CN114280153B - Intelligent detection robot for complex curved surface workpiece, detection method and application - Google Patents
Intelligent detection robot for complex curved surface workpiece, detection method and application Download PDFInfo
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Abstract
The invention discloses an intelligent detection robot for a complex curved surface workpiece, a detection method and application, wherein conversion of a camera coordinate system, a robot coordinate system and a tool coordinate system is realized through robot eye calibration and end tool calibration; acquiring the appearance contour of a complex curved surface workpiece in a multi-angle mode by adopting binocular vision, completing reconstruction of a workpiece model, and automatically identifying marked characteristic points of the workpiece to be detected so as to determine the position of the workpiece; cutting a workpiece reconstruction model to determine a detection area and identify a data boundary, and finishing off-line planning of a detection path according to the detection process requirement; respectively issuing detection tasks and synchronization parameters to the robot controller and the robot terminal pose resolving module through an EtherCAT bus and a TCP/IP protocol; according to the planned detection path, a flexible floating follower clamping sensor at the tail end of the robot is installed to complete a path planning task; and a pose fast resolving module is adopted to resolve the pose of the tool at the tail end of the robot, synchronously detect instrument and equipment and complete detection work.
Description
Technical Field
The invention relates to the technical field of crossing of robots, machine vision and nondestructive testing, in particular to an intelligent detection robot for a complex curved surface workpiece, a detection method and application.
Background
The robot has the advantages of multiple degrees of freedom, low cost and the like, and is widely applied to the production and manufacturing industry. At present, the robot control mainly adopts a teaching mode and an off-line programming mode. The robot controller interpolates adjacent points to realize path planning; the latter firstly carries out off-line programming according to a workpiece theoretical model, then realizes the alignment of the robot and the workpiece position through calibration, further realizes the accurate planning of the robot path, and finally completes the production and manufacturing task. However, when the theoretical model is unknown, the surface has irregular shape and high positioning accuracy (such as automatic grinding and polishing, spraying and the like), the two modes cannot be completely applied.
The structured light machine vision projects certain mode light (such as stripes) to the surface of an object by adopting a laser, a camera detects a structured light image modulated on the surface of the object to be measured, phase and height information is sequentially restored, and finally object appearance point cloud measurement is realized. The profile appearance of the measured object can be quickly reconstructed by the structure optical mechanical device vision, multi-position multi-angle appearance splicing is supported, and the measurement precision is lower than that of contact type three-coordinate measurement.
At present, the robot detection technology receives the curved surface work piece location, detection efficiency, absolute position precision, waits to examine the work piece kind factor influence such as many, does not obtain the wide application in the nondestructive test field, mainly embodies: firstly, when a theoretical model of a workpiece to be detected is unknown, the workload of manually teaching to complete path planning is huge and the precision is low, and an off-line programming mode cannot complete path planning; secondly, nondestructive testing requires high testing efficiency (2-20KHz) and high positioning accuracy (less than 1 mm), and the communication speed and the absolute positioning accuracy of the existing robot cannot meet the testing requirements; thirdly, when the workpieces to be detected are various in types and irregular curved surfaces, the positioning of the workpieces is limited to a certain extent, and the path planning workload is huge; finally, when a contact detection method is adopted, the planned path cannot be completely fit with the surface of the workpiece to be detected, and the sensor is required to be self-adaptive to the contact surface of the workpiece to be detected.
Therefore, the present application needs to design an intelligent detection robot for a complex curved surface workpiece, a detection method and an application thereof, so as to solve the above technical problems.
Disclosure of Invention
The invention aims to solve the defects in the prior art, and provides an intelligent detection robot for a complex curved surface workpiece, a detection method and application thereof, wherein the robot is guided by vision to complete the nondestructive detection of the complex curved surface workpiece, and the intelligent detection robot specifically comprises multi-angle curved surface reconstruction and splicing, miscellaneous curved surface workpiece positioning, detection path planning, self-adaption of the surface of the workpiece to be detected, high detection efficiency (16 KHz), synchronization of other nondestructive detection instruments and equipment and the like.
