CN108170095B - Machining method of full closed-loop system of numerical control machine tool based on vision - Google Patents
Machining method of full closed-loop system of numerical control machine tool based on vision Download PDFInfo
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- CN108170095B CN108170095B CN201711407180.5A CN201711407180A CN108170095B CN 108170095 B CN108170095 B CN 108170095B CN 201711407180 A CN201711407180 A CN 201711407180A CN 108170095 B CN108170095 B CN 108170095B
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- 238000003754 machining Methods 0.000 title claims abstract description 57
- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000012545 processing Methods 0.000 claims abstract description 80
- 230000009471 action Effects 0.000 claims abstract description 27
- 230000000694 effects Effects 0.000 claims abstract description 23
- 238000004458 analytical method Methods 0.000 claims abstract description 16
- 230000008569 process Effects 0.000 claims abstract description 10
- 230000007547 defect Effects 0.000 claims abstract description 5
- 230000003631 expected effect Effects 0.000 claims description 7
- 238000005259 measurement Methods 0.000 claims description 5
- 238000012937 correction Methods 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 description 10
- 238000003384 imaging method Methods 0.000 description 6
- 239000002699 waste material Substances 0.000 description 6
- 230000003287 optical effect Effects 0.000 description 5
- 230000008859 change Effects 0.000 description 4
- 238000005096 rolling process Methods 0.000 description 4
- 238000012876 topography Methods 0.000 description 4
- 239000002173 cutting fluid Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45136—Turning, lathe
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45226—Process control
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Abstract
The invention provides a vision-based full closed-loop system of a numerical control machine tool, which comprises a semi-closed-loop control workbench, a measuring unit, an analysis and calculation unit, a tool holder for processing and a tool; the measuring unit is in a flange disc shape and is additionally arranged beside the tool holder and on the tool shank, and the analysis and calculation unit and the original semi-closed loop control workbench form a full closed loop system together. The analysis and calculation unit calculates the appearance of the surface of the workpiece according to the triangle rule according to the position and the shape of the laser line acquired by the camera; the machining method of the full closed-loop system of the numerical control machine tool based on vision is also introduced, and the completion of one-time machining comprises four steps of scanning a workbench, clamping and modeling, scanning gross defects and modeling, machining and finishing. The invention can measure the processing action effect of the cutter after each movement in real time, rebuilds the appearance in the processing process, brings the processed surface quality such as roughness into a fully closed-loop control system, and can improve the processing precision by times.
Description
Technical Field
The invention relates to the technical field of numerical control machine tool control, in particular to a machining method of a full closed-loop system of a numerical control machine tool based on vision.
Background
The numerical control machine tool is divided into three control modes of open loop, semi-closed loop and closed loop. The open-loop numerical control machine tool has no feedback and low precision; the semi-closed loop numerical control machine tool uses a pulse encoder on a motor as a feedback element, can control the rotating speed of the motor and has higher precision; the closed-loop numerical control machine tool uses the grating ruler as a position feedback element, and the precision is highest.
The cutter for the numerical control machine tool cuts down the material on the blank to be consistent with the design target, but no matter the semi-closed loop and the closed loop, the cutting result of the cutter on the blank is not controlled, and the cutting process is not included in the controlled closed loop. If the cutting process is also incorporated into a closed control loop, the machining accuracy can be improved by controlling the machining result of each step in the machining process.
Thus, significant advances in the art are needed.
