CN117742239B - Vertical correction system and correction method for machine tool - Google Patents
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Abstract
The invention relates to the technical field of electric auxiliary components and discloses a vertical correction system and a correction method of a machine tool, wherein the system comprises a deviation angle acquisition module, an original track compensation calculation module, a Beizer curve processing module, a curve interpolation speed planning module and a motion planning execution module. The invention compensates the machining process through algorithm software, thereby realizing the improvement of the precision of the machine tool and the reduction of the maintenance cost of the machine tool.
Description
Technical Field
The invention relates to the technical field of machine tool control, in particular to a vertical correction system and a correction method of a machine tool.
Background
In recent years, with the strong pushing of the national industrial policy on the laser cutting technology, the scale acceleration of the laser processing market is gradually accelerated, and the laser processing market is widely applied to the fields of heavy industry and light industry such as machinery, automobiles, aviation, steel, shipbuilding, military industry, electronics, metals, textiles, wood and the like. The rapid development of the manufacturing industry in China, the update and upgrade of the traditional industrial manufacturing technology, and the promotion of the sales of laser cutting complete equipment. The laser cutting devices gradually replace the traditional machine tools, and the rapid increase of the market demand of the laser cutting devices is a necessary trend.
The plate cutting mainly comprises a middle-sized and small-sized gantry machine tool, and in view of the special form of the gantry machine tool, the beam is bent to a certain extent due to the influence of adverse factors such as control precision or environmental influence after long-time use, and the perpendicularity of a machining line segment is influenced.
Direct replacement of the entire device if the degree of bending is small tends to be costly.
Disclosure of Invention
The invention aims to solve the problems, and provides a vertical correction system and a correction method of a machine tool, which compensate the machining process through algorithm software to improve the precision of the machine tool and reduce the maintenance cost of the machine tool.
The technical scheme adopted by the invention is as follows:
The vertical correction system of the machine tool is characterized by comprising a deviation angle acquisition module, an original track compensation calculation module, a Beizer curve processing module, a curve interpolation speed planning module and a motion planning execution module, wherein the deviation angle acquisition module comprises a laser gun head arranged on a processing arm of the machine tool, a plane camera arranged on the periphery or below a moving area of the processing arm, the laser gun head moves according to a preset track, the plane camera acquires an actual moving track of the laser gun head, a beam bending angle is calculated through the deviation between the preset track and the actual track, the original track compensation calculation module calculates compensation values of the gun moving in the x-y direction respectively according to the deviation angle, the original track is corrected for processing of the processing arm of the machine tool, the Beizer curve processing module fits the compensated original track discrete points into a smooth curve, the curve interpolation speed planning module interpolates the curve to obtain Cartesian space moving parameters, the joint moving parameters are converted into joint moving parameters, the moving speed of the processing arm of the machine tool is planned and finally combined and sent to the motion planning execution module, and the motion planning execution module receives a motion command to control the machine tool servo motion.
A vertical correction method of a machine tool is characterized by comprising the following steps:
Step one: the machine tool processing arm drives the laser gun head to move according to a preset track, the plane camera records the actual moving track of the laser gun head, and the bending angle of the cross beam is calculated according to the deviation between the actual track and the coordinates of the preset track;
Step two: carrying out perpendicularity correction and compensation calculation on an original track of a to-be-processed workpiece to obtain Cartesian space coordinates of a compensation track;
step three: according to the compensated track coordinates of the compensated workpiece to be processed under the Cartesian coordinate system, partial characteristic position coordinates are obtained, and Bezier curve fitting is carried out on the position coordinates;
Step four: periodically interpolating the curve after Bezier fitting, and converting joint coordinates to obtain joint coordinate positions;
step five: and calculating the difference between the current joint position and the target position, and sending corresponding pulses to a servo motor of the machine tool to execute a motion instruction according to the difference and the pulse equivalent.
