CN110488752B - Automatic surface processing autonomous slicing method for large-scale complex curved surface robot - Google Patents
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Abstract
The invention discloses a method for automatically slicing a curved surface in the automatic surface processing process of a large-scale complex curved surface robot, which comprises the steps of firstly constructing a surface processing process model according to a surface processing mode, and setting a corresponding maximum curvature threshold value of triangular slice surface slicing; carrying out preliminary fragmentation on the triangular patch by taking the approximate curvature of the adjacent triangular patch as a basis; then setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment, and preparing for secondary segment division; and calculating deflection angles of other adjacent triangular patches and the average normal vector based on the average normal vector of the optimized patch, connecting the adjacent triangular patches smaller than the maximum vector deflection angle of the region into the optimized patch to realize secondary segmentation, removing the optimized patch with the ratio of the area of the region to the area of the curved surface model not meeting the requirement, and outputting the final curved surface segmentation result. The method disclosed by the invention has good robustness, obviously reduces the manual adjustment requirement, and has good result consistency and processing feasibility.
Description
Technical Field
The invention relates to the technical field of digital manufacturing, in particular to a method for automatically slicing a curved surface in the automatic surface processing process of a large-scale complex curved surface robot.
Background
The triangular mesh model is widely applied in the fields of modeling and graphics, can be used for simulating the surface of a complex object, and can be simplified to a great extent by operating the triangular mesh model in the process of processing the model with complex surface characteristics, thereby being convenient for analyzing and processing the surface characteristics of the model. In the process of planning the machining process for large complex curved surface components, such as wind power blades, aircraft skins and the like, the surface characteristics of the components need to be considered, and machining areas of the surface to be machined of the model are divided according to curved surface information.
At present, two methods are mainly used for dividing a machining area for curved surface machining, one method is a section method for intersecting a machining range of a tool tail end with a workpiece, but the surface characteristics of the workpiece are not considered in the operation process of the section method, and even the problems of interference, over-cutting and the like in the machining process can be caused by the internal sunken or closed angle characteristics in the slicing result under extreme conditions; the other method is based on the characteristics of a triangular mesh model, the surface of the model is segmented according to the normal vector deflection angle of a triangular patch in the curved surface triangular mesh model, the method can avoid the problems in the section method to a certain extent, the surface characteristics of the model are extracted, but the method does not consider the influence of the curvature on the processing quality in the surface processing process, the segmented result is small in area, large in quantity and lack of optimization steps, and the segmented result still needs to be adjusted manually by an operator.
In summary, a general autonomous machining area division method is still lacking for the robot machining automation planning of large complex curved surfaces.
Disclosure of Invention
The invention aims to solve the technical problem of providing a curved surface autonomous slicing method in the automatic surface processing process of a large-scale complex curved surface robot aiming at the defects in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows:
the method for automatically slicing the curved surface in the automatic surface processing process of the large-scale complex curved surface robot comprises the following steps:
step1, constructing a surface machining process model according to a surface machining mode, and setting a corresponding maximum curvature threshold value of the triangular plate surface slicing;
step2, calculating the curvature of the adjacent triangular surface patches according to the normal vector deflection angle and the centroid distance of the triangular surface patches in the curved surface triangular mesh model, and classifying the triangular surface patches smaller than the maximum curvature threshold value into a combined surface patch to complete the primary slicing of the curved surface;
step3, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface processing process model;
step4, calculating the average normal vector n of the triangular patch and the optimized patch in the combined patch, wherein the triangular patch is adjacent to the boundary triangular patch of the optimized patchavgAnd (3) connecting the adjacent triangular patches with the declination smaller than the maximum vector declination of the region into an optimized patch, realizing secondary segmentation of the primary segmentation result of the curved surface, calculating the ratio of the region area of all optimized patches to the area of the curved surface model after the secondary segmentation is finished, eliminating the optimized patches with the ratio smaller than the minimum ratio of the storage area of the curved surface patches, and outputting the final curved surface segmentation result.