Disclosure of Invention
The technical problem to be solved by the present invention is to provide a full closed-loop system for measuring the three-dimensional topography of a workpiece in real time based on vision, which includes a semi-closed-loop controlled workbench, a measuring unit forming a full closed loop, an analyzing and calculating unit, a tool holder and a tool for processing, and specifically includes the following:
the measuring unit is in a flange disc shape, a rolling bearing is additionally arranged beside the tool holder and on the tool holder, the measuring unit does not rotate along with the tool but moves along with the tool, a plurality of pairs of laser transmitters and cameras are radially and equidistantly arranged on the measuring unit, the cameras are positioned on a large outer ring, the laser transmitters are positioned on a small inner ring, the linear distance between the laser transmitters and the cameras is approximately equal to the distance between the measuring unit and the most common working position of a workpiece, the distance between the laser transmitters and the cameras, the laser curve projected by the laser transmitters on the surface of the workpiece, the distance between the cameras and the laser curve and the length of three sides are approximately equal to form a closed triangle;
the laser emitter vertically downwards emits linear laser which presents different shapes along with the fluctuation of the surface of the part, and the optical axis of the camera deflects towards the direction of a laser line; the optical axis of the camera is not vertically downwards arranged in the vertical direction, but has a deflection angle towards the cutter, the optical axis of the camera deflects towards the cutter, the deflection angle enables the laser line emitted by the laser to pass through the center of an image formed by the camera at the most common working position of the workpiece, the image of the laser line at the uppermost working position of the workpiece is formed, the image of the laser line at the lowermost working position is formed at the lowermost working position of the workpiece, the image of the laser line is within the edge zone of the image of the camera, and the visual field ranges of the two cameras are overlapped; the laser transmitters and the cameras are arranged at intervals, and one measuring unit is provided with at least three pairs of laser transmitters and cameras so as to form a closed laser line shape on the surface of a workpiece; the three sides of the laser emitted by the laser emitter, the linear distance between the laser emitter and the camera and the distance from the laser line to the camera form a closed triangle, and each point where the cutter passes through is measured by the camera at the front and the back at least twice;
the analysis and calculation unit and an original semi-closed loop control workbench form a full closed loop system, and the analysis and calculation unit calculates the appearance of the surface of the workpiece according to the triangle rule and the position and the shape of a laser line acquired by shooting; the shape and position of the laser projected on the surface of the workpiece in the camera can be changed due to the change of the surface shape of the workpiece, the laser straight line can be changed into a laser curve, the surface of the workpiece is changed from the surface of the workpiece before the processing action to the surface of the workpiece after the processing action, the imaging position of the laser can be changed from the imaging of the laser line on the surface of the workpiece after the processing action to the distance between the laser emitter and the camera, the distance between the laser emitter and the camera is equal to the distance between the measuring unit and the most normal working position of the workpiece, the laser emitter and the camera form a closed shape, each point passed by the cutter can be measured at least twice, each processing action of the cutter in the closed loop system can obtain a corresponding processing effect and deviation from an expected effect, a corresponding relation between a processing parameter and the processing effect can be established, and the three-dimensional shapes of the cutter before and after the processing can be reconstructed.
Preferably, the tool is implemented to move in each direction and at least one camera is able to observe the laser line, reconstructing the surface topography of the workpiece.
Preferably, the distance between the workpiece and the measuring unit, whether the workpiece is at the maximum distance position or at the minimum distance position, the fields of view of the adjacent cameras overlap, and the working position where the fields of view of the adjacent cameras do not overlap is an illegal working position.
A machining method of a full closed-loop system of a numerical control machine tool based on vision comprises four steps of scanning a workbench, clamping and modeling, scanning gross damage and modeling, machining and finishing machining, and comprises the following steps:
s1, scanning a workbench, a clamp and modeling
And scanning the workbench and the clamp by using the measuring unit to establish a three-dimensional model of the workbench and the clamp. Inputting machine tool parameters such as the limit position of a workbench, the limit speed of the machine tool, deformation parameters of the machine tool and the cutter condition of the machine tool;
s2, scanning gross defects and modeling
The three-dimensional model and the surface requirement of a processing target are input before processing like scanning a workbench and a clamp and modeling, and then the measuring unit is used for scanning the blank to establish the three-dimensional model of the blank.
S3, processing and dynamically adjusting the track of the prop
Aligning the blank with the processing target, calculating the difference between the three-dimensional model of the processing target and the three-dimensional model of the blank, and automatically generating a processing action sequence according to parameters of maximum stepping, minimum stepping, machine tool shaking and the like of a machine tool;
the analyzing and calculating unit drives the machine tool to start machining according to a machining operation sequence generated in advance. In the processing process, when the cutter moves one step each time, the camera images a closed laser line around the measuring cutter, the analyzing and calculating unit positions the processed cutter track, the surface appearance of a workpiece is rebuilt, the processing effect is fed back, the deviation from the expected effect is calculated, the corresponding relation between the processing parameter and the processing effect is established and corrected, and meanwhile, the pre-generated processing action sequence is corrected according to the processing effect:
step S31: the analysis and calculation unit drives the machine tool to start machining according to a machining action sequence generated in advance;
step S32: in the processing process, when the cutter moves for one step, the camera images a closed laser line around the measuring cutter;
step S33: analyzing and calculating the tool path positioned and processed by the unit, and reconstructing the surface appearance of the workpiece;
step S34: feeding back the processing effect, calculating the deviation from the expected effect, and establishing and correcting the corresponding relation between the processing parameters and the processing effect;
step S35: a correction machining operation sequence is formed based on the machining effect in step S34, and machining is continued.