In order to achieve the purpose, the invention adopts the following technical scheme:
a detection method of an intelligent detection robot for a complex curved surface workpiece adopts a vision guide robot to complete nondestructive detection work of the complex curved surface workpiece:
firstly, calibrating hands and eyes of a robot and calibrating a tail end tool to realize conversion of a camera coordinate system, a robot coordinate system and a tool coordinate system;
then positioning and reconstructing a model of the workpiece to be detected, acquiring the outline of the complex curved surface workpiece by adopting binocular vision in multiple angles, completing reconstruction of the workpiece model, and automatically identifying marked characteristic points of the workpiece to be detected so as to determine the position of the workpiece;
then, performing off-line path planning, cutting the collected point cloud data to determine a detection area and identify a data boundary, and finishing off-line path planning according to the detection process requirement;
respectively issuing detection tasks and synchronization parameters to the robot controller and the robot terminal pose resolving module through an EtherCAT bus and a TCP/IP protocol; according to the planned detection path, a flexible floating follower and a clamping sensor at the tail end of the robot are installed to complete a path planning task;
and a pose fast resolving module is adopted to resolve the pose of the tool at the tail end of the robot, synchronously detect instrument and equipment and complete detection work.
Preferably, the method specifically comprises the following steps:
step 1), calibrating a binocular camera according to needs, and determining internal and external parameters of the two cameras;
step 2), calibrating a flexible floating follower fixed at the tail end of the robot according to needs, and determining a tool matrix;
step 3), selecting a corresponding sensor and a clamping tool thereof according to actual detection requirements, fixing the sensor and the clamping tool thereof at the tail end of the flexible floating follower, calibrating a tool coordinate system (the sensor and the clamping tool thereof), and determining a coordinate transformation matrix;
step 4), calibrating the robot hand and eye, and determining a hand and eye transformation matrix;
step 5), planning a detection path, namely dividing the detection path into a known condition and an unknown condition of a workpiece model to be detected; aiming at the known situation of the workpiece model, acquiring the appearance outline of the complex curved surface workpiece by adopting binocular vision on the basis of the step 4) and identifying the characteristic points, further determining the actual pose of the complex curved surface workpiece, and then planning the detection path by combining the workpiece model and the detection process requirements; aiming at the condition that a workpiece model is unknown, acquiring the outline and the identification characteristic points of the complex curved surface workpiece by binocular vision on the basis of the step 4), positioning the complex curved surface workpiece, and planning a path according to the detection process requirement;
step 6), through a TCP/IP protocol, the industrial PC sends the path planning result of the step 5) to a rapid resolving module of the attitude and position of the robot, and the resolving module sets synchronous parameters of the detection instrument according to the path planning result, wherein the synchronous parameters comprise a detection method, a detection mode, detection precision and trigger frequency;
step 7), the industrial PC issues the path planning result of the step 5) to the robot controller through an EtherCAT bus, and the robot is controlled to complete a corresponding detection task after receiving a detection command issued by the industrial PC;
step 8), the industrial PC issues a detection command to the robot controller, the robot controller controls the robot to complete a corresponding detection track according to a path planning result, meanwhile, the pose fast resolving module in the step 6) resolves the pose of a robot end tool and synchronizes a detection instrument according to set synchronous parameters, the detection instrument returns detection data to the industrial PC in real time while completing a detection task for subsequent processing, and the detection instrument can display a detection result in real time;
and 9) according to the actual detection beat, the industrial PC decides to process the detection data in real time or subsequently, wherein the processing comprises detection result imaging, boundary identification, defect positioning/quantification and workpiece residual life prediction.
Preferably, in step 4), there are two robot eye calibrations, which are manual calibration and checkerboard calibration respectively: manually calibrating, namely acquiring characteristic points in a calibration plate by adopting binocular vision, manually providing space coordinates of calibration points in a robot coordinate system, and determining a transformation matrix between a camera coordinate system and the robot coordinate system; and (3) marking the chessboard by adopting eyes on the hands or eyes outside the hands to solve the problem of AX = XB and determine a transformation matrix X of the binocular camera and the tail end tool of the robot, wherein the A matrix and the B matrix are respectively pose matrixes of the tail end tool moved twice by the robot.
By adopting the technical scheme: the offline path planning is not limited by the theoretical model and the processing precision: aiming at the condition that a theoretical model of a known curved surface workpiece is high in machining precision, the theoretical model can be adopted for off-line path planning; aiming at the condition that the theoretical model is unknown or the machining precision is large, binocular vision is adopted to collect the surface contour of the workpiece to be detected, and then off-line path planning is carried out.
By adopting the technical scheme: can high-speed (16 KHz) synchronous nondestructive test instrument equipment, has high detection efficiency: the pose resolving module is adopted to rapidly resolve the pose of the robot and output the synchronous trigger signal with adjustable precision, the synchronous trigger frequency can be increased to 16KHz, and the problems that the EtherCAT bus of the robot controller is low in output rate (250 Hz) and cannot be directly used for synchronous nondestructive testing instrument equipment are solved.