Further, in the first step, the process of calculating the bending angle of the beam includes:
(1) The method comprises the following steps of converting a coordinate system of an actual rail recorded by a plane camera, wherein the coordinate system comprises the conversion of a world coordinate system, a camera coordinate system, an image coordinate system and a pixel coordinate system, and the conversion process is as follows:
The left side of the equation is the coordinate to be solved of a point in the world coordinate system corresponding to a point in the pixel coordinate system, wherein Zc is the coordinate offset value of the point in the camera coordinate system in the Z direction; the middle of the equation is the calculation process of a world coordinate system, a camera coordinate system, an image coordinate system and a pixel coordinate system in sequence from right to left, wherein (Xw, yw, zw) is a point in the world coordinate system, R is a rotation matrix rotating around each axis when the world coordinate system is converted into the camera coordinate system, T is an offset vector of each direction of the camera coordinate system in the world coordinate system, f is a Z-direction offset of the point in the camera coordinate system, dx and dy respectively represent physical length units (mm) represented by a plurality of rows and columns of pixels, and (u 0, v 0) is an origin offset of an origin of the image coordinate system in the pixel coordinate system; the right side of the equation is the coordinate vector of the point in the combined camera internal parameter, camera external parameter matrix and world coordinate system;
(2) According to a given formula, acquiring the pixel coordinates of the actual track according to the distance corresponding to each pixel in the pixel coordinate system, setting the endpoint coordinates of the actual track in the pixel coordinate system as (x 2, y 2), setting the endpoint coordinates of the preset track as (x 1, y 1), and setting the initial coordinates as (x 0, y 0), wherein the beam bending angle calculation method can calculate the deviation angle through a triangle formula:
。
further, the method for compensating the original track in the second step is to calculate the compensation value of the movement of the laser gun in the x direction and the y direction of the original track according to the deviation angle alpha, and the calculation method of the compensation value is given by the following formula:
。
further, the compensation value is calculated in real time on a periodic basis.
In the third step, the original track Bezier fitting method is to use a least square method to perform Bezier curve fitting on small line segments or discrete points of the position coordinates, obtain a Bezier curve meeting the range of the distance error through recursive calculation,
Assuming Bix and Biy are the x, y coordinates corresponding to the ith point after fitting, and Xi and Yi are the x, y coordinates of the ith point in the source data, and N points are shared, the least square formula applies as follows:
，
When the minimum value is obtained by the above formula, each parameter value is a coefficient of the Bezier curve, and a third-order Bezier curve is used, wherein the curve can be represented by the following formula:
；
in the above formula, P (P0, P1, P2, p3......pn) is: the coordinates of the positions of the two pairs of the three pairs of and t is a curve generation parameter, and a third-order Bezier curve can be generated by taking values from 0 to 1.
Further, in step five, the servo-performed motion command is periodically controlled.
Further, the preset track in the first step is square.
The beneficial effects of the invention are as follows:
(1) The processing process is compensated by software, so that the cost is low, the precision is high, and manual measurement is not needed;
(2) The original track is subjected to Beizer curve processing and then is subjected to speed planning, and compensation value calculation is added in the interpolation issuing stage, so that the problems of speed mutation and jump caused by direct motor compensation in the motor execution stage in the traditional vertical compensation mode are effectively solved;
(3) Because the real motor coordinates are used, the problem of recovery deviation is avoided when the machine tool is suspended or the breakpoint is recovered;
(4) The original track is processed so that no abrupt speed change or jump problem due to the above-mentioned document is generated during operation in the motor shaft.
Drawings
FIG. 1 is a schematic diagram of the arrangement of a laser gun head and a plane camera on a machine tool;
FIG. 2 is a flow chart of the steps of the corrective method of the present invention;
FIG. 3 is a schematic diagram of coordinate transformation;
FIG. 4 is a schematic diagram of the deviation angle acquisition;
FIG. 5 is a schematic diagram of compensation value calculation;
Fig. 6 is a schematic diagram of the vertical correction execution process of the machine tool.
Detailed Description
The following describes in detail a specific embodiment of a vertical correction system and a correction method for a machine tool according to the present invention with reference to the accompanying drawings.
The invention can effectively correct the precision deviation of the middle and small gantry machine tools after long-time use, but is not limited to the gantry machine tools, and can effectively correct the large-stroke machine tools by the method.
The vertical correction system of the machine tool comprises an offset angle acquisition module, an original track compensation calculation module, a Beizer curve processing module, a curve interpolation speed planning module, a motion planning execution module and the like.