S4, finishing the processing
And when the machining is finished, outputting parameters such as the size and the surface requirement of the machined workpiece according to the measurement result.
Preferably, the distance between the laser transmitter and the camera is approximately equal to the distance between the measuring unit and the surface of the workpiece;
preferably, the distance between the workpiece and the measuring unit is such that no matter the workpiece is at the maximum distance position or at the minimum distance position, the fields of view of adjacent cameras are overlapped, and the working position where the fields of view of adjacent cameras are not overlapped is an illegal position;
preferably, the focal length of the laser transmitter is adjusted to the distance from the measuring unit to the surface of the workpiece;
preferably, all lights on the processing machine are turned off to highlight the brightness of the laser on the workpiece surface.
Preferably, the cutting fluid on the machine tool is shut down to improve the accuracy of the camera acquisition.
Preferably, adopt little stride processing to avoid rolling up the cutting waste material, improve the degree of accuracy that the camera gathered the laser line.
Preferably, the analysis and calculation unit may identify the rolled-up cutting waste based on the rolled-up cutting waste being higher than the pre-machining workpiece.
The invention has the advantages that: the processing action effect of the cutter after each movement can be measured in real time, the appearance in the processing process is reconstructed, the processed surface quality such as roughness and the like is also brought into a fully closed-loop control system, and the processing precision can be improved exponentially; because each action is fed back, parameters such as machine tool shaking and the like and dynamic characteristics can be accurately identified, compensation can be automatically completed, and the machining quality of the machine tool is improved under the condition that the machine tool is not changed; because the three-dimensional model of the processing target is input, the gross defects are also scanned, the processing action sequence can be automatically planned in the analysis and calculation unit, the error of the previous processing action can be automatically compensated in the processing process, and the processing can be automatically stopped after the required quality is achieved, so that the processing task can be finished with higher automation degree.
Drawings
Fig. 1 is a schematic structural diagram of a fully closed-loop system of a vision-based numerically-controlled machine tool according to the present invention.
Fig. 2 is a schematic view of a measuring unit of the vision-based full closed loop system of the numerically controlled machine tool according to the present invention.
FIG. 3 is a schematic view of the measurement during the machining process of the vision-based full closed-loop system of the numerically controlled machine tool.
FIG. 4 is a schematic diagram showing the positional relationship among a laser, a camera and a tool in the process of machining the full closed-loop system of the vision-based numerically-controlled machine tool.
FIG. 5 is a flow chart of a calculation process of a full closed-loop system of a vision-based numerically-controlled machine tool.
In the figure:
1. tool holder
2. Cutting tool
3. Laser transmitter
4. Measuring unit
5. Camera head
6. Linear distance between laser emitter and camera
7. Overlapping fields of view of adjacent cameras
8. Visual field range of camera
9. Vertical downward looking laser line (laser emitter viewing angle)
10. Laser line seen by camera (oblique observation angle)
11. Uppermost working position of workpiece
12. Imaging of laser lines in the uppermost operating position
13. Lowest working position of workpiece
14. Imaging of laser lines at the lowermost working position
15. Imaging of laser lines on workpiece surfaces prior to machining action
16. Surface of workpiece before machining action
17. Surface of work after machining action
18. Imaging of laser lines on workpiece surfaces after machining actions
19. Most frequent working position of workpiece
20. Vertical downward laser line
21. Workpiece
22. Deflection angle
Detailed Description
Aiming at a numerical control milling machine, the invention is implemented as follows:
as shown in figures 1-5, a full closed-loop system of a numerical control machine tool based on vision is based on the basic idea of measuring the three-dimensional appearance of a part in real time in the machining process so as to improve the machining precision, and specifically comprises a semi-closed-loop control workbench, a measuring unit forming a full closed loop, an analysis and calculation unit, a tool holder and a tool bit for machining,
