CN114283204A - Error calibration method of five-axis dispensing machine based on industrial camera - Google Patents
Error calibration method of five-axis dispensing machine based on industrial camera Download PDFInfo
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Abstract
The invention relates to the technical field of mechanical calibration of five-axis dispensing machines, and discloses an error calibration method of a five-axis dispensing machine based on an industrial camera, which comprises the following steps: s1, calibrating mechanical structure parameters of a five-axis dispensing machine, and regarding the mechanical structure of the five-axis dispensing machine and a workpiece as a rigid mechanical structure; s2, dividing a rigid mechanical structure into two processing kinematic chains; s3, establishing a standard orthogonal axis coordinate system for each rigid body in the processing kinematic chain; s4, converting the coordinate systems of all rigid bodies according to a robot kinematics method to obtain a conversion matrix; s5, performing mechanical calibration operation on the five-axis dispensing machine according to the conversion matrix and the five-axis calibration flow; and S6, acquiring a conversion relation between each parameter matrix of the rigid mechanical structure and the rigid mechanical structure coordinate system according to mechanical calibration operation, and performing error calibration. The method is used for calibrating the mechanical geometric structure parameters of five shafts, calculating various errors of the five-shaft machine and improving the machining precision of the five-shaft machine.
Description
Technical Field
The invention relates to the technical field of mechanical calibration of five-axis dispensing machines, in particular to an error calibration method of a five-axis dispensing machine based on an industrial camera, which is used for calibrating the mechanical geometric structure parameters of five axes, calculating various errors of a five-axis machine, improving the machining precision of the five-axis machine and being popularized and applied to five-axis equipment for machining of five-axis numerical control machines and other precise instruments.
Background
Compared with the traditional three-axis machine, the five-axis machine has the characteristics of higher machining precision, higher machining efficiency, capability of machining workpieces with more complex structures and the like, and has more competitive advantages in the market. Meanwhile, due to the addition of two rotating shafts, the mechanical structure of the five-axis machine becomes more complex, and in addition, geometric errors exist in the mechanical structure of the machine, abrasion is caused when the machine runs, and the like, and the factors provide requirements for calibrating geometric structure parameters of the five-axis machine.
The commonly used prior art is mostly translation shaft detection technology, rotation shaft detection technology and error compensation technology: the detection of the translational shafts mostly adopts measuring instruments such as a laser interferometer, a dial indicator and the like to detect the geometric precision of the three translational shafts and the verticality among the translational shafts; in the rotating shaft detection technology, five-axis machines on the market are mainly divided into a double-turntable structure, a single-pendulum platform-single-turntable structure and a double-pendulum head structure, corresponding geometric mathematical models are established according to different mechanical structures, radial, axial and tangential axis deviations of a rotating shaft are measured through instruments such as a level meter and a ball bar instrument, and data such as eccentricity of the rotating shaft are calculated; in the error compensation technology, error compensation is performed according to error data so as to achieve the purpose of improving the processing precision.
The five-axis mechanical equipment on the market has different structures, the use of the existing measuring tool is restricted by a specific mechanical structure, the applicability is not strong, and the existing five-axis calibration technology has the disadvantages of excessively complicated calibration process, more required time and lower efficiency. The technical requirements for technicians who perform calibration are high due to the complicated process. Compared with an industrial camera used in the invention, the measurement instruments such as the ball rod instrument and the laser interferometer required by calibration are more expensive, and the use cost of manufacturers can be increased in practical application.
Therefore, the technical scheme provided by the invention can solve the problems, and is different from the calibration processing of a five-axis machine by using measuring instruments such as a laser interferometer, a dial indicator and a ball rod instrument.
Disclosure of Invention
The invention aims to provide an error calibration method of a five-axis dispenser based on an industrial camera, which can finish data acquisition and calibration operation only by the industrial camera and a designed calibration method, greatly simplifies the calibration process and reduces the use cost of calibration.
The invention is realized by the following technical scheme: an error calibration method of a five-axis dispensing machine based on an industrial camera comprises the following steps:
s1, determining a mechanical structure of a five-axis dispensing machine, wherein the mechanical structure of the five-axis dispensing machine comprises a machine tool base, a translation axis X shaft, a translation axis Y shaft, a translation axis Z shaft, a rotating axis A shaft, a rotating axis C shaft, a glue valve and a camera, and the mechanical structure and a workpiece of the five-axis dispensing machine are regarded as a rigid mechanical structure;
s2, dividing a rigid mechanical structure into two processing kinematic chains;
s3, establishing a standard orthogonal axis coordinate system for each rigid body in the processing kinematic chain;
s4, establishing a conversion matrix and a conversion relation for the coordinate system of each rigid body according to a robot kinematics method;
s5, performing mechanical calibration operation on the five-axis dispensing machine according to the conversion matrix and the five-axis calibration flow to obtain data required by calibration calculation;
and S6, carrying out error calibration calculation according to the data obtained by the mechanical calibration operation, obtaining the conversion relation between each parameter matrix of the rigid mechanical structure and the rigid mechanical structure coordinate system, and carrying out error analysis.
