基于CCD传感器的数控车床螺纹自动对刀研究
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摘要
现实中广泛存在着需按工件原有螺纹螺旋线基础上再进行加工工件的数控加工,如石油钻杆接头螺纹的修复加工,丝杠精加工等,由于其需要在原有螺纹沟槽基础上进行加工,工件安装定位时轴向不易定位,同时很难保证主轴零位信号发生位置与原有的螺纹螺旋线起点相一致,因此需要寻求新方法以实现上述零件的数控车床加工。
本文以石油钻杆接头螺纹修复加工为例,针对沿工件原有螺纹沟槽上进行数控车床螺纹加工的对刀问题,提出基于CCD传感器及数字图像处理技术获取工件位置及参数信息的方法,通过运动控制卡实现自动对刀加工。
本课题结合实际情况,选用了符合要求的CCD摄像头、图像采集卡、计算机系统及运动控制卡,与数控车床实现硬件组成。通过采用CCD摄像头和图像采集卡把螺纹类工件图像提取到计算机并在屏幕上显示,然后经过图像处理方法去除图像噪声,进行图像分割、特征图像边缘提取及图像参数信息分析,求解图像轮廓点的相对坐标,测量得到工件几何参数信息。然后根据坐标系之间的逻辑关系,通过调用运动控制卡的控制函数,生成数控加工程序,辅以零位校正系统,实现螺纹加工自动对刀,最终修复损坏螺纹。
通过以上研究,本文中完成了基于CCD传感器的数控车床螺纹加工自动对刀方法。该方法设计中发挥了CCD传感器非接触测量的优点,实现了采用智能寻位加工理论中的“寻位加工”替代传统的“定位加工”,高效率、高精度地完成对受损螺纹的数控车床修复加工,延长了工件使用寿命,同时也为以CCD为视觉传感器的非接触测量方法,针对数控系统中其他类型工件的在线检测加工应用提供了先例。
The numerical control that broad existence is machining again on workpiece according to its original thread helical line basis in reality, like Petroleum boring bar connection thread renovation machining ,screw finish machining etc. As lathing is required to be implemented on original thread groove basis, and it is not easy to assemble the time axis fixing position, at the same time it is very difficult to ensure that chief axis zero position signal happening location point is consistent with original thread helical line Starting point, the numerically controlled lathing needs to explore new method to implement the above-mentioned accessory lathing.
In this paper, take petroleum boring bar connection thread renovation machining as an example, against the emendation problem of processing the CNC lathe along trench on original workpiece thread, submit methods based on CCD sensors and digital image processing technology access to the workpiece location and parameters of information, implement automated processing emendation through Motion control card.
This issue of the actual situation, selected to meet the requirements of the CCD camera, image capture card, computer systems and motion control cards, make up the hardware with CNC lathes. Through the use of CCD camera and image capture card to distill image from the thread workpiece to a computer and show it on the screen, remove image noise with the image processing methods, image segmentation, feature extraction and image parameters information analysis, solving image contours Point the relative coordinates, get workpiece geometry information via measuring. According to coordinate relations between the logic, motion control card by calling the control function, generate NC procedures, combined with zero signal correction system, and automatic processing thread of emendation, to finally repair damaged threads.
Through study above, completed the methods based on the CCD sensor CNC lathes thread on the automatic processing knife methods. This designed methods display the advantages of a CCD sensor non-contact measurement, implement that replace from "searching processing" of intelligent search processing theory to traditional "targeting process", high efficiently, high-precisely completed repair processing of the damaged threads Controlled lathes, and extended the life of the workpiece, also provide a precedent for the visual non-contact measurement method of CCD sensor, against other types of numerical control systems online workpiece detection processing applications.
