3D义齿磨削机器人系统研究
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摘要
随着计算机及逆向工程的广泛应用,CAD/CAM技术被引入口腔修复领域,陶瓷义齿制作变为现实,义齿制作的质量、效率大大提高,使得传统的牙齿修复技术产生质的飞跃。义齿修复体磨削机器人系统是口腔CAD/CAM系统的重要组成部分,论文以义齿修复体磨削成型技术为研究对象,系统研究了3D义齿磨削机器人系统平台的设计、3D数据处理及建模、刀具轨迹规划及插补算法等相关理论、方法及关键技术。
在系统分析牙齿曲面加工工艺方案的基础上,设计了3D义齿磨削机器人本体及其控制系统。根据牙齿修复体的曲面形状特点,及快速磨削成型的需要,设计了基于双磨针并行摆动磨削的机器人机构,系统可实现5-DOF运动,金刚石磨针可对包括陶瓷材料在内的多种材质的义齿修复体成型磨削。设计了计算机加运动控制卡的开放式控制系统,并根据机器人学理论对系统进行了运动学建模,确定了系统工作空间及各关节运动参数。
针对义齿修复体3D模型扫描数据中的脉冲噪声问题,采用相邻点方向角判别法确定了脉冲噪声点,并利用样条插值法进行了消除。由于一次扫描数据的不完整性,采用二次扫描方法,并根据ICP算法进行拼接处理。针对传统ICP算法点到点配准存在的建模精度问题,提出了点集与线段集最小距离迭代的改进ICP配准算法,实现了两次测量的点云数据的配准,并对叠加点数据进行了裁减和拼接处理。对处理后的点云数据进行了三角网格划分,建立了牙齿曲面三角片形式的多面体模型,完成了直接驱动磨削加工的STL格式3D数据转换及存储。
根据磨削机器人系统的机构特点及牙齿曲面形状特点,给出了双磨针并行磨削无干涉刀具路径规划方法,使两个磨针加工时速度不相互影响,磨削路径不产生干涉。研究了多面体模型的数据存储及快速搜索方法,将四叉树理论引入刀具轨迹计算过程,提出了满格PR四叉树划分法,提高了STL格式义齿多面体模型刀位点(CLP)计算时刀具投影区三角片的搜索效率,加快了刀具轨迹生成速度。在此基础上分别研究了锥形磨针、平底磨针和球形磨针三种磨削刀具进行牙齿曲面磨削时的刀具轨迹生成算法。论文还对点云数据直接驱动磨削加工的刀具轨迹生成算法进行了研究。
论文研究了牙齿曲面磨削时的刀具轨迹插补算法,根据义齿磨削机器人系统的机构特点,进行了变形Zigzag刀具路径规划,提出了展平-弯曲B样条曲线插补算法,算法保证了刀具运动轨迹位于圆弧驱动面上,实现了径向进给速度的自适应控制,既保证了插补精度,又避免了磨削振动。
最后选择四种典型牙齿(磨齿、切齿、臼齿和门齿)形状,进行了牙齿曲面磨削实验。通过扫描得到的点云数据,按照论文研究的相关技术,生成了CAD模型,并利用所设计的义齿磨削机器人,进行了牙齿曲面磨削加工实验,得到了磨削后的牙齿曲面模型,验证了系统设计的正确性和算法的可行性。
With the widespread of computers and reversing engineering technology, CAD/CAM is implemented into stomatology restoration, and the manufacture of ceramic false teeth becomes feasible. The improvement of manufacture quality and efficiency changed the traditional stomatology restoration dramatically. The robot system for grinding the artifacial teeth prosthesis is the important part of the whole stomatology CAD/CAM system. The form-grinding technology of dental restoration is systematically studied in this thesis such as the design of dental restoration grinding robot system, the modeling and processing approaches for 3D data, the motion generation and interpolation methods, etc.