In the technical scheme, the defects that a calibration process is complex, execution efficiency is low, a required measuring instrument is expensive and the like are overcome. The invention combines computer vision and a five-axis dispenser mechanical structure to realize the parameter calibration function of the mechanical structure. The required measuring tools only need an industrial camera and a calibration board. The calibration cost is greatly reduced. In the calibration process, only an operator needs to simply adopt the drawing for the calibration plate, so that the calibration flow is greatly simplified. The key technology provided by the technical scheme is that an industrial camera is connected in series to a double-turntable five-axis machine tool kinematic chain, a rigid body transformation (homogeneous coordinate transformation) method of a coordinate system is adopted to establish a series kinematic model comprising a camera coordinate system, a Z axis, an X axis, a Y axis, an A axis, a C axis and a world coordinate system (a machining coordinate system), the model is used for restraining and obtaining the conversion relation of a workpiece space point in a pixel coordinate system and the world coordinate system, the conversion relation is coupled with a machine tool position independent error factor (PIGE) caused by the installation of a moving axis, the position independent error of the machine tool can be eliminated through the workpiece space point coordinate and the pose solved by the model, and the machining precision is improved.
In order to better implement the present invention, further, the two processing kinematic chains in step S2 include:
one processing kinematic chain comprises a translation axis X axis, a translation axis Z axis glue valve and a camera;
the other processing kinematic chain comprises a translation axis Y axis, a rotation axis A axis, a rotation axis C axis and a workpiece;
and carrying out dispensing processing on the workpiece through the camera and the glue valve.
In order to better implement the present invention, step S3 further includes:
establishing a machine tool base coordinate system { M }, wherein the machine tool base coordinate system is used as a reference coordinate system of all coordinate system poses, and a coordinate origin is located at a mechanical origin;
establishing a coordinate system { X } of a translational axis X axis, wherein the coordinate X axis is parallel to the actual X translational axis, and a coordinate origin is superposed with the coordinate system { M } when the machine tool is reset;
establishing a coordinate system { Y } of a Y axis of the translational axis, and coinciding the coordinate with the coordinate system { W } when the machine tool is reset;
establishing a coordinate system { Z } of a translational axis Z axis, wherein the coordinate Z axis is parallel to an actual Z translational axis, and a coordinate origin is superposed with the coordinate system { M } when the machine tool is reset;
establishing a coordinate system { A } of an axis A of a rotating shaft, wherein each axial direction is parallel to the coordinate system { W }, and the origin of coordinates is positioned on the axis A when the machine tool is reset;
establishing a coordinate system { C } of a rotating shaft C axis, wherein each axial direction is parallel to the coordinate system { W }, and the origin of coordinates is positioned on the C axis when the machine tool is reset;
establishing a glue valve and a camera coordinate system { V }, wherein the glue valve is represented by a camera, the origin of coordinates is at the optical center of the camera, the Z axis of coordinates is coincident with the optical axis direction of the camera, and a pixel coordinate system { E };
and establishing a workpiece coordinate system { W }, wherein when the calibration is performed, no relative displacement exists between the calibration plate and the workbench, the workpiece coordinate system is set to be the same as the calibration plate coordinate system, and the workpiece coordinate system and the calibration plate coordinate system are defined as the workpiece coordinate system.
In order to better implement the present invention, step S4 further includes:
describing the rotation process and translation process between the coordinate systems through a rotation matrix R and a translation vector T defined in a rigid motion transformation method;
definitional symbol RxyT represents a rotation matrix converted from a { Y } coordinate system to a { X } coordinate systemxyRepresenting a translation vector converted from the { Y } coordinate system to the { X } coordinate system; similarly, a symbol R may be definedvz、Tvz、Rzx、Tzx、Rya、Tya、Rac、Tac、Rcw、TcwTo represent the corresponding rotation matrix and translation vector.
Wherein:
Rvza rotation matrix representing a conversion from the { Z } coordinate system to the { V } coordinate system;
Tvzrepresenting translation from the { Z } coordinate system to the { V } coordinate systemAn amount;
Rzza rotation matrix representing a conversion from the { X } coordinate system to the { Z } coordinate system;
Tzxrepresenting a translation vector converted from the { X } coordinate system to the { Z } coordinate system;
Ryaa rotation matrix representing a conversion from the { A } coordinate system to the { Y } coordinate system;
Ryarepresenting a translation vector converted from the { A } coordinate system to the { Y } coordinate system;
Raca rotation matrix representing a conversion from the { C } coordinate system to the { A } coordinate system;
Tacrepresenting a translation vector converted from the { C } coordinate system to the { A } coordinate system;
Rcwa rotation matrix representing a conversion from the { W } coordinate system to the { C } coordinate system;
Tcwrepresenting a translation vector converted from the { W } coordinate system to the { C } coordinate system;
the definition of the coordinate system is combined with the kinematic chain relation of the five-axis dispensing machine, and the mechanical coordinates [ x, y, z, a, c ] of any dispensing machine are known]There are the following functional mapping relationships: t iszx＝f(z)、Txy＝f(x)、Tya＝f(y)、Rac＝f(a)、Rcw＝f(c)。
I.e., T in the above transformation matrix \ vectorvz、Txy、Tya、Rac、RcwThe numerical value of (a) is related to the mechanical coordinate of the dispenser; and R isvz、Rzx、Tzx、Rxy、Rya、Tac、TcwThe numerical value of (a) is related to the geometric parameters of the dispenser and is a fixed value.
From the above conclusion, the conversion relationship from the workpiece coordinate system to the camera coordinate system can be established as follows:
in the above formula, the first and second carbon atoms are,
respectively representing the homogeneous coordinates of the space point under the camera coordinate system and the workpiece coordinate, and the meaning of other symbols is the same as that of the previous symbols.