the measuring unit 4 is in a flange disc shape as shown in the attached drawing 2, a rolling bearing is additionally arranged beside the tool holder 1 and on the tool holder and does not rotate along with the tool 2, but moves along with the tool 2, the measuring unit 4 is provided with a plurality of pairs of laser transmitters 3 and cameras 5 at equal intervals in the radial direction, the cameras 5 are positioned on a large outer ring, the laser transmitters 3 are positioned on a small inner ring, in order to improve the measuring accuracy, the linear distance 6 between each laser transmitter and each camera is approximately equal to the distance between the measuring unit 4 and the most common working position 19 of the workpiece, the linear distance 6 between each laser transmitter and each camera, the laser curve projected by the laser transmitters 3 on the surface of the workpiece 21, the distances between each camera and the laser curve, and the length of three sides are approximately equal, and a closed triangle is formed;
the laser emitter 3 vertically emits linear laser downwards, the linear laser can be in different shapes along with the fluctuation of the surface of a part, the observed laser curve 10 on a curved surface is realized, the plurality of cameras 5 are installed on the installation surface of the measuring unit 4 in a radiation mode towards the circle center, and the optical axis of each camera deflects towards the direction of a laser line; the optical axis of the camera 5 is not vertically installed downwards in the vertical direction, but has a deflection angle 22 towards the tool 2, and the deflection angle 22 satisfies the following conditions: on the most common working position 19 of the workpiece, a laser line 9 emitted by a laser passes through the center of an image formed by the camera, an image 12 of the laser line at the uppermost working position is formed at the uppermost working position 11 of the workpiece, an image 14 of the laser line at the lowermost working position is formed at the lowermost working position 13 of the workpiece, the laser line emitted by the laser emitter 3 is within the edge zone of the image formed by the camera 5, and the vision ranges 8 of two adjacent cameras are partially overlapped, namely the overlapped vision ranges 7 of the two adjacent cameras, so that each laser line can be completely collected; the laser emitters 3 and the cameras 5 are arranged alternately one by one, one measuring unit 4 at least comprises three pairs of laser emitters 3 and cameras 4 so as to form closed laser lines on the surface of the workpiece, and at least one camera 5 can observe the laser lines no matter which direction the cutter 2 moves, so that the surface appearance of the workpiece can be reconstructed; a vertical downward laser line 20 emitted by the laser emitter 3, a linear distance 6 between the laser emitter and the camera, and a distance from a laser line (an oblique observation angle) 10 seen by the camera to the camera 5 form a closed triangle, and the cutter is measured by the cameras at the front and the back at least twice through each point of the workpiece;
due to the change of the surface topography of the workpiece, the shape and position of the image of the laser projected on the surface of the workpiece in the camera 5 will change, for example, the straight line of the laser in the vertical direction in fig. 3, that is, the laser line (the observation angle of the laser emitter) 9 seen vertically downwards becomes a laser curve in the camera viewing angle, that is, the laser line (the oblique observation angle) 10 seen by the camera, whereas in fig. 4, the surface of the workpiece changes from the surface 16 of the workpiece before the processing action to the surface 17 of the workpiece after the processing action, and the image position of the laser will change from the image 15 of the laser line on the surface of the workpiece before the processing action to the image 19 of the laser line on the surface of the workpiece after the processing action.
The analysis and calculation unit and an original semi-closed loop control workbench form a full closed loop system as shown in fig. 1, and the analysis and calculation unit calculates the topography of the surface of the workpiece according to the triangle rule according to the position and the shape of the laser line acquired by the camera 5. In order to improve the accuracy of the measurement, the distance 6 between the laser transmitter and the camera is approximately equal to the distance from the measuring unit 4 to the most frequent working position 19 of the workpiece. Because the linear distance 6 between the laser emitter and the camera, the laser curve projected on the surface of the workpiece 21 by the laser emitter 3, the distance between the camera and the laser curve, and the length of three sides are approximately equal to form a closed triangle, each point passed by the cutter 2 is measured at least twice, so that each processing action (which can be understood as a line of G codes) of the cutter 2 in the full closed-loop system can obtain a corresponding processing effect and a deviation from an expected effect, and can establish a corresponding relation among machine tool parameters, processing parameters and the processing effect, and dynamically set the machine tool parameters. The full closed-loop system which is refined to each machining action dynamically adjusts the machining parameters according to the machine tool parameters which are set in real time, and a more accurate machining effect is obtained.