本文以石油钻杆接头螺纹修复加工为例,针对沿工件原有螺纹沟槽上进行数控车床螺纹加工的对刀问题,提出基于CCD传感器及数字图像处理技术获取工件位置及参数信息的方法,通过运动控制卡实现自动对刀加工。
本课题结合实际情况,选用了符合要求的CCD摄像头、图像采集卡、计算机系统及运动控制卡,与数控车床实现硬件组成。通过采用CCD摄像头和图像采集卡把螺纹类工件图像提取到计算机并在屏幕上显示,然后经过图像处理方法去除图像噪声,进行图像分割、特征图像边缘提取及图像参数信息分析,求解图像轮廓点的相对坐标,测量得到工件几何参数信息。然后根据坐标系之间的逻辑关系,通过调用运动控制卡的控制函数,生成数控加工程序,辅以零位校正系统,实现螺纹加工自动对刀,最终修复损坏螺纹。
通过以上研究,本文中完成了基于CCD传感器的数控车床螺纹加工自动对刀方法。该方法设计中发挥了CCD传感器非接触测量的优点,实现了采用智能寻位加工理论中的“寻位加工”替代传统的“定位加工”,高效率、高精度地完成对受损螺纹的数控车床修复加工,延长了工件使用寿命,同时也为以CCD为视觉传感器的非接触测量方法,针对数控系统中其他类型工件的在线检测加工应用提供了先例。
The numerical control that broad existence is machining again on workpiece according to its original thread helical line basis in reality, like Petroleum boring bar connection thread renovation machining ,screw finish machining etc. As lathing is required to be implemented on original thread groove basis, and it is not easy to assemble the time axis fixing position, at the same time it is very difficult to ensure that chief axis zero position signal happening location point is consistent with original thread helical line Starting point, the numerically controlled lathing needs to explore new method to implement the above-mentioned accessory lathing.
In this paper, take petroleum boring bar connection thread renovation machining as an example, against the emendation problem of processing the CNC lathe along trench on original workpiece thread, submit methods based on CCD sensors and digital image processing technology access to the workpiece location and parameters of information, implement automated processing emendation through Motion control card.
This issue of the actual situation, selected to meet the requirements of the CCD camera, image capture card, computer systems and motion control cards, make up the hardware with CNC lathes. Through the use of CCD camera and image capture card to distill image from the thread workpiece to a computer and show it on the screen, remove image noise with the image processing methods, image segmentation, feature extraction and image parameters information analysis, solving image contours Point the relative coordinates, get workpiece geometry information via measuring. According to coordinate relations between the logic, motion control card by calling the control function, generate NC procedures, combined with zero signal correction system, and automatic processing thread of emendation, to finally repair damaged threads.
Through study above, completed the methods based on the CCD sensor CNC lathes thread on the automatic processing knife methods. This designed methods display the advantages of a CCD sensor non-contact measurement, implement that replace from "searching processing" of intelligent search processing theory to traditional "targeting process", high efficiently, high-precisely completed repair processing of the damaged threads Controlled lathes, and extended the life of the workpiece, also provide a precedent for the visual non-contact measurement method of CCD sensor, against other types of numerical control systems online workpiece detection processing applications.