By coupling the geometric error parameters in equation (1), equation (1) can be converted into the following equation:
in the above formula, RvaA rotation matrix representing { A } coordinate system to a camera coordinate system; r (a) represents a rotation matrix generated by the rotation of the rotation axis a; r (C) represents a rotation matrix generated by the rotation of the rotation axis C; vvmCan be represented as Hvm＝[Vx，Vy，Vz]In which V isx、Vy、VzRespectively represent the axial vectors of the translational axis X, Y, Z in the camera coordinate system; t isvmWhen the mechanical reset is carried out, the offset vectors of the origin points of the workpiece coordinate system and the camera coordinate system are obtained; column vector [ X Y Z1]TIndicating homogeneous coordinates constituted by the coordinate values of the mechanical translational axis X, Y, Z (superscript)TAs a transposed representation of a vector or matrix); rac、Tac、Rcw、Tcw、
The meaning is the same as before.
Through the formula (2), the conversion relation between the workpiece coordinate system and the camera coordinate system can be calculated through any mechanical coordinate, and meanwhile, the corresponding mechanical coordinate can be inversely solved according to the coordinate values of the workpiece under the workpiece coordinate system and the camera coordinate system, so that five-axis linkage dispensing machining is realized; meanwhile, the geometric structure error parameter value of the five-axis dispensing machine can be obtained by performing decoupling analysis on the formula (2), so that error compensation is realized, and the five-axis dispensing precision is improved. Therefore, the parameter values of each rotation matrix and offset vector in the formula (2) are the core solution targets of the calibration method.
To calibrate and solve equation (2), further analysis of equation (2) is required, and when the dispenser rotation shaft A, C is kept in the reset state, there are:
in the formula (3), RvwIndicating a rotation matrix between the workpiece coordinate system and the camera coordinate system when the pivot axis A, C is held in a reset state, R since the pivot axis is held in a reset statevwIs a fixed parameter matrix, other parameters.
When the point gum machine only rotated axis of rotation A, had:
in the above formula, RaAnd TaRepresenting a rotation matrix and an offset vector generated for the workpiece coordinate system by rotating the rotation axis A back to the reset zero point; and obtaining other symbols is the same as before.
Therefore, the revolution axis of any rotating shaft in the workpiece coordinate system can be obtained through the formula (4) by independently rotating any rotating shaft.
In order to better implement the present invention, the five-axis calibration process in step S5 further includes:
s5.1, adjusting a rigid mechanical structure and a calibration plate of the five-axis dispensing machine;
s5.2, collecting pictures by using a five-axis glue dispenser;
s5.3, acquiring a camera built-in parameter matrix K and an external reference rotation matrix R under each photographing pose through a camera calibration algorithm according to the acquired picturesiOuter reference translation vector TiAnd calibrating pixel coordinates of points on the plate;
s5.4, performing mechanical calibration solving operation, wherein the mechanical calibration solving operation comprises a method A for solving initial solution operation and a method B for obtaining optimal solution operation through iterative optimization;
s5.5, solving the related parameter matrix of each rigid body mechanical structure through the steps,
and S5.6, acquiring relevant parameters of the rigid mechanical structure.
In order to better implement the present invention, further, step S5.1 comprises:
s5.1.1, fixing a calibration plate on a workbench;
s5.1.2, setting the initial state of the axis A of the rotating shaft and the axis C of the rotating shaft, namely when the axis A of the rotating shaft and the axis C of the rotating shaft are both at 0 degree, enabling the calibration plate to be parallel to the plane of the machine tool base;
and S5.1.3, fixing the camera and the glue valve on the translational axis Z axis, and enabling the camera and the translational axis Z axis to be in a parallel state and to be perpendicular to the plane of the machine tool base.
In order to better implement the present invention, further, step S5.2 comprises:
s5.2.1, under the condition that a translation shaft Y shaft, a translation shaft Z shaft, a rotating shaft A shaft and a rotating shaft C shaft do not move, moving a translation shaft X shaft for multiple times, and collecting n groups of pictures only translating the translation shaft X shaft;
s5.2.2, acquiring n groups of pictures only translating the Y axis and n groups of pictures only translating the Z axis according to the mode of the step S5.2.1, and acquiring 3n pictures acquired under the translation axis;
s5.2.3, collecting m pictures under the rotation of an axis A of a rotating shaft at an equal angle theta and m pictures under the rotation of an axis C of the rotating shaft at an equal angle alpha;
s5.2.4, recording and collecting mechanical coordinates P of each picture while collecting the pictureM。
To better implement the present invention, further, the method a of solving the initial solution operation in step S5.4 includes:
step A1, obtaining 3n groups of rotation matrixes corresponding to 3n pictures collected under the movable translational axis, taking the mean value, and then performing singular value decomposition meeting the constraint condition of the rotation matrixes to obtain R in the formula (3)vwThe initial solution of (a);
step A2, according to the kinematic relationship and the camera imaging relationship between the glue valve and the camera coordinate system { V } and the workpiece coordinate system { W }, respectively passing through the formula (3) and the external reference rotation matrix R under the corresponding photographing poseiOuter reference translation vector TiEstablishing 3n unknowns Hvm、TvmTo find H in the formula (3)vm、TvmThe initial solution of (a);
step A3 presetting the direction vector of the axis A of the rotating shaft under the coordinate system { W } of the workpiece of the rotating shaft as Va＝[Kx，Ky，Kz]TWith point P on axis A of rotationa(ii) a According to the external reference rotation matrix R of the corresponding photographing pose of the m pictures under the rotation of the equal angle theta of the axis A of the rotation shaftiOuter reference translation vector TiIn combination with equation (4), m unknowns R can be establisheda、TaEquation and calculating and obtaining an axis vector V of the axis A of the rotating shaft under a workpiece coordinate systemaAnd point T on the axisa；
Step A4, presetting a direction vector of the rotating shaft C axis under the coordinate system { C } of the rotating shaft C axis, and obtaining an axis vector V of the rotating shaft C axis under the workpiece coordinate system according to the mode of the step A3cAnd point T on the axisc；
In order to better implement the present invention, 9, the method B for obtaining the optimal solution by iterative optimization operation in step S5.4 includes:
b1, establishing a transformation relation from the workpiece coordinate system { W } to the glue valve and camera coordinate system { V } according to the formula (2);
b2, according to the step S5.3, obtaining a transformation relation from a glue valve and a camera coordinate system { V } to a pixel coordinate system { E };
b3, calculating theoretical pixel coordinates of the feature points on the calibration plate according to the transformation relation between the workpiece coordinate system { W } and the glue valve and camera coordinate system { V } and the transformation relation from the glue valve and camera coordinate system { V } to the pixel coordinate system { E };
step B4., establishing an optimized objective function based on the modular minimum of the differences between the theoretical and measured values of the points on the calibration plate in the pixel coordinate system { E };
step B5. is based on equations (2), (3), (4), based on Hvm、Tvm、Va、Ta、Vc、TcSet Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmInitial values of R (a), R (c);
step B6., presetting a Jacobian matrix of a target function;
step B7., solving the optimization function according to the L-M algorithm to obtain Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmThe optimal solution of (1).
