面向再制造的机器人三维视觉检测系统研究
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摘要
为了将集机器人技术与非接触检测等先进技术于一体的机器人三维视觉检测系统有效地应用于再制造领域,构建加工-检测-再制造的闭环制造过程,提高再制造工程的自动化和智能化水平,本文重点研究该系统构建中的关键技术,并将其成功应用于工件快速修复系统与涂层厚度检测系统中。主要研究内容和贡献如下：
1.建立了包括机器人运动学、线结构光视觉传感器和系统检测模型在内的机器人三维视觉检测系统的数学模型。
2.完成了机器人三维视觉检测系统的软硬件结构设计。硬件设计中以包含应用约束的传感器检测误差为优化目标,能够设计出符合现场需求的线结构光传感器。软件设计集中考虑了扩展、兼容以及交互性方面的诸多因素,最终搭建出功能完备的机器人三维视觉检测系统的软件平台。
3.在线结构光传感器的现场标定问题的研究中,基于统一的二维平面标靶,首先通过机器人的已知位置关系的运动,标定出系统的内参数与手眼关系参数,其次通过三点透视原理与双重交比不变法标定出光平面参数。
4.提出一种高效的机器人三维视觉检测系统的并发式工作方式。该方式利用缓冲区技术与多线程控制技术将数据的采集与处理流程解耦,能够独立并发执行检测任务中的各耗时环节。
5.研究海量检测数据与标准数据的内存管理与调度,三维显示方式,及带有破损信息的检测数据与标准数据的配准问题。
6.基于本文研究的机器人三维视觉检测系统,设计并实现工件快速修复系统与涂层厚度检测系统,给出各自的系统标定方法,并将机器人三维视觉检测系统实际应用于再制造工程,满足了再制造工程中对产品的在线检测与现场修复两大需求。
最后在总结全文工作的基础上,给出进一步的工作展望。
For making the remanuaturing system to be more intelligent, the robotic and laser sanning technologies are combined and an integrated robotic remanfacturing system with 3D surface inspection function is presented so that the closed-loop remanufacturing process is implemented. Some key technologies and theory are researched and some application results are given in the thesis. The main works are summarized as follows:
1. The mathematical model of the robotic inspecting system with vision measurement is established, including the main body model of robot, the mathematical models of line structured light vision sensor and the whole system models.
2. The mathematical models of the robotic inspection system are estabilshed, which include dynamic model of the robot body, model of the vision sensor and the model of the integrated system.
3. The framework of hardware and software of the system are constructed and implemented, which is a feature-rich platform with exensible and friendly interface. The measurement error of the line structured light sensor is taken as optimal performance, and the rubust vision sensor is designed based on the consideration for field environment.
4. The field catibration scheme with two steps is presented. First, based on the uniform 2D plane target particular designed and the known position information of the robot, the parameters about the hand-eye relationship are calibrated. Then, the parameters of the laser plane are obtained via the principle of perspective three points and double cross ratio invance.
5. A parallel mode of operation of the system is developed. Each time-consuming phase can be executed independently by decoupling the data collection and process using both the public buffer zone and multi-thread technology.
6. The management, scheduling and 3D showing schemes for massive data are studied. Also, the registration algorithm between the scanned damaged data and the CAD data is presented.
7. The presented robotic 3D inspection system is applied to design a fast repairing system and a coating thickness measurement system, so that the problems of on-line 3D nspection and fast repairing on site are sloved properly.
Finally, future work is listed based on the conclusion of whole work.
1.建立了包括机器人运动学、线结构光视觉传感器和系统检测模型在内的机器人三维视觉检测系统的数学模型。
2.完成了机器人三维视觉检测系统的软硬件结构设计。硬件设计中以包含应用约束的传感器检测误差为优化目标,能够设计出符合现场需求的线结构光传感器。软件设计集中考虑了扩展、兼容以及交互性方面的诸多因素,最终搭建出功能完备的机器人三维视觉检测系统的软件平台。
3.在线结构光传感器的现场标定问题的研究中,基于统一的二维平面标靶,首先通过机器人的已知位置关系的运动,标定出系统的内参数与手眼关系参数,其次通过三点透视原理与双重交比不变法标定出光平面参数。
4.提出一种高效的机器人三维视觉检测系统的并发式工作方式。该方式利用缓冲区技术与多线程控制技术将数据的采集与处理流程解耦,能够独立并发执行检测任务中的各耗时环节。
5.研究海量检测数据与标准数据的内存管理与调度,三维显示方式,及带有破损信息的检测数据与标准数据的配准问题。
6.基于本文研究的机器人三维视觉检测系统,设计并实现工件快速修复系统与涂层厚度检测系统,给出各自的系统标定方法,并将机器人三维视觉检测系统实际应用于再制造工程,满足了再制造工程中对产品的在线检测与现场修复两大需求。
最后在总结全文工作的基础上,给出进一步的工作展望。
For making the remanuaturing system to be more intelligent, the robotic and laser sanning technologies are combined and an integrated robotic remanfacturing system with 3D surface inspection function is presented so that the closed-loop remanufacturing process is implemented. Some key technologies and theory are researched and some application results are given in the thesis. The main works are summarized as follows:
1. The mathematical model of the robotic inspecting system with vision measurement is established, including the main body model of robot, the mathematical models of line structured light vision sensor and the whole system models.
2. The mathematical models of the robotic inspection system are estabilshed, which include dynamic model of the robot body, model of the vision sensor and the model of the integrated system.
3. The framework of hardware and software of the system are constructed and implemented, which is a feature-rich platform with exensible and friendly interface. The measurement error of the line structured light sensor is taken as optimal performance, and the rubust vision sensor is designed based on the consideration for field environment.
4. The field catibration scheme with two steps is presented. First, based on the uniform 2D plane target particular designed and the known position information of the robot, the parameters about the hand-eye relationship are calibrated. Then, the parameters of the laser plane are obtained via the principle of perspective three points and double cross ratio invance.
5. A parallel mode of operation of the system is developed. Each time-consuming phase can be executed independently by decoupling the data collection and process using both the public buffer zone and multi-thread technology.
6. The management, scheduling and 3D showing schemes for massive data are studied. Also, the registration algorithm between the scanned damaged data and the CAD data is presented.
7. The presented robotic 3D inspection system is applied to design a fast repairing system and a coating thickness measurement system, so that the problems of on-line 3D nspection and fast repairing on site are sloved properly.
Finally, future work is listed based on the conclusion of whole work.
引文
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