引文
[1]王庆有.CCD应用技术[M].天津:天津大学出版社,2000,166-188
[2]夏良正.数字图像处理[M].南京:东南大学出版社,2001
[3]陈延标,夏良正.数字图像处理[M].北京:人民邮电出版社,1990
[4]K.R Castleman.数字图像处理[M].北京:清华大学出版社,1996
[5]夏德深,傅得胜.现代图像处理技术[M].南京:东南大学出版社,1997
[6]张占收,李力,袁立强.普通车床增加数控车螺纹功能[J].河北工业科技,1999,1:27-29
[7]徐创文,穆玺清.数控车床螺纹加工方法[J].阀门,2002,3:25-27
[8]黄卉,程顺.用于螺纹加工的车床数控改造[J].机械与自动化,2002,9:13-14
[9]周永鹏,沈安文,万淑芸.螺纹加工伺服的高精度切入控制[J].机械与电子,2002,2:61-62
[10]项占琴.螺纹加工的控制方法[J].机电工程,1996,4:24-25
[11]张剑英.螺纹插补算法的改进[J].兵工自动化,2002,3:34-36
[12]彭晓艳,王虎符,王文格.CNC车床螺纹加工的插补方法[J].机械与电子,1997,2:15-16
[13]毛德柱,周凯,张伯鹏.新型智能寻位数控机床及其应用研究[J].机械工艺师,2001,2:50-51
[14]周凯,毛德柱,廖强.敏捷制造中智能寻位加工技术的研究[J].中国机械工程,1998,8
[15]邱茂林.计算机视觉中摄像机定标综述[J].自动化学报.2000,26(1):43-54
[16]Zhou K,Zhang B P.Fixture-Free Manufacturing.In:Proc.of International Workshop on Automotive Manufacturing Science and Technology[J].Shanghai:Shanghai Scientific and Technological Literature Publishing House,1996:81-85
[17]Wright P.K.Open Architecture Manufacturing:The Impact of Open Computer Systems on Self Sustaining Machinery and the Machine Tool Industry.Proceeding of the Manufacturing International '90-Part2[J],Advance in Manufacturing Systems,Atlanta,GA.Mar.1990:41-47
[18]Nagel R N.21th century manufacturing enterprise strategy[M].Bethehem:Iacocca Institute,Lehigh University,1992,1-4
[19]曹庆.数控车床螺纹加工对刀方法研究[D].甘肃:兰州理工大学,2004,5
[20]章毓晋.图像处理和分析[M].北京:清华大学出版社,1999
[21]李弼程,彭天强,彭波.智能图像处理技术[M].北京:电子工业出版社,2004
[22]于起峰,陆宏伟,刘肖邻.基于图像的精密测量与运动测量[M].北京:科学出版社,2002
[23]刘军,王侃夫,吉顺如.基于开放式控制器PMAC的数控系统[J].上海电机技术高等专科学校学报,2002,2:17-19
[24]Deatl Tua Data system Inc.PMAC2-Lite Hardware Reference Manual.1999
[25]Deatl Tua Data system Inc.Programmable Multi-Axils Controller.1998
[26]白建华,刘恒娟,范剑.基于PMAC运动控制器的开放式数控系统[J].机电工程,2004,4:16-18
[27]王隆太,李吉中,李雪峰.基于PMAC开放式数控系统的开发研究[J].扬州大学学报(自然科学版),2003,5:38-41
[28]杨淑茵.VC++图像处理程序设计[M].北京:清华大学出版社,2003
[29]何斌,马天予.Visual C++数字图像处理(第二版)[M].北京:人民邮电出版社,2002
[30]张宏林.Visual C++数字图像模式识别技术及工程实践[M].北京:人民邮电出版社,2002
[31]荆仁杰,叶秀清,徐胜荣.计算机图像处理[M].杭州:浙江大学出版社,1990,236-302
[32]徐建华.图像处理与分析[M].北京:科学出版社,1992,14-98
[33]Christer O.Kiselman.Regularity properties of distance transformations in image analysis[J].Computer vision and image understanding,1996,64(3):390-396
[34]李红俊,韩冀皖.数字图像处理技术及其应用[J].计算机测量与控制:2002,10(9):620-622
[35]于起峰,陆宏伟,刘肖琳.基于图像的精密测量与运动测量[M].北京:科学技术出版社,2002,2-9
[36]Kenneth,R.Castleman.Digital image Processing[M],PrenticeHall International Inc.1998:6
[37]Zhang Ye,Wang Wensheng,Guo Yangxue.Non-contact and automatic measurement ment of 2D size with CCD matrix and computer system[J].Semiconductor photonics and teehnology.2003(9):3
[38]Masahiro TANAKA,Tohru KATAYAMA.Edge detection and restoration of noisy images by the expectation-maximization algorithm[J].Signal proeessing.1989(17):213-226
[39]向光蓉,张旗,徐发淙.数字图像处理在顶点识别中的应用研究[J].控制工 程,2003,10(1):94-96
[40]Feng,Suency,et al.Edge extraction of image by reconstruction using wavelet decomposition details at different resolution levels[J].International Journal of Pattern Recognition and Artificial Intelligence,2000,14(6):779-793
[41]俞巧云,刑晓正,胡红专.直线拟合方法在一维图像边缘检测中的应用[J].光电工程,2001,28(6):56-58,65
[42]缑西梅,贾晓辉.数字图像处理的边缘检测技术研究[J].中原工学院学报,2007,18(3):64-66
[43]皮明红,李德仁.一种多尺度边缘检测的方法[J].信号处理,2000,16(1):5-8.