In order to better implement the present invention, step S6 further includes:
step S6.1. mixing HvmSplitting according to the rows to obtain the axis vectors of the X axis of the translational axis, the Y axis of the translational axis and the Z axis of the translational axis under the coordinate system { V } of the glue valve and the camera, and recording as V after unitizationx、VyAnd Vz；
S6.2, obtaining an axis unit vector V of the axis A of the rotating shaft and the axis C of the rotating shaft under the coordinate system (V) of the rubber valve and the camera through the rotating axis vectors corresponding to the rotating matrixes R (a), R (C) through the conversion relation between the coordinate systemsaAnd Vc；
S6.3, unit vector V is calculated according to the included angle calculation formulaxAnd VyCalculating to obtain the included angle between the X axis of the translational axis and the Y axis of the translational axis, and obtaining the included angle between any other two axes;
step S6.4. according to Rva、Rac、Tac、Rcw、Tcw、hvm、TvmSetting each parameter matrix in the transformation relation of the workpiece coordinate system { W }, the rubber valve and camera coordinate system { V }, establishing the transformation relation of the workpiece coordinate system { W }, the rubber valve and camera coordinate system { V } and the machine tool base coordinate system { M }, and carrying out subsequent error compensation.
Compared with the prior art, the invention has the following advantages and beneficial effects:
(1) the invention combines computer vision and a five-axis dispenser mechanical structure to realize the parameter calibration function of the mechanical structure. The required measuring tools only need an industrial camera and a calibration board. The calibration cost is greatly reduced. In the calibration process, only an operator needs to simply collect the drawing of the calibration plate, so that the calibration flow is greatly simplified;
(2) the method is used for realizing accurate five-axis linkage control, a processing chain is established according to the mechanical structure of the five-axis dispensing machine, and a mathematical model for conversion among rigid coordinate systems in the processing chain is established;
(3) the method comprises the steps of calculating the pose between a camera and a calibration plate by using a vision technology, calculating an initial solution by combining a kinematic model, establishing an optimization function, and performing iterative optimization on the initial solution;
(4) the invention has no requirement on the specific mechanical structure of the five-axis dispensing machine, describes an algorithm principle with universality, and can be applied to any control system of the five-axis dispensing machine.
Drawings
The invention is further described in connection with the following figures and examples, all of which are intended to be open ended and within the scope of the invention.
Fig. 1 is a flowchart of an error calibration method of a five-axis dispenser based on an industrial camera provided by the invention.
FIG. 2 is a schematic view of a processing kinematic chain in the error calibration method of a five-axis dispenser based on an industrial camera according to the present invention;
FIG. 3 is a schematic diagram of a coordinate system of a main rigid body in the error calibration method of a five-axis dispenser based on an industrial camera according to the present invention;
fig. 4 is a flowchart of mechanical calibration operation in the error calibration method of the five-axis dispensing machine based on the industrial camera provided by the invention.
Detailed Description
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, 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 should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and therefore should not be considered as a limitation to the scope of protection. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1:
in the error calibration method of the five-axis dispensing machine based on the industrial camera, as shown in fig. 1, in the present embodiment, the purpose of mechanical calibration is to calibrate mechanical geometric structure parameters of the five-axis dispensing machine, calculate error data of five-axis equipment, and establish a transformation matrix of a workpiece coordinate system, a camera coordinate system, and a machine tool coordinate system. As shown in fig. 2, the five-axis dispensing machine mainly comprises a machine tool base, three translational axes (X axis, Y axis, Z axis), and two rotational axes (a axis, C axis). The linkage between the machine tool base and each shaft and the connection between the shafts form a processing kinematic chain, and five-axis linkage is realized. In the motion process, based on the kinematics thought of a robot, a machine tool base, a motion shaft, a glue valve, a workpiece and a camera of a five-axis glue dispenser are all regarded as rigid bodies, so that the mechanical structure of the rigid bodies is divided into two processing motion chains, a coordinate system is established for each rigid body in the processing motion chains, according to the mechanical structure in fig. 2, a coordinate system of the main rigid body in fig. 2 is established, and all the established coordinate systems are standard orthogonal shaft coordinate systems.
