加工中心在机复合式检测系统的关键技术研究
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摘要
随着先进制造技术的发展,对加工中心工件的在机检测提出了更高的要求。如对于具有复杂型面结构特征的长周期加工件,如何在保证检测精度的同时,提高检测效率。针对当前加工中心在机检测中,单一的传感器在检测精度、检测效率等方面存在的不足和局限,本文提出了一种加工中心在机复合式检测的原创设计方案,并重点对检测系统建立过程中所涉及到的关键技术进行了研究。主要的研究内容和贡献如下：
1.基于逆向工程中的接触式和非接触检测原理,设计了可以集成于加工中心刀库中的复合式检测装置,提出了复合式检测判据。在此基础上,按照检测系统的设计思路阐述了复合式检测系统的工作原理。
2.建立了系统相关的数学模型,包括基于线结构光视觉的非接触检测模型、考虑测量延时的接触式检测模型,以及使复合式检测数据融合统一的数学模型。
3.对于系统中加工中心的定位误差,通过建立误差数据库,提出了基于程序G代码修正的误差补偿方案。对系统数学模型中所涉及的参数求解进行了标定：采用同心圆平面靶标,对摄像机内参数、光平面参数进行了标定；使用标准球实现了等效补偿半径的标定；对于摄像机外参数,提出了基于单个同心圆和标准球的间接标定方法,实现了复合式检测数据在检测坐标系下的统一。
4.为保证接触式测头在自动测量时的安全性和检测的准确性,提出了基于工件加工特征的复合式检测规划方案。对工件非接触检测获得的点云数据进行误差补偿后,通过对点云数据进行特征提取、特征拟合构建出加工几何特征,从而基于该几何特征进行接触式检测路径规划,并通过检测实验验证了该方案的可行性。
5.对检测系统的软件设计进行了介绍,通过检测实例给出了当前系统的检测精度,对影响检测精度的误差因素进行了分析,定性地提出了减小误差的方法。
最后在总结全文研究工作的基础上,对检测系统的深入研究提出了工作展望。
With the development of advanced manufacturing technology, the requirement for the on-machine inspecting function of machining center is becoming more and more high, which is how to ensure the inspecting accuracy and improve the inspecting efficiency for the long-period processed workpiece with complex features. In order to avoid deficiencies and limitations existed in the current on-machine inspecting mode with the single sensor, an on-machine composite inspecting method is presented, and some key technologies are researched in the composite inspecting system developed. Main contributions are summarized as follows:
1. Based on the principle of non-contact and contact inspection applied in reverse engineering, a composite inspecting equipment is designed, which can be integrated in tool magazine of machining center. And, the composite inspecting criterion is introduced. Furthermore, according to the design ideas, the work principle of composite inspecting system is given.
2. Mathematical models of inspecting system are established, including the non-contact inspecting model of line structured light vision sensor, contact inspecting model with the inspecting delay, and the mathematical model for the fusion of composite inspecting data.
3. Based on the established error database, the G codes modification sheme is proposed so that the positioning error of machining center is compensated effectively. And, the calibration work for parameters related to mathematical models of inspecting system is finished, including calibrations for intrinsic parameters of camera and parameters of light plane by designed plane target with concentric circles, equivalent radius of inspecting sphere calibrated by standard ball, and the calibration for extrinsic parameters of camera indirectly by single concentric circle and standard ball, which bring the fusion of composite inspecting data into effect.
4. To guarantee the safety and accuracy of contact inspection in the process of automatic inspection, the composite inspecting planning is proposed based on machining features of workpiece. Firstly, the error compensation work is realized for the point cloud data from non-contact inspection for workpiece. Then, geometric features corresponding to machining items are reconstructed by feature extraction and fitting from the point cloud data compensated. Lastly, the contact inspecting path is planned based on geometric features. And, the feasibility of the plan proposed is verified by composite inspecting experiment.