The deviation angle acquisition module comprises a laser gun head arranged on a processing arm of a gantry machine tool, a plane camera arranged below the machine tool, and the plane camera arranged on the opposite side of the moving direction of the processing arm for other machine tools with large strokes.
Referring to fig. 1, the plane camera measures by observing the moving track of the red light of the laser gun head as an actual moving track. The laser gun head moves according to a preset track, the plane camera obtains the actual moving track of the laser gun head, and the bending angle of the cross beam is calculated through the deviation between the preset track and the actual track, and the specific calculation method refers to the method in the embodiment.
The original track compensation calculation module calculates compensation values of gun movement in the x direction and the y direction according to the deviation angle, and corrects the original track of the machine tool machining arm. And Beizer, fitting the compensated original track discrete points into a smooth curve by a curve processing module. The curve interpolation speed planning module interpolates the curve to obtain Cartesian space movement parameters, converts the Cartesian space movement parameters into joint movement parameters, plans the movement speed of a machine tool processing arm, and finally merges and sends the movement planning parameters to the motion planning execution module. And the motion planning execution module receives the motion instruction and controls the servo motion of the machine tool.
Referring to fig. 2, the above modular machine vertical correction system performs the specific correction method as follows:
Step one: the machine tool processing arm drives the laser gun head to move according to a preset track, the plane camera records the actual moving track of the laser gun head, and the bending angle of the cross beam is calculated according to the deviation between the actual track and the coordinates of the preset track.
Referring to fig. 3, the system before observation of the plane camera performs a coordinate system conversion, where the conversion includes a conversion from a world coordinate system (object coordinate system), a camera coordinate system, an image coordinate system, and a pixel coordinate system, and the coordinate conversion process can be given by the following formula:
The above formula represents the process of converting a point in the world coordinate system to the pixel coordinate system. The left side of the equation is the coordinate to be solved of a point in the world coordinate system corresponding to a point in the pixel coordinate system, wherein Zc is the coordinate offset value of the point in the camera coordinate system in the Z direction. The middle of the equation is the calculation process of a world coordinate system, a camera coordinate system, an image coordinate system and a pixel coordinate system in sequence from right to left, wherein (Xw, yw, zw) is a point in the world coordinate system, R is a rotation matrix rotating around each axis when the world coordinate system is converted into the camera coordinate system, T is an offset vector of each direction of the camera coordinate system in the world coordinate system, f is a Z-direction offset of the point in the camera coordinate system, dx and dy respectively represent physical length units (mm) represented by a plurality of rows and columns of pixels, and (u 0, v 0) is an origin offset of an origin of the image coordinate system in the pixel coordinate system. The right side of the equation is the coordinate vector for the point in the combined camera intrinsic, camera extrinsic matrix and world coordinate system.
According to a given formula, the plane camera observes the blank moving track of the red point of the laser gun head according to a preset pattern from the lower side and obtains the continuous coordinates of the track in a pixel coordinate system. The parameter sources of the beam bending angle calculation are obtained by observing the actual moving track of the laser gun through a plane camera and converting the actual moving track into the track in a pixel coordinate system. And acquiring the track coordinate of the actual movement of the laser gun head according to the distance corresponding to each pixel in the pixel coordinate system, setting the endpoint coordinate of the idle movement track in the pixel coordinate system as (x 2, y 2), setting the theoretical idle movement endpoint coordinate of the theoretical graph as (x 1, y 1), and setting the initial coordinate as (x 0, y 0). At this time, the beam bending angle calculation method can calculate the deviation angle through a triangular formula:
。
Step two: and (3) carrying out perpendicularity correction and compensation calculation on the original track of the to-be-processed workpiece to obtain Cartesian space coordinates of the compensated track.
The original track is compensated by respectively calculating compensation values of the movement of the laser gun in the x direction and the y direction of the original track according to the magnitude of the deviation angle alpha, and the calculation method of the compensation values is given by the following formula:
，
The calculation of the compensation value is performed periodically, each period is calculated in real time, and the formula shows that the compensation is started in the y direction only when the movement increment starts in the x direction, so that the biaxial movement is performed synchronously.