Example 2:
the present embodiment is further optimized based on embodiment 1.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 3:
in this embodiment, further optimization is performed on the basis of embodiment 1, as shown in fig. 3, a machine tool base coordinate system { M }, which can be used as a reference coordinate system of all coordinate system poses, and the origin of coordinates is located at the mechanical origin; a workpiece coordinate system { W }, wherein during calibration, no relative displacement exists between the calibration plate and the workbench, and the workpiece coordinate system is considered to be the same as the calibration plate coordinate system, and hereinafter the workpiece coordinate system and the calibration plate coordinate system are collectively referred to as a workpiece coordinate system; a coordinate system { X } of an X axis, wherein the coordinate X axis is parallel to an actual X translation axis, and an origin is coincided with { M }; a coordinate system { Y } of the Y axis, which is coincident with { W } when the A axis and the C axis are not rotated; a coordinate system { Z } of a Z axis, wherein the coordinate Z axis is parallel to an actual Z translation axis, and an origin is superposed with { M }; the coordinate system of the A axis is { A }, each axial direction is parallel to { W }, and the origin is positioned at one point on the A axis; a coordinate system { C } of the C axis, each axial direction is parallel to { W }, and the origin is positioned at one point on the C axis; camera coordinate system V (with the needle represented by the camera), with origin of coordinates at the optical center and Z axis of coordinates coincident with the direction of the optical axis of the camera.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 4:
this embodiment is further optimized based on embodiment 1, and in the kinematics of the robot, it is considered that any two coordinate systems can be coincided by rotation plus translation. In practical application, a rotation process is described through a rotation matrix R, and a translation process is described through a translation vector T; similarly, in the camera imaging model, the spatial point can be transformed from the world coordinate system to the camera coordinate system through the external reference rotation matrix R and the translation vector T; i.e. has PA＝R·PB+ T (5) (in the above formula PA、PBAnd coordinate values of the space point on a coordinate system A and a coordinate system B are respectively represented, R represents a rotation matrix, and T represents a translation vector. ) Both can complete the transformation of coordinate values of the space points between the coordinate system A and the coordinate system B through the formula (5);
other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 5:
in this embodiment, a further optimization is performed on the basis of embodiment 1, as shown in fig. 4, on the basis of formula (2), formula (3), and formula (4), a mechanical calibration operation may be performed, a rigid mechanical structure and a calibration plate of a five-axis dispensing machine are adjusted so that the calibration plate can be clearly imaged in a camera image, then the five-axis dispensing machine is used to collect an image, according to the collected image, a camera calibration algorithm is used to obtain a camera built-in parameter matrix K, a camera external reference rotation matrix R, an external reference translation vector T, and pixel coordinates (U, V) of points on the calibration plate, a mechanical calibration solution operation is performed, the process includes an initial solution operation method a and an iterative optimization acquisition optimal solution operation method B, to obtain relevant parameters of the rigid mechanical structure, and finally a relevant parameter matrix of each rigid mechanical structure is solved through the above steps, that is to calculate each item of data error existing in five-axis equipment, And establishing a transformation matrix of a workpiece coordinate system, a camera coordinate system and a machine tool coordinate system.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 6:
in this embodiment, a measurement tool required for five-axis calibration is a calibration board and a camera in the whole five-axis calibration process, and the adjustment of the rigid mechanical structure and the calibration board of the five-axis dispensing machine includes the installation of the measurement tool, and the installation requirement is as follows: the calibration plate is fixed on the workbench, the calibration plate is parallel to the plane of a machine tool base under the initial state of an A, C shaft (the default is that the A, C shaft is 0 degree), a camera (a glue valve) is fixed on a Z shaft, the camera and the Z shaft are in a parallel state, the camera is perpendicular to the plane of the machine tool base, the height, the aperture and the focal length of the camera are adjusted, and therefore the calibration plate can clearly image in a camera picture and then acquire pictures by using a five-shaft glue dispenser.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 7:
the embodiment is further optimized on the basis of the embodiment 1, the five-axis dispenser is used for collecting pictures, firstly, the X axis is moved for multiple times to collect n groups of pictures under the condition that the Y axis, the Z axis, the A axis and the C axis do not move, and the method is also used for collecting n groups of pictures only translating the Y axis and n groups of pictures only translating the Z axis; m-piece chart collected under A-axis equal-angle theta rotationM pictures under the rotation of the sheet and the C axis at the equal angle alpha; then recording the mechanical coordinate P when each picture is acquired at the same time of acquiring the picturem＝[xi yi ziai ci]Wherein x isiFor acquiring the mechanical coordinate, y, of the translational axis X in the ith pictureiFor acquiring the mechanical coordinate of the translational axis Y, z, for the ith pictureiFor acquiring the mechanical coordinate of the translational axis Z in the ith picture, aiFor acquiring the mechanical coordinates of the translational axis A during the ith picture, ciThe mechanical coordinate of the translational axis C is acquired when the ith picture is acquired.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 8:
in this embodiment, a further optimization is performed on the basis of embodiment 1, in this embodiment, step a1, obtaining 3n sets of rotation matrices corresponding to 3n pictures collected under only the moving translational axis, averaging the rotation matrices, and then performing singular value decomposition meeting the constraint condition of the rotation matrices to obtain R in formula (3)vwThe initial solution of (a);
step A2, according to the kinematic relationship and the camera imaging relationship between the glue valve and the camera coordinate system { V } and the workpiece coordinate system { W }, respectively passing through the formula (3) and the external reference rotation matrix R under the corresponding photographing poseiOuter reference translation vector TiEstablishing 3n unknowns Hvm、TvmTo find H in the formula (3)vm、TvmThe initial solution of (a);
step A3 presetting the direction vector of the axis A of the rotating shaft under the coordinate system { W } of the workpiece of the rotating shaft as Va＝[Kx，Ky，Kz]TWith point P on axis A of rotationa(ii) a According to the external reference rotation matrix R of the corresponding photographing pose of the m pictures under the rotation of the equal angle theta of the axis A of the rotation shaftiOuter reference translation vector TiIn combination with equation (4), m unknowns R can be establisheda、TaEquation and calculating and obtaining an axis vector V of the axis A of the rotating shaft under a workpiece coordinate systemaAnd point T on the axisa；
Step A4, presetting the rotation of a rotating shaft C shaftThe direction vector of the C axis of the rotating shaft in the coordinate system { C } can be obtained by the same manner as in the step A3 according to the direction vector of the C axis of the rotating shaft in the coordinate system of the workpiececAnd point T on the axisc。
Obtaining 3n groups of rotation matrixes R corresponding to 3n pictures collected under the moving translational axisiAnd an offset vector TiAccording to the transformation relation of adjacent coordinate systems in the robot kinematics method, namely the transformation relation of the coordinate systems described by a rotation matrix and a translation vector or a homogeneous transformation matrix, R can be obtained by combining the formula (3)vw＝Ri (6)；
The symbols in the above formula have the same meanings as described above.