The invention also provides an intelligent detection robot for the complex curved surface workpiece, which comprises six robots, a visual unit and a flexible floating unit, wherein the visual unit and the flexible floating unit are arranged at the tail ends of the six robots, a detection probe is arranged on the flexible floating unit and comprises a detection instrument and a water circulation coupler, the detection instrument is connected with an industrial PC, the industrial PC is connected with the visual unit, and the six robots are connected with a controller.
Preferably, a pose resolving module is installed inside the tail end of the six-axis robot, and the pose resolving module is respectively connected with the vision unit and the flexible floating unit.
Preferably, the vision unit is a binocular camera.
Preferably, the inspection instruments include conventional ultrasonic detectors, phased array detectors, eddy current detectors, and magnetic flux leakage detectors.
By adopting the technical scheme: the intelligent detection robot belongs to a general detection platform, and can meet the requirements of high-precision positioning detection such as ultrasound, eddy current, magnetic flux leakage and the like according to actual detection requirements.
The invention also provides an application of the detection method of the intelligent detection robot for the complex curved surface workpiece, and the intelligent detection robot can realize nondestructive detection of the complex curved surface workpiece such as ultrasonic, phased array, eddy current, magnetic flux leakage and the like.
The invention has the following beneficial effects:
1. the invention can select corresponding detection process and probe according to the actual detection requirement of the complex curved surface workpiece to complete the detection of the complex curved surface workpiece such as ultrasonic, phased array, eddy current, magnetic flux leakage and the like.
2. The off-line path planning method is not limited by a theoretical model and the machining precision of the complex curved surface workpiece, gives consideration to the fact that the theoretical model is unknown and the theoretical model is known but the machining precision is low, and can effectively complete the detection path planning.
3. The robot end pose rapid resolving module can improve the pose acquisition rate and the synchronous trigger frequency to 16KHz, the trigger precision is adjustable (less than 1 mm), and the problem that the absolute positioning precision of the robot is low (the absolute positioning precision of KUKA KR210R2700 is +/-0.6 mm) and the communication barrier between the robot and a detection instrument is overcome.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a schematic structural diagram of the intelligent inspection robot of the present invention;
FIG. 3 is a schematic diagram of the calibration of the hand and eye of the intelligent detection robot according to the present invention; wherein, the figure (a) is that eyes are on hands, namely binocular vision is fixed at the tail end of the robot; (b) The figure shows the eyes outside the hands, namely the binocular vision is fixed on the external fixing frame;
FIG. 4 is a schematic diagram of a calibration plate for calibrating the hand and eye of the intelligent inspection robot according to the present invention;
FIG. 5 is a graph showing an actual test result of a manual simulation test sample, and graphs (a) and (b) and (c) showing an actual test result of a manual simulation test sample according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Referring to fig. 1-5, a complicated curved surface work piece intellectual detection system robot, intellectual detection system robot includes six robots 1, installs at the terminal visual unit 2 of six robots 1 and flexible unit 3 that floats, install test probe 4 on the flexible unit 3 that floats, test probe 4 includes detecting instrument 5 and water circulation coupler 6, detecting instrument 5 is connected with industry PC7, industry PC7 is connected with visual unit 2, six robots 1 are connected with controller 8.
Specifically, a pose resolving module is installed inside the tail end of the six-axis robot 1 and is respectively connected with the vision unit 2 and the flexible floating unit 3.
Specifically, the vision unit 2 is a binocular camera.
Specifically, the detecting instrument 5 includes a conventional ultrasonic detector, a phased array detector, an eddy current detector, and a magnetic flux leakage detector.
The intelligent detection robot is used for carrying out detection experiments on the manual simulation samples. The artificial simulation sample is of a semi-cylindrical shape, the length of the artificial simulation sample is 150mm, the inner diameter of the artificial simulation sample is 50mm, the outer diameter of the artificial simulation sample is 60mm, the inner surface of the artificial simulation sample is carved with 'IMR NDT' artificial defects, the depth of the defects is 3mm, the depth of the defects is 5mm, the detection range is 140 multiplied by 100mm, and both the triggering interval and the stepping interval are 0.2mm.