Step three: and obtaining partial characteristic position coordinates according to the compensated track coordinates of the part to be processed under the Cartesian coordinate system, and performing Bezier curve fitting on the position coordinates.
The original track Bezier fitting method is to use a least square method to fit a Bezier curve to a small line segment or discrete point, and the principle is that a section of Bezier curve is firstly generated through giving a minimum error, then the maximum error point in the generated Bezier curve is searched, two sections of Beziers are regenerated after the maximum error point is split, the operation is continuously carried out on the two sections of newly generated Bezier curves, and a proper Bezier curve of which each point meets the range of distance errors is found in the process of continuous recursion calculation. Assuming Bix and Biy are the x, y coordinates corresponding to the ith point after fitting, and Xi and Yi are the x, y coordinates of the ith point in the source data, and N points are shared, the least square formula applies as follows:
，
when the minimum value is obtained by the above formula, each parameter value is a coefficient of a Bezier curve, and a third-order Bezier curve is generally used, and the curve can be represented by the following formula:
；
in the above formula, P (P0, P1, P2, p3......pn) is: the coordinates of the positions of the two pairs of the three pairs of and t is a curve generation parameter, and a third-order Bezier curve can be generated by taking values from 0 to 1.
Step four: and performing periodic interpolation on the curve after Bezier fitting, and performing joint coordinate conversion on the curve to obtain a joint coordinate position.
Step five: and calculating the difference between the current joint position and the target position, and sending corresponding pulses to a servo motor of the machine tool to execute a motion instruction according to the difference and the pulse equivalent. The compensation value is calculated in real time on a periodic basis.
The following is a description of specific examples.
Referring to fig. 4, 5 and 6, after the graphic is imported by the operation interface and the vertical correction is started, the system starts to execute the following steps:
1. Fig. 4 is a pixel coordinate system converted by a world coordinate system, in which, the left side of the end point of the actual track of the processing graph is calculated according to the length represented by the pixel, the coordinate of the upper right end of the actual track is set as (100, 80), the coordinate of the upper right end of the theoretical track is set as (100.1, 75.223), and the starting point (0, 0), then the deviation angle can be calculated by a system call formula, and the calculation method is as follows:
。
2. the system compensates the original graph after obtaining the deviation angle, the compensation method is shown in a compensation calculation schematic diagram 5, the inclined edge in the diagram is an actual gun movement track generated under the alpha deviation angle, and the right-angle edge is a command track of gun movement, and the inclined edge needs to be projected to the right-angle edge. Therefore, when the displacement is commanded in the x direction, a compensation value needs to be added to form the length of the sloping side, and meanwhile, a negative compensation value needs to be added in the y direction to compensate the actual gun track into the required gun track. As shown in the vertical correction execution diagram, the simultaneous compensation in the x and y directions can compensate the hypotenuse trajectory of the actual gun movement to the required right angle trajectory. The calculation of the compensation is completed by the automatic calculation of a system call formula, and the calculation process is as follows:
；
3. Bezier processing is carried out on the original track based on the processing graph, and according to the track point information (0, 0), (0, 75.223), (100.1,0), (100.1, 75.223) after known compensation, each point is brought into a Bezier curve formula to obtain the following steps: ；
4. And (3) interpolating t in the formula between 0 and 1, issuing an instruction position instruction, executing an interpolation function after the motion planning module receives the instruction position, converting each position into a joint moving target in each period, and controlling servo motion, namely controlling gun movement according to the distance and pulse equivalent transmission pulse quantity, so as to finally achieve the aim of correcting verticality.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (5)
1. A method for vertical correction of a machine tool, characterized by: the machine tool vertical correction system comprises a deviation angle acquisition module, an original track compensation calculation module, a Beizer curve processing module, a curve interpolation speed planning module and a motion planning execution module,
The deviation angle acquisition module comprises a laser gun head arranged on a processing arm of a machine tool, a plane camera arranged at the periphery or below a moving area of the processing arm, wherein the laser gun head moves according to a preset track, the plane camera acquires an actual moving track of the laser gun head, calculates the bending angle of a cross beam through the deviation between the preset track and the actual track,