Since the rotation matrix R is obtained by each pictureiThe error exists, so 3n groups of rotation matrixes corresponding to 3n pictures are averaged, singular value decomposition meeting the constraint condition of the rotation matrixes is carried out, and an initial solution R is obtainedvw；
The symbols in the above formula have the same meanings as described above.
3n unknowns H can be established from the 3n picturesvmAnd TvmMatrix equation of (1), matrix HvmSum vector TvmThe total number of unknowns is 12, so when the equation number is greater than or equal to 12, namely n is greater than or equal to 4, the matrix H can be solvedvmSum vector TvmIs the least squares solution of (i) is HvmAnd TvmThe initial solution of (a).
In this embodiment, m sets of rotation matrices R corresponding to m pictures acquired under only the rotation axis a are acquirediAnd an offset vector TiLet V be the direction vector of the A axis under the { W } coordinate systema＝[Kx，Ky，Kz]THaving a point T on axis AaAccording to the Rodrigues rotation formula, from VaTheta to obtain a rotation matrix R (a),
in the formula, I is a unit matrix, theta is an A-axis rotation angle, and other parameters have the same meanings as above.
According to the formula (4) and the corresponding rotation matrix of each picture,
Rvw·R(a)＝Ri (9)
from each picture a corresponding set of V's can be derivedaFor m groups VaThe average value is calculated and unitized, and the initial solution V of the A-axis rotation axis vector can be obtaineda；
According to the formula (4) and the corresponding offset vector matrix of each picture,
m unknown numbers T can be obtained according to m picturesawSo that T is obtained when m is 3 or moreawIs the least square solution of (A), i.e. point T on the A axisaCoordinate values in the workpiece coordinate system.
Obtaining the rotation axis vector V of the C axis in the same waycAnd TaCoordinate values in the workpiece coordinate system.
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 9:
in this embodiment, each initial solution of the transformation relationship of the workpiece coordinate system { W } camera coordinate system { V } is obtained according to the kinematic model and the transformation relationship between the adjacent coordinate systems.
The transformation of the machine coordinate system { V } into the pixel coordinate system { E } is as follows: pE＝K·PV(13) Wherein K is a camera reference matrix;
calculating pixel coordinates according to formula (2) and formula (13)
Establishing an optimization objective function according to the mode minimum sum of the difference between the theoretical value and the measured value of the point on the calibration plate in the pixel coordinate system (n groups of pictures and machine tool coordinates are collected together, and m points are selected from the calibration plate for calculation), and expressing the function as follows:
wherein
Refers to the j index point pixel coordinate of the ith image calculated by a five-axis machine tool kinematic model and a camera imaging model,
refers to the pixel coordinates of the jth index point of the ith map extracted by image processing. K is the camera reference matrix, RvaIs a rotation matrix of { A } relative to { V }, HvmIs an affine matrix of translation axes, TvmIs a translation axis static offset vector, RacMeans a rotation matrix of { C } relative to { A }, TacRefers to the translation vector of { C } relative to { A }, RcwIs a rotation matrix of { W } relative to { C }, TcwIs the translation vector of W relative to C,
is the world coordinate of the jth calibration point of the ith graph under { W };
the objective function Jacobian matrix J can be expressed as:
wherein
Respectively representing the internal reference matrix K and the rotation matrix R of the objective functionvaA rotation matrix RacTranslation vector TacA rotation matrix RcwTranslation vector TcwAffine matrix HvmTranslation vector TvmThe partial derivatives are calculated, and specific numerical values can be obtained easily by combining the formula (2) and the chain derivative rule.
Before solving the optimized objective function, it is necessary to set the initial values of the solving parameters, wherein H is the abovevm、TvmLet R be knownacE (E is identity matrix), Rcw＝E、Tac＝Tc-Ta、Tcw＝-TcThe rotation axes of the rotation matrixes R (a), R (c) are vectors V of the rotation axis A, C in the workpiece coordinate systemaAnd VcSo far, the optimization objective function can begin to be solved;
the optimization objective function is known to be a nonlinear function, and the optimization function can be solved according to an L-M algorithm to obtain Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmThe optimal solution of (1).
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
Example 10:
this embodiment is further optimized based on embodiment 1, and in this embodiment, H isvmSplitting according to rows to obtain an axis vector V of an X axis, a Y axis and a Z axis under a camera coordinate systemx,Vy,VzObtained after unitization
Then, the V is putaAnd VcObtaining an axis unit vector V of the A axis and the C axis under the camera coordinate system through the conversion relation between the coordinate systemsaAnd
by the formula of the included angle:
obtaining an included angle alpha between the X axis and the Y axisxyAcquiring included angles between any other two shafts, acquiring each parameter matrix in the formula (2) according to a formula (3) -a formula (16), and establishing a conversion relation among a workpiece coordinate system { W }, a rubber valve and camera coordinate system { V } and a machine tool base coordinate system { M }; the subsequent error compensation can also be performed according to equation (2).
