complex conjugate of (a); />An n-order m-degree polynomial of the moment in a unit circle of a polar coordinate system;
under discrete conditions, binary profile imagesMoment->The definition in the unit circle is as follows:
，
moment (V)Rotate->The angular relationship function is defined as follows:
，
before the ideal step model of the sub-pixel edge rotates, gray values at two sides of a straight line L in a unit circle are respectively as followsAnd->Wherein->For gray step difference, the length of the line segment from the origin to the straight line L in the unit circle is +.>，/>For line segment->And->An included angle of the shaft;
after the sub-pixel edge ideal step model rotates, obtaining according to different orders of Zernike moments after rotation、/>、/>The following formula is shown:
，
wherein,is->2 nd order constant term of->Is->1 st order item of (2)>Is->The rotated 1 st order term,is the real part of the 1 st order term, +.>An imaginary part that is a 1 st order term;
the judgment condition of the edge point is thatWherein->For a preset +.>Threshold of->For a predetermined line segment->A threshold value of (2); the formula for calculating the sub-pixel edge detection is as follows:
，
wherein,the coordinate value of the sub-pixel of the edge is N, and the size of the template adopted in the edge detection is N;
the method for calculating the relative positions of the electrode tube (8) and the electrode wire (7) comprises the following steps:
vertical relative height of electrode tube (8) and electrode wire (7)The calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube (8) is circumscribed by the ordinate of the upper left corner coordinate of the rectangle, +.>The outline of the electrode tube (8) is circumscribed by a rectangular height +.>The outline of the electrode wire (7) is circumscribed with the ordinate of the upper left corner coordinate of the rectangle, +.>The outline of the electrode wire (7) is externally connected with the height of the rectangle;
horizontal relative height of electrode tube (8) and electrode wire (7)The calculation formula of (2) is as follows:
，
wherein,the outline of the electrode tube (8) is circumscribed with the abscissa of the upper left corner coordinate of the rectangle, +.>The outline of the electrode tube (8) is circumscribed by the width of the rectangle, < >>The outline of the electrode wire (7) is circumscribed with the abscissa of the upper left corner coordinate of the rectangle, +.>The outline of the electrode wire (7) is circumscribed by the width of the rectangle.
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