According to the technical scheme, the surface processing mode comprises surface grinding and surface spraying, and the surface processing model comprises a surface grinding processing model and a surface spraying processing model.
According to the technical scheme, the maximum curvature threshold value kappa of the curved surface slice of the surface grinding process modelmaxThe setting is based on the following principle,
wherein, the ratio of the minimum pressure intensity to the maximum pressure intensity of the polishing area is shown, d is the indentation depth, LcThe contact width is machined for grinding.
According to the technical scheme, the maximum allowable curvature threshold α of the spraying area of the surface spraying machining process modelmaxThe setting is based on the following principle,
wherein, is Δ QdFor maximum permissible deviation of the coating thickness, Q, of the coating areadTo average paint film thickness, QminIs the minimum paint film thickness.
According to the technical scheme, the specific process of the Step2 is as follows:
step21, analyzing the topological information of the curved surface triangular mesh model, and recording normal vectors and centroid coordinates of all triangular patches;
step22, constructing a combined patch by taking any unsegmented triangular patch in the curved surface triangular mesh model as a starting point;
step23, taking a boundary triangular patch of the combined patch, calculating the normal vector deflection angle and the centroid distance of the boundary triangular patch and the adjacent triangular patch, and calculating the approximate curvature of the adjacent triangular patch;
step24, comparing the approximate curvature of the adjacent triangular patches with the maximum curvature threshold, and if the approximate curvature is smaller than the maximum curvature threshold, connecting the adjacent triangular patches into a combined patch as a new boundary triangular patch;
step25, repeating Step 23-Step 24 until the approximate curvatures of the boundary triangular patch of the combined patch and all adjacent triangular patches are larger than the maximum curvature threshold value, finishing the construction of the combined patch and finishing the division of one curved surface patch;
and Step26, repeating Step 22-Step 25 until all the triangular patches in the curved surface triangular mesh model complete the construction of the combined patches, and completing the initial segmentation of the curved surface.
According to the technical scheme, the approximate curvature of the triangular facets is the ratio of the normal vector deflection angle of two adjacent triangular facets to the arc length of the arc of the approximate curvature, and the arc length of the arc of the approximate curvature is set according to the following processing that if the subsequent processing is surface grinding processing, the arc length of the arc of the approximate curvature is set as the distance between the mass centers of the adjacent triangular facets; if the subsequent processing is surface spraying processing, the value is set to 1.
In the technical scheme, the specific process of Step4 includes the following steps:
step41, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface processing process model;
step42, constructing an optimized patch by taking the boundary triangular patch as a starting point according to the surface initial slicing result of the Step26, and calculating the average normal vector n of the optimized patchavg；
Step43, searching a triangular patch adjacent to the boundary triangular patch of the optimized patch in the combined patch in the surface preliminary patch result, if the normal vector of the adjacent triangular patch and the average normal vector n of the optimized patchavgIf the deflection angle is smaller than the maximum vector deflection angle, the adjacent triangular patches are connected into the optimized patch, and the average normal vector n of the optimized patch is updatedavg；
Step44, repeating Step43 until all boundary triangular patches in the optimized patches do not have adjacent triangular patches meeting the maximum vector deflection angle, and completing the division of one optimized patch area;
step45, repeating the steps from Step42 to Step44 until all the optimized regions in the combined patch are divided;
step46, calculating the ratio of the area of each optimized patch to the area of the curved surface model, if the ratio is smaller than the minimum ratio of the storage area of the curved surface patch, removing the optimized patch area from the patch result, and outputting the final curved surface patch result.
Following the above technical solution, in Step4, the average normal vector n of the patch is optimizedavgThe calculation method of (2) is as follows:
wherein N is the number of triangular patches in the current optimized patch, SiAnd niRespectively representing the area and normal vector of the ith triangular patch in the combined patch.