Other parts of this embodiment are the same as embodiment 1, and thus are not described again.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and all simple modifications and equivalent variations of the above embodiments according to the technical spirit of the present invention are included in the scope of the present invention.
Claims (10)
1. An error calibration method of a five-axis dispensing machine based on an industrial camera is characterized by comprising the following steps:
s1, determining a mechanical structure of a five-axis dispensing machine, wherein the mechanical structure of the five-axis dispensing machine comprises a machine tool base, a translation axis X shaft, a translation axis Y shaft, a translation axis Z shaft, a rotating axis A shaft, a rotating axis C shaft, a glue valve and a camera, and the mechanical structure and a workpiece of the five-axis dispensing machine are regarded as a rigid mechanical structure;
s2, dividing a rigid mechanical structure into two processing kinematic chains;
s3, establishing a standard orthogonal axis coordinate system for each rigid body in the processing kinematic chain;
s4, establishing a conversion matrix and a conversion relation for the coordinate system of each rigid body according to a robot kinematics method;
s5, performing mechanical calibration operation on the five-axis dispensing machine according to the conversion matrix and the five-axis calibration flow to obtain data required by calibration calculation;
and S6, carrying out error calibration calculation according to the data obtained by the mechanical calibration operation, obtaining the conversion relation between each parameter matrix of the rigid mechanical structure and the rigid mechanical structure coordinate system, and carrying out error analysis.
2. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the two processing kinematic chains in step S2 include:
one processing kinematic chain comprises a translation axis X axis, a translation axis Z axis glue valve and a camera;
the other processing kinematic chain comprises a translation axis Y axis, a rotation axis A axis, a rotation axis C axis and a workpiece;
and carrying out dispensing processing on the workpiece through the camera and the glue valve.
3. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the step S3 includes:
establishing a machine tool base coordinate system { M }, wherein the machine tool base coordinate system is used as a reference coordinate system of all coordinate system poses, and a coordinate origin is located at a mechanical origin;
establishing a coordinate system { X } of a translational axis X axis, wherein the coordinate X axis is parallel to the actual X translational axis, and a coordinate origin is superposed with the coordinate system { M } when the machine tool is reset;
establishing a coordinate system { Y } of a Y axis of the translational axis, and coinciding the coordinate with the coordinate system { W } when the machine tool is reset;
establishing a coordinate system { Z } of a translational axis Z axis, wherein the coordinate Z axis is parallel to an actual Z translational axis, and a coordinate origin is superposed with the coordinate system { M } when the machine tool is reset;
establishing a coordinate system { A } of an axis A of a rotating shaft, wherein each axial direction is parallel to the coordinate system { W }, and the origin of coordinates is positioned on the axis A when the machine tool is reset;
establishing a coordinate system { C } of a rotating shaft C axis, wherein each axial direction is parallel to the coordinate system { W }, and the origin of coordinates is positioned on the C axis when the machine tool is reset;
establishing a glue valve and a camera coordinate system { V }, wherein the glue valve is represented by a camera, the origin of coordinates is at the optical center of the camera, the Z axis of coordinates is coincident with the optical axis direction of the camera, and a pixel coordinate system { E };
and establishing a workpiece coordinate system { W }, wherein when the calibration is performed, no relative displacement exists between the calibration plate and the workbench, the workpiece coordinate system is set to be the same as the calibration plate coordinate system, and the workpiece coordinate system and the calibration plate coordinate system are defined as the workpiece coordinate system.
4. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the step S4 includes:
describing the rotation process and translation process between the coordinate systems through a rotation matrix R and a translation vector T defined in a rigid motion transformation method;
definitional symbol RxyT represents a rotation matrix converted from a { Y } coordinate system to a { X } coordinate systemxyRepresenting a translation vector converted from the { Y } coordinate system to the { X } coordinate system; similarly, a symbol R may be definedvx、Tvz、Rzx、Tzx、Rya、Tya、Rac、Tac、Rcw、TcwTo represent the corresponding rotation matrix and translation vector, wherein:
Rvza rotation matrix representing a conversion from the { Z } coordinate system to the { V } coordinate system;
Tvzrepresenting a translation vector converted from the { Z } coordinate system to the { V } coordinate system;
Rzxa rotation matrix representing a conversion from the { X } coordinate system to the { Z } coordinate system;
Tzxrepresenting a translation vector converted from the { X } coordinate system to the { Z } coordinate system;
Ryaa rotation matrix representing a conversion from the { A } coordinate system to the { Y } coordinate system;
Ryarepresenting a translation vector converted from the { A } coordinate system to the { Y } coordinate system;
Raca rotation matrix representing a conversion from the { C } coordinate system to the { A } coordinate system;
Tacrepresenting a translation vector converted from the { C } coordinate system to the { A } coordinate system;
Rcwa rotation matrix representing a conversion from the { W } coordinate system to the { C } coordinate system;
Tcwrepresents a translation vector converted from the { W } coordinate system to the { C } coordinate system.
5. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the five-axis calibration process in the step S5 includes:
s5.1, adjusting a rigid mechanical structure and a calibration plate of the five-axis dispensing machine;
s5.2, collecting pictures by using a five-axis glue dispenser;
s5.3, acquiring a camera built-in parameter matrix K and an external reference rotation matrix R under each photographing pose through a camera calibration algorithm according to the acquired picturesiOuter reference translation vector TiAnd calibrating pixel coordinates of points on the plate;
s5.4, performing mechanical calibration solving operation, wherein the mechanical calibration solving operation comprises a method A for solving initial solution operation and a method B for obtaining optimal solution operation through iterative optimization;
s5.5, solving a related parameter matrix of each rigid body mechanical structure through the steps;
and S5.6, acquiring relevant parameters of the rigid mechanical structure.
6. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 5, wherein the step S5.1 comprises:
s5.1.1, fixing a calibration plate on a workbench;
s5.1.2, setting the initial state of the axis A of the rotating shaft and the axis C of the rotating shaft, namely when the axis A of the rotating shaft and the axis C of the rotating shaft are both at 0 degree, enabling the calibration plate to be parallel to the plane of the machine tool base;
and S5.1.3, fixing the camera and the glue valve on the translational axis Z axis, and enabling the camera and the translational axis Z axis to be in a parallel state and to be perpendicular to the plane of the machine tool base.
7. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the step S5.2 comprises:
s5.2.1, under the condition that a translation shaft Y shaft, a translation shaft Z shaft, a rotating shaft A shaft and a rotating shaft C shaft do not move, moving a translation shaft X shaft for multiple times, and collecting n groups of pictures only translating the translation shaft X shaft;
s5.2.2, acquiring n groups of pictures only translating the Y axis and n groups of pictures only translating the Z axis according to the mode of the step S5.2.1, and acquiring 3n pictures acquired under the translation axis;
s5.2.3, collecting m pictures under the rotation of an axis A of a rotating shaft at an equal angle theta and m pictures under the rotation of an axis C of the rotating shaft at an equal angle alpha;
s5.2.4, recording and collecting mechanical coordinates P of each picture while collecting the pictureM。
8. The error calibration method of the five-axis dispenser based on the industrial camera as claimed in claim 5, wherein the method A for solving the initial solution operation in the step S5.4 comprises:
step A1, obtaining 3n groups of rotation matrixes corresponding to 3n pictures collected under the movable translational axis, taking the mean value, then performing singular value decomposition meeting the constraint condition of the rotation matrixes, and obtaining RvwThe initial solution of (a);
step A2, according to the kinematic relationship and the camera imaging relationship between the glue valve and the camera coordinate system { V } and the workpiece coordinate system { W } and the external reference rotation matrix R under the corresponding photographing poseiOuter reference translation vector TiEstablishing 3n unknowns Hvm、TvmObtaining Hvm、TvmThe initial solution of (a);
step A3 presetting the direction vector of the axis A of the rotating shaft under the coordinate system { W } of the workpiece of the rotating shaft as Va＝[Kx，Ky，Kz]TWith point P on axis A of rotationa(ii) a According to the external reference rotation matrix R of the corresponding photographing pose of the m pictures under the rotation of the equal angle theta of the axis A of the rotation shaftiOuter reference translation vector TiEstablishing m unknowns Ra、TaEquation and calculating and obtaining an axis vector V of the axis A of the rotating shaft under a workpiece coordinate systemaAnd point T on the axisa；
Step A4, presetting a direction vector of the rotating shaft C axis under the coordinate system { C } of the rotating shaft C axis, and obtaining an axis vector V of the rotating shaft C axis under the workpiece coordinate system according to the mode of the step A3cAnd point T on the axisc。
9. The error calibration method of the five-axis dispenser based on the industrial camera as claimed in claim 1, wherein the method B of obtaining the optimal solution by the iterative optimization operation in the step S5.4 comprises:
step R1, establishing a transformation relation from the workpiece coordinate system { W } to the glue valve and camera coordinate system { V };
b2, according to the step S5.3, obtaining a transformation relation from a glue valve and a camera coordinate system { V } to a pixel coordinate system { E };
b3, calculating theoretical pixel coordinates of the feature points on the calibration plate according to the transformation relation between the workpiece coordinate system { W } and the glue valve and camera coordinate system { V } and the transformation relation from the glue valve and camera coordinate system { V } to the pixel coordinate system { E };
step B4., establishing an optimized objective function based on the modular minimum of the differences between the theoretical and measured values of the points on the calibration plate in the pixel coordinate system { E };
step B5. is according to Hvm、Tvm、Va、Ta、Vc、TcSet Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmInitial values of R (a), R (c);
step B6., presetting a Jacobian matrix of a target function;
step B7., solving the optimization function according to the L-M algorithm to obtain Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmThe optimal solution of (1).
10. The error calibration method of the five-axis glue dispenser based on the industrial camera as claimed in claim 1, wherein the step S6 includes:
step S6.1. mixing HvmSplitting according to a row to obtain a horizontal axis X axisThe axis vectors of the translation axis Y and the translation axis Z under the coordinate system of the rubber valve and the camera { V }, and the axis vectors are recorded as V after unitizationx、VyAnd Vz；
S6.2, obtaining an axis unit vector V of the axis A of the rotating shaft and the axis C of the rotating shaft under the coordinate system (V) of the rubber valve and the camera through the rotating axis vectors corresponding to the rotating matrixes R (a), R (C) through the conversion relation between the coordinate systemsaAnd Vc；
S6.3, unit vector V is calculated according to the included angle calculation formulaxAnd VyCalculating to obtain the included angle between the X axis of the translational axis and the Y axis of the translational axis, and obtaining the included angle between any other two axes;
step S6.4. according to Rva、Rac、Tac、Rcw、Tcw、Hvm、TvmSetting each parameter matrix in the transformation relation of the workpiece coordinate system { W }, the rubber valve and camera coordinate system { V }, establishing the transformation relation of the workpiece coordinate system { W }, the rubber valve and camera coordinate system { V } and the machine tool base coordinate system { M }, and carrying out subsequent error compensation.
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