[44]薛东辉,朱耀庭,朱光喜.一种综合的有噪图像边缘提取方法[J].数据采集与处理,1995,10(4):330-333.
[45]王展,皇甫堪,万建伟.基于零交叉的二维边缘检测算子的计算近似[J].计算机工程与科学,1999,21(6):40-44.
[46]Jensen K,Anastassiou.Sub pixel edge localization and the interpolation of still images[J].IEEE Trans on PAMI,1995,4(3):285-295
[47]张凯丽,刘辉.边缘检测技术的发展研究[J].昆明理工大学学报,2000,25(5):36-39.
[48]郑成义.计算方法[M].广州:华南理工大学出版社,2003
[49]王永章.机床数字控制技术[M].哈尔滨:哈尔滨工业大学出版社,1995
[50]严爱珍.机床数控原理与系统[M].北京:机械工业出版社,1999
[51]李文斌.数控技术及应用[M].北京:煤炭工业出版社,2000:28-29
[2]夏良正.数字图像处理[M].南京:东南大学出版社,2001
[3]陈延标,夏良正.数字图像处理[M].北京:人民邮电出版社,1990
[4]K.R Castleman.数字图像处理[M].北京:清华大学出版社,1996
[5]夏德深,傅得胜.现代图像处理技术[M].南京:东南大学出版社,1997
[6]张占收,李力,袁立强.普通车床增加数控车螺纹功能[J].河北工业科技,1999,1:27-29
[7]徐创文,穆玺清.数控车床螺纹加工方法[J].阀门,2002,3:25-27
[8]黄卉,程顺.用于螺纹加工的车床数控改造[J].机械与自动化,2002,9:13-14
[9]周永鹏,沈安文,万淑芸.螺纹加工伺服的高精度切入控制[J].机械与电子,2002,2:61-62
[10]项占琴.螺纹加工的控制方法[J].机电工程,1996,4:24-25
[11]张剑英.螺纹插补算法的改进[J].兵工自动化,2002,3:34-36
[12]彭晓艳,王虎符,王文格.CNC车床螺纹加工的插补方法[J].机械与电子,1997,2:15-16
[13]毛德柱,周凯,张伯鹏.新型智能寻位数控机床及其应用研究[J].机械工艺师,2001,2:50-51
[14]周凯,毛德柱,廖强.敏捷制造中智能寻位加工技术的研究[J].中国机械工程,1998,8
[15]邱茂林.计算机视觉中摄像机定标综述[J].自动化学报.2000,26(1):43-54
[16]Zhou K,Zhang B P.Fixture-Free Manufacturing.In:Proc.of International Workshop on Automotive Manufacturing Science and Technology[J].Shanghai:Shanghai Scientific and Technological Literature Publishing House,1996:81-85
[17]Wright P.K.Open Architecture Manufacturing:The Impact of Open Computer Systems on Self Sustaining Machinery and the Machine Tool Industry.Proceeding of the Manufacturing International '90-Part2[J],Advance in Manufacturing Systems,Atlanta,GA.Mar.1990:41-47
[18]Nagel R N.21th century manufacturing enterprise strategy[M].Bethehem:Iacocca Institute,Lehigh University,1992,1-4
[19]曹庆.数控车床螺纹加工对刀方法研究[D].甘肃:兰州理工大学,2004,5
[20]章毓晋.图像处理和分析[M].北京:清华大学出版社,1999
[21]李弼程,彭天强,彭波.智能图像处理技术[M].北京:电子工业出版社,2004
[22]于起峰,陆宏伟,刘肖邻.基于图像的精密测量与运动测量[M].北京:科学出版社,2002
[23]刘军,王侃夫,吉顺如.基于开放式控制器PMAC的数控系统[J].上海电机技术高等专科学校学报,2002,2:17-19
[24]Deatl Tua Data system Inc.PMAC2-Lite Hardware Reference Manual.1999