By analyzing the manufacture process of teeth surface, the mechanical and controlling system of the 3D dental restoration grinding robot is designed. According to the geometric characteristics of the restoration, and the requirements of manufacture speed, a parallel structure with two grinding needles is adopted, which can realize 5-axis synchronism movement. The diamond needles can manufacture most kinds of materials including ceramic and porcelain. The flexible control system with PC and motion control card is developed. The kinematics model is built and corresponding working space and kinematic parameters are determined.
Aiming at the pulse noise problem of scanned data of the 3D model for teeth restoration, the criterion of adjacent angle is introduced to indentify the pulse noise point and spline interpolation method is used to eliminate noise. Double-scanning is applied for the imperfection of the scanned data and ICP approach is used for data joint. Since there is precision problem in point to point registration by using the traditional ICP approach, a recurrent registration method based on the minimum distance between point sets and segment sets is proposed. The discrete point cloud data got by scanning will be registered and accurately spliced, partitioned by triangular grid, and then the polyhedral model in form of the triangular patches is built. The 3D data in STL format for direct grinding driving are transferred and stored.
For the specific characteristic of the teeth surface, a motion generation method without confliction for parallel grinding of twin-burs is proposed. The velocities of the two burs are not interfered with each other and not kinematic conflicts exit in the grinding path. The fast searching and storing technologies of the polyhedral model data is studied. The Quard-tree method is implemented in the calculation of tool trajectory, a full-grid PR Quard-tree partition method is proposed. For restoration model of STL format, the searching efficiency of triangular cutter projected area facet in CLP calculation is improved, therefore the tool trajectory generation is speed up. With this method, the tool motion trajectory generation algorithms of the grinding tool are studied for flatted-bur, ball-bur and taper-bur, respectively. The tool trajectory generation method directly based on the point cloud data is also investigated.
The interpolation method of the tool trajectory is investigated. According to the mechanism characteristics of the robot system, the Zigzag tool-path is modified, a stretch-bending B-spline interpolation method is proposed which restricted tool trajectory inside the arc drive surface, and the radial feeding velocity is adapted. The interpolation precision is guaranteed meanwhile reduced the grinding vibration.
Finally grinding experiments are performed for kinds of typical teeth surfaces such as canine、incisor、cheek tooth and fore tooth. Based on the point cloud data obtained by scanning, the CAD model is generated with the methods mentioned above. And the dental restoration model is grinded using the designed robot system the whole system the corresponding algorithms are validated correct and feasible
在系统分析牙齿曲面加工工艺方案的基础上,设计了3D义齿磨削机器人本体及其控制系统。根据牙齿修复体的曲面形状特点,及快速磨削成型的需要,设计了基于双磨针并行摆动磨削的机器人机构,系统可实现5-DOF运动,金刚石磨针可对包括陶瓷材料在内的多种材质的义齿修复体成型磨削。设计了计算机加运动控制卡的开放式控制系统,并根据机器人学理论对系统进行了运动学建模,确定了系统工作空间及各关节运动参数。
针对义齿修复体3D模型扫描数据中的脉冲噪声问题,采用相邻点方向角判别法确定了脉冲噪声点,并利用样条插值法进行了消除。由于一次扫描数据的不完整性,采用二次扫描方法,并根据ICP算法进行拼接处理。针对传统ICP算法点到点配准存在的建模精度问题,提出了点集与线段集最小距离迭代的改进ICP配准算法,实现了两次测量的点云数据的配准,并对叠加点数据进行了裁减和拼接处理。对处理后的点云数据进行了三角网格划分,建立了牙齿曲面三角片形式的多面体模型,完成了直接驱动磨削加工的STL格式3D数据转换及存储。
根据磨削机器人系统的机构特点及牙齿曲面形状特点,给出了双磨针并行磨削无干涉刀具路径规划方法,使两个磨针加工时速度不相互影响,磨削路径不产生干涉。研究了多面体模型的数据存储及快速搜索方法,将四叉树理论引入刀具轨迹计算过程,提出了满格PR四叉树划分法,提高了STL格式义齿多面体模型刀位点(CLP)计算时刀具投影区三角片的搜索效率,加快了刀具轨迹生成速度。在此基础上分别研究了锥形磨针、平底磨针和球形磨针三种磨削刀具进行牙齿曲面磨削时的刀具轨迹生成算法。论文还对点云数据直接驱动磨削加工的刀具轨迹生成算法进行了研究。
论文研究了牙齿曲面磨削时的刀具轨迹插补算法,根据义齿磨削机器人系统的机构特点,进行了变形Zigzag刀具路径规划,提出了展平-弯曲B样条曲线插补算法,算法保证了刀具运动轨迹位于圆弧驱动面上,实现了径向进给速度的自适应控制,既保证了插补精度,又避免了磨削振动。