The invention has the following beneficial effects: according to the automatic curved surface slicing method in the automatic surface processing process of the large-scale complex curved surface robot, the triangular surface patches in the curved surface triangular mesh model are subjected to preliminary slicing according to the approximate curvatures of the adjacent surface patches, so that the processing thickness uniformity is ensured, the invagination or closed angle characteristics existing on the surface of a workpiece to be processed can be effectively avoided, and the possibility of over-cutting in the processing process is reduced; and optimizing the primary slicing result by using the area average vector as a normal vector of the optimized surface patch to ensure that the curved surface slicing result has approximate planarization characteristics, and screening the slicing result according to the area ratio of the regions to avoid the existence of regions which are not suitable for receiving and processing in the current processing parameter environment in the slicing result. The method provided by the invention has good robustness, obviously reduces the manual adjustment requirement, and has good result consistency and processing feasibility.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is the general steps of the autonomic sharding method of the present invention;
FIG. 2 is a flow chart of the preliminary fragmentation of the autonomic fragmentation method of the present invention;
fig. 3(a) is a first expansion diagram of a surface preliminary autonomous slicing combination patch of the autonomous slicing method of the present invention;
fig. 3(b) is a second development diagram of the surface preliminary autonomous slicing and combining patch of the autonomous slicing method of the present invention;
FIG. 4 is an optimized fragmentation flow diagram of the autonomic fragmentation method of the present invention;
FIG. 5 is a diagram illustrating a result of the completion of the surface optimization autonomous segmentation of the autonomous segmentation method of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As shown in fig. 1, the invention provides a method for autonomously slicing a curved surface in an automatic surface processing process of a large-scale complex curved surface robot, which comprises the following steps:
and S1, constructing a surface machining process model according to the surface machining mode, and setting a corresponding maximum curvature threshold value of the triangular plate surface.
S2, calculating the curvature of the adjacent triangular patches according to the normal vector deflection angle and the centroid distance of the triangular patches in the curved surface triangular mesh model, and classifying the triangular patches smaller than the maximum curvature threshold into a combined patch to complete the primary slicing of the curved surface; the automatic slicing of the curved surface is finished by using the approximate curvature as a basis, the uniformity of the processing thickness is ensured, the invagination or closed angle characteristic existing on the surface of the workpiece to be processed can be effectively avoided, and the possibility of over-cutting in the processing process is reduced.
And S3, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface processing process model.
S4, calculating the average normal vector n of the triangular patch and the optimized patch in the combined patch, wherein the triangular patch is adjacent to the boundary triangular patch of the optimized patchavgThe adjacent triangular patches with the deflection angles smaller than the maximum vector deflection angle of the region are connected into an optimized patch, so that secondary fragmentation is carried out on the primary fragmentation result of the curved surface; the area average vector is used as the normal vector of the optimized patch to optimize the patch result, so that the curved surface patch result has approximate planarization characteristic, good processing feasibility, good result consistency and high robustness.
And after the secondary slicing is finished, calculating the ratio of the area of all optimized surface patches to the area of the curved surface model, eliminating the optimized surface patches of which the ratio is smaller than the minimum ratio of the storage area of the curved surface slices, and outputting the final curved surface slicing result. And screening the slicing result according to the area ratio of the regions, so that the regions which are not suitable for receiving and processing in the current processing parameter environment are avoided from the slicing result, the final slicing result is matched with the subsequent processing technological process, and the manual adjustment requirement is obviously reduced.
Further, the surface processing mode is surface grinding and surface spraying, the surface processing model is divided into a surface grinding processing model and a surface spraying processing model, and different processing models have different process parameter models.