5. The software design of inspecting system is introduced, and the inspecting accuracy of composite inspecting system is presented by the inspecting example, beside that, sources of inspecting error are analyzed and the method of decreasing inspecting error is qualitatively proposed.
Finally, further research contents for inspecting system are listed based on the conclusion of the whole work.
1.基于逆向工程中的接触式和非接触检测原理,设计了可以集成于加工中心刀库中的复合式检测装置,提出了复合式检测判据。在此基础上,按照检测系统的设计思路阐述了复合式检测系统的工作原理。
2.建立了系统相关的数学模型,包括基于线结构光视觉的非接触检测模型、考虑测量延时的接触式检测模型,以及使复合式检测数据融合统一的数学模型。
3.对于系统中加工中心的定位误差,通过建立误差数据库,提出了基于程序G代码修正的误差补偿方案。对系统数学模型中所涉及的参数求解进行了标定：采用同心圆平面靶标,对摄像机内参数、光平面参数进行了标定；使用标准球实现了等效补偿半径的标定；对于摄像机外参数,提出了基于单个同心圆和标准球的间接标定方法,实现了复合式检测数据在检测坐标系下的统一。
4.为保证接触式测头在自动测量时的安全性和检测的准确性,提出了基于工件加工特征的复合式检测规划方案。对工件非接触检测获得的点云数据进行误差补偿后,通过对点云数据进行特征提取、特征拟合构建出加工几何特征,从而基于该几何特征进行接触式检测路径规划,并通过检测实验验证了该方案的可行性。
5.对检测系统的软件设计进行了介绍,通过检测实例给出了当前系统的检测精度,对影响检测精度的误差因素进行了分析,定性地提出了减小误差的方法。
最后在总结全文研究工作的基础上,对检测系统的深入研究提出了工作展望。
With the development of advanced manufacturing technology, the requirement for the on-machine inspecting function of machining center is becoming more and more high, which is how to ensure the inspecting accuracy and improve the inspecting efficiency for the long-period processed workpiece with complex features. In order to avoid deficiencies and limitations existed in the current on-machine inspecting mode with the single sensor, an on-machine composite inspecting method is presented, and some key technologies are researched in the composite inspecting system developed. Main contributions are summarized as follows:
1. Based on the principle of non-contact and contact inspection applied in reverse engineering, a composite inspecting equipment is designed, which can be integrated in tool magazine of machining center. And, the composite inspecting criterion is introduced. Furthermore, according to the design ideas, the work principle of composite inspecting system is given.
2. Mathematical models of inspecting system are established, including the non-contact inspecting model of line structured light vision sensor, contact inspecting model with the inspecting delay, and the mathematical model for the fusion of composite inspecting data.
3. Based on the established error database, the G codes modification sheme is proposed so that the positioning error of machining center is compensated effectively. And, the calibration work for parameters related to mathematical models of inspecting system is finished, including calibrations for intrinsic parameters of camera and parameters of light plane by designed plane target with concentric circles, equivalent radius of inspecting sphere calibrated by standard ball, and the calibration for extrinsic parameters of camera indirectly by single concentric circle and standard ball, which bring the fusion of composite inspecting data into effect.
4. To guarantee the safety and accuracy of contact inspection in the process of automatic inspection, the composite inspecting planning is proposed based on machining features of workpiece. Firstly, the error compensation work is realized for the point cloud data from non-contact inspection for workpiece. Then, geometric features corresponding to machining items are reconstructed by feature extraction and fitting from the point cloud data compensated. Lastly, the contact inspecting path is planned based on geometric features. And, the feasibility of the plan proposed is verified by composite inspecting experiment.
5. The software design of inspecting system is introduced, and the inspecting accuracy of composite inspecting system is presented by the inspecting example, beside that, sources of inspecting error are analyzed and the method of decreasing inspecting error is qualitatively proposed.
Finally, further research contents for inspecting system are listed based on the conclusion of the whole work.
引文
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