The invention carries out phased array detection on the curved surface workpiece, and the method comprises the following specific steps:
step 1), calibrating a binocular camera according to needs, and determining internal and external parameters of the two cameras;
step 2), calibrating a flexible floating follower fixed at the tail end of the robot according to needs, and determining a tool matrix;
step 3), selecting a corresponding sensor and a clamping tool thereof according to actual detection requirements, fixing the sensor and the clamping tool thereof at the tail end of the flexible floating follower, calibrating a tool coordinate system (the sensor and the clamping tool thereof), and determining a coordinate transformation matrix;
step 4), robot hand-eye calibration, and determining a hand-eye transformation matrix, wherein the calibration methods comprise two methods, namely manual calibration and checkerboard calibration: manually calibrating, namely acquiring characteristic points in a calibration plate by using binocular vision, manually providing space coordinates of calibration points in a robot coordinate system, and determining a transformation matrix between a camera coordinate system and the robot coordinate system; the checkerboard calibration adopts the method that eyes are on the hands or outside the hands, the problem of AX = XB is solved, and a transformation matrix X of a binocular camera and a robot tail end tool is determined (wherein matrixes A and B are pose matrixes of the robot moving the tail end tool twice respectively);
and 5) planning the inspection path, namely dividing the inspection path into a known condition and an unknown condition of the model of the workpiece to be inspected. Aiming at the known condition of the workpiece model, acquiring the outline of the complex curved surface workpiece by adopting binocular vision on the basis of the step 4), identifying characteristic points, further determining the actual pose of the complex curved surface workpiece, and planning a detection path by combining the workpiece model and the detection process requirements; aiming at the unknown condition of the workpiece model, acquiring the outline and the identification characteristic points of the complex curved surface workpiece based on the binocular vision in the step 4), positioning the complex curved surface workpiece, and planning the path according to the detection process requirement;
step 6), through a TCP/IP protocol, the industrial PC sends the path planning result of the step 5) to a rapid resolving module of the attitude and position of the robot, and the resolving module sets synchronous parameters of the detection instrument according to the path planning result, wherein the synchronous parameters mainly comprise detection parameters such as a detection method, a detection mode, detection precision, trigger frequency and the like;
step 7), the industrial PC issues the path planning result of the step 5) to the robot controller through an EtherCAT bus, and the robot is controlled to complete a corresponding detection task after receiving a detection command issued by the industrial PC;
step 8), the industrial PC issues a detection command to the robot controller, the robot controller controls the robot to complete a corresponding detection track according to a path planning result, meanwhile, the pose fast resolving module in the step 6) resolves the pose of a robot end tool and synchronizes a detection instrument according to set synchronous parameters, the detection instrument returns detection data to the industrial PC in real time while completing a detection task for subsequent processing, and the detection instrument can display a detection result in real time;
and 9) according to the actual detection beat, the industrial PC decides to process the detection data in real time or subsequently, wherein the processing comprises detection result imaging, boundary identification, defect positioning/quantification, workpiece residual life prediction and the like.
In conclusion, the invention adopts the vision-guided robot to complete the nondestructive detection work of the complex curved surface workpiece, and specifically comprises multi-angle curved surface reconstruction and splicing, miscellaneous curved surface workpiece positioning, detection path planning, self-adaption to the surface of the workpiece to be detected, high detection efficiency (16 KHz), synchronization of other nondestructive detection instruments and equipment and the like.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (3)
1. The detection method of the intelligent detection robot for the complex curved surface workpiece is characterized in that the robot is guided by vision to complete the nondestructive detection work of the complex curved surface workpiece:
firstly, calibrating hands and eyes of a robot and calibrating a tail end tool to realize conversion of a camera coordinate system, a robot coordinate system and a tool coordinate system;
then positioning a workpiece to be detected and reconstructing a model, acquiring the appearance contour of the complex curved surface workpiece by adopting binocular vision at multiple angles, completing reconstruction of the workpiece model, and automatically identifying marked characteristic points of the workpiece to be detected so as to determine the position of the workpiece;
then, performing off-line path planning, cutting the acquired point cloud data to determine a detection area and identify a data boundary, and completing the off-line path planning according to the detection process requirement;
respectively issuing detection tasks and synchronization parameters to the robot controller and the robot terminal pose resolving module through an EtherCAT bus and a TCP/IP protocol; according to the planned detection path, a flexible floating follower and a clamping sensor at the tail end of the robot are installed to complete a path planning task;