Further, in specific implementation, the ratio of the minimum pressure to the maximum pressure of the polishing area for measuring the surface processing uniformity is set according to the curved surface to be ground, and the maximum curvature threshold value kappa of the curved surface slice of the surface grinding process model is calculated according to the ratiomaxThe calculation formula is derived as follows:
analyzing the curved surface grinding model, the grinding force pressure distribution in the grinding area range is as follows:
wherein, P0In order to achieve the maximum pressure in the polishing area,
solve the data for the pressure distribution region, let LcTo grind the contact width. The ratio of the minimum pressure intensity to the maximum pressure intensity in the parameter grinding area is introduced, and the pressure intensity at the tail end of the grinding contact width can meet the following requirements:
the maximum curvature threshold of the available grinding area satisfies the formula (1).
The approximate curvature of the triangular plate surface is the ratio of the normal vector deflection angle theta of two adjacent triangular plate surfaces to the arc length l of the arc of the approximate curvature, for surface grinding, the centroid distance is approximate to the arc length l of the arc of the curvature of the curved surface along the adjacent direction, and the approximate curvature of the curved surface along the adjacent direction can be calculated as
Further, in specific implementation, the maximum allowable deviation delta Q of the spraying thickness of the spraying area for measuring the uniformity of the surface processing is set according to the curved surface of the spraying processingdAnd calculating α the maximum curvature threshold of the spray area of the surface spray machining process model based on the maximum allowable deviationmaxThe calculation formula is derived as follows, a curved surface spraying processing model is analyzed, and the minimum Q in the spraying area range is calculatedminAnd average paint film thickness QdIf the thickness deviation of the spraying area is required to be less than the maximum allowable deviation Delta QdThen, it should satisfy:
Qd-Qmincosαth≤ΔQd(7)
from which a spray coating can be obtainedRegion allowed maximum curvature threshold αmaxSatisfies the formula (2).
The approximate curvature of triangle facet is the ratio of the normal vector declination theta of two adjacent triangle facets to the approximate curvature circular arc length l, and to surface spraying processing, in the process of calculating the approximate curvature, the curvature circular arc length l of the curved surface along the adjoining direction is set as 1 by default, namely:
further, after the maximum curvature threshold of the curved surface slicing is set by the surface processing technology model, the preliminary slicing is started, and the detailed flow in the specific implementation is as follows:
s201, analyzing topological information of the curved surface triangular mesh model, recording normal vectors and centroid coordinates of all triangular surface patches and a maximum curvature threshold of the curved surface patches.
S202, constructing a combined patch by taking any non-segmented triangular patch in the curved surface triangular mesh model as a starting point.
S203, a boundary triangular patch of the combined patch is selected, the normal vector deflection angle and the centroid distance of the boundary triangular patch and the adjacent triangular patch are calculated, and the approximate curvature of the adjacent triangular patch is calculated, namely the adjacent triangular patch is searched and the approximate curvature is calculated.
S204, executing S205 to connect the adjacent triangular patches into a combined patch and serve as a new boundary triangular patch to realize the extension of the patch area, wherein the approximate curvature is smaller than the maximum curvature threshold of the curved surface patch, and the triangular patch marked by 'o' in the figure 3(a) jumps to S203 to continue execution; otherwise, S206 is performed to determine whether there is an adjacent triangular patch that satisfies the curvature threshold requirement.
S206, if an adjacent triangular patch meeting the curvature threshold requirement exists, jumping to S203 to continue execution; otherwise, a combined patch is constructed, for example, a triangle patch marked by "x" in fig. 3(b), to realize the division of a patch area of the curved surface, and S207 is continuously executed to determine whether the non-patch triangle patch set is non-empty.
S207, if the triangular patch set which is not partitioned is not empty, jumping to S202 to continue execution; otherwise, executing S208 to output the combined patch, and ending the surface preliminary patch.
The triangular surface patches in the curved surface triangular mesh model are subjected to preliminary slicing by taking the approximate curvature of the adjacent surface patches as a basis, the uniformity of the processing thickness is ensured, the invagination or closed angle characteristics existing on the surface of a workpiece to be processed can be effectively avoided, and the possibility of over-cutting in the processing process is reduced.