The correction method comprises the following steps:
Step one: the machine tool processing arm drives the laser gun head to move according to a preset track, the plane camera records the actual moving track of the laser gun head, and the bending angle of the cross beam is calculated according to the deviation between the actual track and the coordinates of the preset track;
Step two: carrying out perpendicularity correction and compensation calculation on an original track of a to-be-processed workpiece to obtain Cartesian space coordinates of a compensation track;
step three: according to the compensated track coordinates of the compensated workpiece to be processed under the Cartesian coordinate system, partial characteristic position coordinates are obtained, and Bezier curve fitting is carried out on the position coordinates;
Step four: periodically interpolating the curve after Bezier fitting, and converting joint coordinates to obtain joint coordinate positions;
step five: calculating the difference between the current joint position and the target position, sending corresponding pulses to a servo motor of the machine tool to execute a motion instruction according to the difference and the pulse equivalent,
In the first step, the process of calculating the bending angle of the cross beam comprises the following steps:
(1) The method comprises the following steps of converting a coordinate system of an actual rail recorded by a plane camera, wherein the coordinate system comprises the conversion of a world coordinate system, a camera coordinate system, an image coordinate system and a pixel coordinate system, and the conversion process is as follows:
The left side of the equation is the coordinate to be solved of a point in the world coordinate system corresponding to a point in the pixel coordinate system, wherein Zc is the coordinate offset value of the point in the camera coordinate system in the Z direction; the middle of the equation is a calculation process of a world coordinate system, a camera coordinate system, an image coordinate system and a pixel coordinate system in sequence from right to left, wherein (Xw, yw, zw) is a point in the world coordinate system, R is a rotation matrix rotating around each axis when the world coordinate system is converted into the camera coordinate system, T is an offset vector of each direction of the camera coordinate system in the world coordinate system, f is a Z-direction offset of the point in the camera coordinate system, dx and dy respectively represent physical length unit mm represented by a plurality of rows and columns of pixels, and (u 0, v 0) is an origin offset of an origin of the image coordinate system in the pixel coordinate system; the right side of the equation is the coordinate vector of the point in the combined camera internal parameter, camera external parameter matrix and world coordinate system;
(2) According to a given formula, acquiring the pixel coordinates of the actual track according to the distance corresponding to each pixel in the pixel coordinate system, setting the endpoint coordinates of the actual track in the pixel coordinate system as (x 2, y 2), setting the endpoint coordinates of the preset track as (x 1, y 1), and setting the initial coordinates as (x 0, y 0), wherein the beam bending angle calculation method can calculate the deviation angle through a triangle formula:
α＝arccos[(x2-x0)/(x1-x0)]，
the method for compensating the original track in the second step is to calculate the compensation value of the movement of the laser gun in the x direction and the y direction of the original track according to the deviation angle alpha, and the calculation method of the compensation value is given by the following formula:
Δx＝(x1-x0)/cosα-(x1-x0)
Δy＝-(x1-x0)·tanα。
2. The method for vertical correction of a machine tool according to claim 1, characterized in that: the compensation value is calculated in real time on a periodic basis.
3. The method for vertical correction of a machine tool according to claim 1, characterized in that:
in the third step, the original track Bezier fitting method is to use a least square method to perform Bezier curve fitting on small line segments or discrete points of the position coordinates, obtain a Bezier curve meeting the range of distance errors through recursive calculation,
Assuming Bix and Biy are the x, y coordinates corresponding to the ith point after fitting, and Xi and Yi are the x, y coordinates of the ith point in the source data, and N points are shared, the least square formula applies as follows:
When the minimum value is obtained by the above formula, each parameter value is a coefficient of the Bezier curve, and a third-order Bezier curve is used, wherein the curve can be represented by the following formula:
B3(t)＝(1-t)3P0+3t(1-t)2P1+3t2(1-t)P2+t3P3 t[0,1];
in the formula, P (P0, P1, P2 and P3) is the coordinates of each position, t is a curve generation parameter, and a third-order Bezier curve can be generated by taking values from 0 to 1.
4. A method of vertical correction of a machine tool according to any one of claims 1 to 3, characterized in that: in step five, the servo-performed motion command is periodically controlled.
5. A method of vertical correction of a machine tool according to any one of claims 1 to 3, characterized in that: the preset track in the first step is square.
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