最后选择四种典型牙齿(磨齿、切齿、臼齿和门齿)形状,进行了牙齿曲面磨削实验。通过扫描得到的点云数据,按照论文研究的相关技术,生成了CAD模型,并利用所设计的义齿磨削机器人,进行了牙齿曲面磨削加工实验,得到了磨削后的牙齿曲面模型,验证了系统设计的正确性和算法的可行性。
With the widespread of computers and reversing engineering technology, CAD/CAM is implemented into stomatology restoration, and the manufacture of ceramic false teeth becomes feasible. The improvement of manufacture quality and efficiency changed the traditional stomatology restoration dramatically. The robot system for grinding the artifacial teeth prosthesis is the important part of the whole stomatology CAD/CAM system. The form-grinding technology of dental restoration is systematically studied in this thesis such as the design of dental restoration grinding robot system, the modeling and processing approaches for 3D data, the motion generation and interpolation methods, etc.
By analyzing the manufacture process of teeth surface, the mechanical and controlling system of the 3D dental restoration grinding robot is designed. According to the geometric characteristics of the restoration, and the requirements of manufacture speed, a parallel structure with two grinding needles is adopted, which can realize 5-axis synchronism movement. The diamond needles can manufacture most kinds of materials including ceramic and porcelain. The flexible control system with PC and motion control card is developed. The kinematics model is built and corresponding working space and kinematic parameters are determined.
Aiming at the pulse noise problem of scanned data of the 3D model for teeth restoration, the criterion of adjacent angle is introduced to indentify the pulse noise point and spline interpolation method is used to eliminate noise. Double-scanning is applied for the imperfection of the scanned data and ICP approach is used for data joint. Since there is precision problem in point to point registration by using the traditional ICP approach, a recurrent registration method based on the minimum distance between point sets and segment sets is proposed. The discrete point cloud data got by scanning will be registered and accurately spliced, partitioned by triangular grid, and then the polyhedral model in form of the triangular patches is built. The 3D data in STL format for direct grinding driving are transferred and stored.
For the specific characteristic of the teeth surface, a motion generation method without confliction for parallel grinding of twin-burs is proposed. The velocities of the two burs are not interfered with each other and not kinematic conflicts exit in the grinding path. The fast searching and storing technologies of the polyhedral model data is studied. The Quard-tree method is implemented in the calculation of tool trajectory, a full-grid PR Quard-tree partition method is proposed. For restoration model of STL format, the searching efficiency of triangular cutter projected area facet in CLP calculation is improved, therefore the tool trajectory generation is speed up. With this method, the tool motion trajectory generation algorithms of the grinding tool are studied for flatted-bur, ball-bur and taper-bur, respectively. The tool trajectory generation method directly based on the point cloud data is also investigated.
The interpolation method of the tool trajectory is investigated. According to the mechanism characteristics of the robot system, the Zigzag tool-path is modified, a stretch-bending B-spline interpolation method is proposed which restricted tool trajectory inside the arc drive surface, and the radial feeding velocity is adapted. The interpolation precision is guaranteed meanwhile reduced the grinding vibration.
Finally grinding experiments are performed for kinds of typical teeth surfaces such as canine、incisor、cheek tooth and fore tooth. Based on the point cloud data obtained by scanning, the CAD model is generated with the methods mentioned above. And the dental restoration model is grinded using the designed robot system the whole system the corresponding algorithms are validated correct and feasible
引文
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