Further, after the preliminary slicing of the curved surface is completed, further optimization is performed based on the constructed combined dough sheet, and secondary slicing is performed, as shown in fig. 4, the specific process includes the following steps:
s401, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface machining process model.
S402, according to the result of the surface primary slicing, constructing an optimized patch by taking the boundary triangular patch as a starting point, and calculating an average normal vector of the optimized patch.
And S403, searching a triangular patch adjacent to the boundary triangular patch of the optimized patch in the combined patch in the curved surface preliminary patch result, and calculating the deflection angle between the normal vector of the adjacent triangular patch and the average normal vector of the optimized patch.
S404, if the deviation angle between the normal vector of the adjacent triangular patch and the average normal vector of the optimized patch is smaller than the maximum vector deviation angle of the area, executing S405 to connect the adjacent triangular patch into the optimized patch, and jumping to S403 to continue executing; otherwise, S406 is performed.
S406, judging whether an adjacent triangular patch meeting the requirement of the vector deflection angle threshold exists or not, and if so, jumping to S403 to continue execution; otherwise, it indicates that one optimized patch is complete, and S407 is performed.
S407, calculating the ratio of the area of the optimized patch to the area of the curved surface model, judging whether the ratio is smaller than the minimum occupation ratio of the storage area of the curved surface patch, if so, executing S408 to remove the optimized patch, as shown by the shaded part in FIG. 5, and then executing S409; otherwise, directly executing S409 to continue optimizing the patch slicing.
S409, judging whether the unoptimized triangular patch set is empty, and if not, skipping to S402 to search for optimization again; if the result is null, it indicates that the optimization is finished, and S410 is executed to output the optimized patch, as shown in fig. 5, the curved surface patch is finished.
Further, optimizing the patch average normal vector navgThe calculation method of (2) is as follows:
wherein N is the number of triangular patches in the current optimized patch, SiAnd niRespectively representing the area and normal vector of the ith triangular patch in the combined patch.
And optimizing the primary slicing result by using the area average vector as a normal vector of the optimized surface patch to ensure that the curved surface slicing result has approximate planarization characteristics, and screening the slicing result according to the area ratio of the regions to avoid the existence of regions which are not suitable for receiving and processing in the current processing parameter environment in the slicing result. The method provided by the invention has good robustness, obviously reduces the manual adjustment requirement, and has good result consistency and processing feasibility.
It will be understood that modifications and variations can be made by persons skilled in the art in light of the above teachings and all such modifications and variations are intended to be included within the scope of the invention as defined in the appended claims.
Claims (8)
1. A method for automatically slicing a curved surface in the automatic surface processing process of a large-scale complex curved surface robot is characterized by comprising the following steps:
step1, constructing a surface machining process model according to a surface machining mode, and setting a corresponding maximum curvature threshold value of the triangular plate surface slicing;
step2, calculating the curvature of the adjacent triangular surface patches according to the normal vector deflection angle and the centroid distance of the triangular surface patches in the curved surface triangular mesh model, and classifying the triangular surface patches smaller than the maximum curvature threshold value into a combined surface patch to complete the primary slicing of the curved surface;
step3, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface processing process model;
step4, calculating the average normal vector n of the triangular patch and the optimized patch in the combined patch, wherein the triangular patch is adjacent to the boundary triangular patch of the optimized patchavgAnd (3) connecting the adjacent triangular patches with the declination smaller than the maximum vector declination of the region into an optimized patch, realizing secondary segmentation of the primary segmentation result of the curved surface, calculating the ratio of the region area of all optimized patches to the area of the curved surface model after the secondary segmentation is finished, eliminating the optimized patches with the ratio smaller than the minimum ratio of the storage area of the curved surface patches, and outputting the final curved surface segmentation result.