[25]Deatl Tua Data system Inc.Programmable Multi-Axils Controller.1998
[26]白建华,刘恒娟,范剑.基于PMAC运动控制器的开放式数控系统[J].机电工程,2004,4:16-18
[27]王隆太,李吉中,李雪峰.基于PMAC开放式数控系统的开发研究[J].扬州大学学报(自然科学版),2003,5:38-41
[28]杨淑茵.VC++图像处理程序设计[M].北京:清华大学出版社,2003
[29]何斌,马天予.Visual C++数字图像处理(第二版)[M].北京:人民邮电出版社,2002
[30]张宏林.Visual C++数字图像模式识别技术及工程实践[M].北京:人民邮电出版社,2002
[31]荆仁杰,叶秀清,徐胜荣.计算机图像处理[M].杭州:浙江大学出版社,1990,236-302
[32]徐建华.图像处理与分析[M].北京:科学出版社,1992,14-98
[33]Christer O.Kiselman.Regularity properties of distance transformations in image analysis[J].Computer vision and image understanding,1996,64(3):390-396
[34]李红俊,韩冀皖.数字图像处理技术及其应用[J].计算机测量与控制:2002,10(9):620-622
[35]于起峰,陆宏伟,刘肖琳.基于图像的精密测量与运动测量[M].北京:科学技术出版社,2002,2-9
[36]Kenneth,R.Castleman.Digital image Processing[M],PrenticeHall International Inc.1998:6
[37]Zhang Ye,Wang Wensheng,Guo Yangxue.Non-contact and automatic measurement ment of 2D size with CCD matrix and computer system[J].Semiconductor photonics and teehnology.2003(9):3
[38]Masahiro TANAKA,Tohru KATAYAMA.Edge detection and restoration of noisy images by the expectation-maximization algorithm[J].Signal proeessing.1989(17):213-226
[39]向光蓉,张旗,徐发淙.数字图像处理在顶点识别中的应用研究[J].控制工 程,2003,10(1):94-96
[40]Feng,Suency,et al.Edge extraction of image by reconstruction using wavelet decomposition details at different resolution levels[J].International Journal of Pattern Recognition and Artificial Intelligence,2000,14(6):779-793
[41]俞巧云,刑晓正,胡红专.直线拟合方法在一维图像边缘检测中的应用[J].光电工程,2001,28(6):56-58,65
[42]缑西梅,贾晓辉.数字图像处理的边缘检测技术研究[J].中原工学院学报,2007,18(3):64-66
[43]皮明红,李德仁.一种多尺度边缘检测的方法[J].信号处理,2000,16(1):5-8.
[44]薛东辉,朱耀庭,朱光喜.一种综合的有噪图像边缘提取方法[J].数据采集与处理,1995,10(4):330-333.
[45]王展,皇甫堪,万建伟.基于零交叉的二维边缘检测算子的计算近似[J].计算机工程与科学,1999,21(6):40-44.
[46]Jensen K,Anastassiou.Sub pixel edge localization and the interpolation of still images[J].IEEE Trans on PAMI,1995,4(3):285-295
[47]张凯丽,刘辉.边缘检测技术的发展研究[J].昆明理工大学学报,2000,25(5):36-39.
[48]郑成义.计算方法[M].广州:华南理工大学出版社,2003
[49]王永章.机床数字控制技术[M].哈尔滨:哈尔滨工业大学出版社,1995
[50]严爱珍.机床数控原理与系统[M].北京:机械工业出版社,1999
[51]李文斌.数控技术及应用[M].北京:煤炭工业出版社,2000:28-29