a pose fast resolving module is adopted to resolve the pose of the tool at the tail end of the robot, so that the instrument and equipment are synchronously detected and the detection work is finished;
the method specifically comprises the following steps:
step 1), calibrating a binocular camera according to needs, and determining internal and external parameters of the two cameras;
step 2), calibrating a flexible floating follower fixed at the tail end of the robot according to needs, and determining a tool matrix;
step 3), selecting a corresponding sensor and a clamping tool thereof according to actual detection requirements, fixing the sensor and the clamping tool at the tail end of the flexible floating follower, calibrating a tool coordinate system, and determining a coordinate transformation matrix;
step 4), calibrating the robot hand and eye, and determining a hand and eye transformation matrix;
step 5), planning a detection path, namely dividing the detection path into a known condition and an unknown condition of a workpiece model to be detected; aiming at the known situation of the workpiece model, acquiring the appearance outline of the complex curved surface workpiece by adopting binocular vision on the basis of the step 4) and identifying the characteristic points, further determining the actual pose of the complex curved surface workpiece, and then planning the detection path by combining the workpiece model and the detection process requirements; aiming at the unknown condition of the workpiece model, acquiring the outline and the identification characteristic points of the complex curved surface workpiece based on the binocular vision in the step 4), positioning the complex curved surface workpiece, and planning the path according to the detection process requirement;
step 6), through a TCP/IP protocol, the industrial PC sends the path planning result of the step 5) to a rapid resolving module of the attitude and position of the robot, and the resolving module sets synchronous parameters of the detection instrument according to the path planning result, wherein the synchronous parameters comprise a detection method, a detection mode, detection precision and trigger frequency;
step 7), the industrial PC issues the path planning result of the step 5) to the robot controller through an EtherCAT bus, and the robot is controlled to complete a corresponding detection task after receiving a detection command issued by the industrial PC;
step 8), the industrial PC issues a detection command to the robot controller, the robot controller controls the robot to complete a corresponding detection track according to a path planning result, meanwhile, the pose rapid resolving module in the step 6) resolves the pose of a tool at the tail end of the robot and synchronizes a detection instrument according to set synchronous parameters, the detection instrument completes a detection task and simultaneously returns detection data to the industrial PC in real time for subsequent processing, and the detection instrument can display a detection result in real time;
step 9), according to the actual detection beat, the industrial PC makes a decision to process the detection data in real time or subsequently, wherein the detection data comprises detection result imaging, boundary identification, defect positioning/quantification and workpiece residual life prejudgment;
in the step 4), the robot hand-eye calibration has two types, namely manual calibration and checkerboard calibration: manually calibrating, namely acquiring characteristic points in a calibration plate by using binocular vision, manually providing space coordinates of calibration points in a robot coordinate system, and determining a transformation matrix between a camera coordinate system and the robot coordinate system; and (3) marking the checkerboard by adopting the mode that eyes are on the hands or the eyes are outside the hands, solving the problem of AX = XB, and determining a transformation matrix X of a binocular camera and a terminal tool of the robot, wherein matrixes A and B are pose matrixes of the terminal tool moved by the robot twice respectively.
2. An intelligent detection robot for the detection method of the intelligent detection robot for the complex curved surface workpiece according to claim 1, wherein the intelligent detection robot comprises six-axis robots, a vision unit and a flexible floating unit, the vision unit is installed at the tail ends of the six-axis robots, detection probes are installed on the flexible floating unit, the detection probes comprise detection instruments and a water circulation coupler, the detection instruments are connected with an industrial PC, the industrial PC is connected with the vision unit, and the six-axis robots are connected with a controller;
a pose resolving module is installed inside the tail end of the six-axis robot and is respectively connected with the vision unit and the flexible floating unit;
the vision unit is a binocular camera;
the detecting instrument comprises a conventional ultrasonic detector, a phased array detector, a vortex detector and a magnetic flux leakage detector.
3. The application of the detection method of the intelligent detection robot for the complex-surface workpiece according to claim 1 is characterized in that the intelligent detection robot can realize ultrasonic, phased array, eddy current and magnetic flux leakage nondestructive detection of the complex-surface workpiece.
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| CN115229805B (en) * | 2022-09-21 | 2022-12-09 | 北京壹点灵动科技有限公司 | Hand-eye calibration method and device for surgical robot, storage medium and processor |
| CN115326932A (en) * | 2022-10-13 | 2022-11-11 | 征图新视(江苏)科技股份有限公司 | Nondestructive detection device and method for defects of inner layer of composite material of middle frame of mobile phone |
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