2. The method according to claim 1, wherein the surface processing mode is surface grinding and surface spraying, and the surface processing model is divided into a surface grinding processing model and a surface spraying processing model.
3. The method of claim 2, wherein the surface grinding process model has a maximum curvature threshold κ for a surface slicemaxThe setting is based on the following principle,
wherein, the ratio of the minimum pressure intensity to the maximum pressure intensity of the polishing area is shown, d is the indentation depth, LcThe contact width is machined for grinding.
4. The method of claim 2, wherein the spray area of the surface spray finishing process model allows a maximum curvature threshold value of αmaxThe setting is based on the following principle,
wherein, is Δ QdFor maximum permissible deviation of the coating thickness, Q, of the coating areadTo average paint film thickness, QminIs the minimum paint film thickness.
5. The method as claimed in claim 1, wherein Step2 comprises the following steps:
step21, analyzing the topological information of the curved surface triangular mesh model, and recording normal vectors and centroid coordinates of all triangular patches;
step22, constructing a combined patch by taking any unsegmented triangular patch in the curved surface triangular mesh model as a starting point;
step23, taking a boundary triangular patch of the combined patch, calculating the normal vector deflection angle and the centroid distance of the boundary triangular patch and the adjacent triangular patch, and calculating the approximate curvature of the adjacent triangular patch;
step24, comparing the approximate curvature of the adjacent triangular patches with the maximum curvature threshold, and if the approximate curvature is smaller than the maximum curvature threshold, connecting the adjacent triangular patches into a combined patch as a new boundary triangular patch;
step25, repeating Step 23-Step 24 until the approximate curvatures of the boundary triangular patch of the combined patch and all adjacent triangular patches are larger than the maximum curvature threshold value, finishing the construction of the combined patch and finishing the division of one curved surface patch;
and Step26, repeating Step 22-Step 25 until all the triangular patches in the curved surface triangular mesh model complete the construction of the combined patches, and completing the initial segmentation of the curved surface.
6. The method according to claim 5, wherein the approximate curvature of the triangular facets is a ratio of a normal vector deflection angle of two adjacent triangular facets to an arc length of an arc of the approximate curvature, and the arc length of the arc of the approximate curvature is set according to the distance between the centers of mass of the adjacent triangular facets if the subsequent processing is surface grinding processing; if the subsequent processing is surface spraying processing, the value is set to 1.
7. The method as claimed in claim 5, wherein the specific process of Step4 comprises the following steps:
step41, setting the minimum ratio of the maximum vector deflection angle of the region to the storage area of the curved surface segment according to the surface processing process model;
step42, constructing an optimized patch by taking the boundary triangular patch as a starting point according to the surface initial slicing result of the Step26, and calculating the average normal vector n of the optimized patchavg；
Step43, searching a triangular patch adjacent to the boundary triangular patch of the optimized patch in the combined patch in the surface preliminary patch result, if the normal vector of the adjacent triangular patch and the average normal vector n of the optimized patchavgIf the deflection angle is smaller than the maximum vector deflection angle, the adjacent triangular patches are connected into the optimized patch, and the average normal vector n of the optimized patch is updatedavg；
Step44, repeating Step43 until all boundary triangular patches in the optimized patches do not have adjacent triangular patches meeting the maximum vector deflection angle, and completing the division of one optimized patch area;
step45, repeating the steps from Step42 to Step44 until all the optimized regions in the combined patch are divided;
step46, calculating the ratio of the area of each optimized patch to the area of the curved surface model, if the ratio is smaller than the minimum ratio of the storage area of the curved surface patch, removing the optimized patch area from the patch result, and outputting the final curved surface patch result.
8. The method of claim 1, wherein Step4 is performed to optimize the patch average normal vector navgThe calculation method of (2) is as follows:
wherein N is the number of triangular patches in the current optimized patch, SiAnd niRespectively representing the area and normal vector of the ith triangular patch in the combined patch.
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