A vision-based processing method for a full closed loop system of a numerical control machine tool comprises four steps of scanning a workbench, clamping and modeling, scanning gross damage and modeling, processing and processing ending after one-time processing, as shown in figure 5, the contents are respectively as follows:
s1, scanning a workbench, a clamp and modeling
And scanning the workbench and the clamp by using the measuring unit to establish a three-dimensional model of the workbench and the clamp. Inputting machine tool parameters such as the limit position of a workbench, the limit speed of the machine tool, deformation parameters of the machine tool and the cutter condition of the machine tool;
s2, scanning gross defects and modeling
Inputting a three-dimensional model and surface requirements of a processing target before processing in the same way of scanning a workbench and a clamp and modeling, and then scanning the blank by using a measuring unit to establish a three-dimensional model of the blank;
s3, processing and dynamically adjusting prop track
Aligning the blank with the processing target, calculating the difference between the three-dimensional model of the processing target and the three-dimensional model of the blank, and automatically generating a processing action sequence according to parameters of maximum stepping, minimum stepping, machine tool shaking and the like of a machine tool;
the analysis and calculation unit drives the machine tool to start machining according to a machining operation sequence generated in advance. In the processing process, when the cutter moves one step each time, the camera images a closed laser line around the cutter, the analysis and calculation unit positions the processed cutter track, reconstructs the surface appearance of a workpiece, feeds back the processing effect, calculates the deviation from the expected effect, establishes and corrects the corresponding relation between the processing parameters and the processing effect, and corrects a pre-generated processing action sequence according to the processing effect:
step S31: the analysis and calculation unit drives the machine tool to start machining according to a machining action sequence generated in advance;
step S32: in the processing process, when the cutter moves for one step, the camera images a closed laser line around the measuring cutter;
step S33: analyzing and calculating the tool path after positioning and processing by the unit, and reconstructing the surface appearance of the workpiece;
step S34: feeding back the processing effect, calculating the deviation from the expected effect, and establishing and correcting the corresponding relation between the processing parameters and the processing effect;
step S35: a corrected machining operation sequence is formed based on the machining effect in step S34, and machining is continued.
S4, finishing the processing
And when the machining is finished, outputting parameters such as the size and the surface requirement of the workpiece according to the measurement result.
In this embodiment, no matter the distance between the workpiece 21 and the measuring unit 4, whether the workpiece 21 is located at the maximum distance position or the minimum distance position, the fields of view of the adjacent cameras are overlapped, and the working position where the fields of view of the adjacent cameras 5 are not overlapped is an illegal working position; adjusting the focal length of the laser emitter 3 to be the distance from the measuring unit 4 to the surface of the workpiece 21; turning off all lights on the processing machine tool to highlight the brightness of the laser on the surface of the workpiece; cutting fluid on the processing machine tool is closed so as to improve the accuracy of the acquisition of the camera 5; small step processing is adopted to avoid rolling up cutting waste and improve the accuracy of the camera for collecting laser lines; the analysis and calculation unit may recognize the rolled cutting waste based on the rolled cutting waste being higher than the workpiece before machining.
While one embodiment of the present invention has been described in detail, the description is only a preferred embodiment of the present invention and should not be taken as limiting the scope of the invention. All equivalent changes and modifications made within the scope of the present invention shall fall within the scope of the present invention.
Claims (1)
1. A machining method of a full closed loop system of a numerical control machine tool based on vision is characterized in that one-time machining is completed, and the machining method comprises four steps of scanning a workbench, clamping and modeling, scanning gross defects and modeling, machining and finishing, and comprises the following steps:
step S1: scanning the workbench and the clamp and modeling, scanning the workbench and the clamp by using a measuring unit, and establishing a three-dimensional model of the workbench and the clamp;
step S2: scanning the blank and modeling, inputting a three-dimensional model and surface requirements of a processing target, then scanning the blank by using a measuring unit, and establishing a three-dimensional model of the blank;
and step S3: processing, aligning the blank with a processing target, calculating the difference between the three-dimensional model of the processing target and the three-dimensional model of the blank, and automatically generating a processing action sequence according to parameters of maximum stepping, minimum stepping, machine tool shaking and the like of a machine tool;
and step S4: after the machining is finished, outputting parameters such as the size and the surface requirement of the machined workpiece according to the measurement result when the machining is finished;
the step S3 specifically comprises the following steps:
step S31: the analysis and calculation unit drives the machine tool to start machining according to a machining action sequence generated in advance;
step S32: in the processing process, when the cutter moves for one step, the camera images a closed laser line around the measuring cutter;
step S33: analyzing and calculating the tool path after positioning and processing by the unit, and reconstructing the surface appearance of the workpiece;
step S34: feeding back the machining effect, calculating the deviation between the actual effect and the expected effect by a calculating unit, and establishing and correcting the corresponding relation between the machining parameters and the machining effect;
step S35: a correction machining operation sequence is formed based on the machining effect in step S34, and machining is continued.
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| CN112859742B (en) * | 2021-01-12 | 2021-08-06 | 广州盛硕科技有限公司 | Numerical control machine tool control system based on visual identification |
| CN114273976B (en) * | 2022-01-06 | 2024-04-26 | 高崎智能装备(丽水)有限公司 | On-line monitoring intelligent regulation management cloud system of numerical control machining center |
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