CN117781882B - Industrial hardware detects MES data acquisition analysis system - Google Patents
Industrial hardware detects MES data acquisition analysis system Download PDFInfo
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Abstract
The invention relates to the field of data acquisition and analysis, in particular to an industrial hardware detection MES data acquisition and analysis system, which comprises an appearance parameter acquisition module, an appearance parameter analysis module, a deformation degree detection module, a compressive strength analysis module, a wear detection module, a wear resistance analysis module, a comprehensive evaluation index analysis module and a management database.
Description
Technical Field
The invention relates to the field of data acquisition and analysis, in particular to an industrial hardware detection MES data acquisition and analysis system.
Background
Industrial hardware is a variety of metal products used in the industrial production process, including bolts, nuts, screws, studs and the like, and plays roles in connecting, fixing and supporting mechanical equipment and components, so that the stability and reliability of the equipment and the components are ensured.
With the rapid development of industrialization, industrial hardware is widely applied to various industries such as machine manufacturing, automobiles, aerospace and the like as an important manufacturing material, and strict detection and test are generally required for the industrial hardware in order to ensure the quality and reliability of the hardware.
The existing detection of the industrial hardware mostly adopts manual work or utilizes measuring tools such as vernier calipers to detect the specification of the industrial hardware, or the industrial hardware is assembled into corresponding products to test the functions and performances of the industrial hardware in actual use, but the method has the defects that the following aspects are particularly shown: 1. the manual measurement needs the operator to measure the specification of hardware one by one, including parameters such as size, diameter, length, and the like, and this process wastes time and energy, and produces the error easily, and manual measurement can only detect the size of industry hardware simultaneously, can't evaluate its performance and function comprehensively, to the condition that needs grasp product performance and function fast, only relies on manual measurement can't satisfy the demand.
2. The industrial hardware needs to withstand long-term use and repeated load, and under different working environments and application scenes, the pressure changes suffered by the hardware are different, so that the wear resistance performance of the industrial hardware is possibly different, and the method for testing the functions and the performances of the industrial hardware by assembling the industrial hardware into corresponding products can only simulate a part of use conditions, cannot completely restore the real use environments and conditions, and can not accurately evaluate the performances of the industrial hardware.
3. In the prior art, when the pressure resistance performance of the hardware is tested, a single direction pressure loading is often adopted, for example, a vertical direction pressure test is adopted, however, the industrial hardware may be subjected to pressures from all directions in actual use, and if the hardware cannot bear the pressures, accidents may occur.
Disclosure of Invention
In order to solve the above problems, the present invention provides an industrial hardware detection MES data acquisition and analysis system, including: the appearance parameter acquisition module is used for acquiring appearance parameters of the industrial hardware, wherein the appearance parameters comprise size data and chromaticity data.
Appearance parameter analysis module for obtaining dimension conformity according to dimension data of industrial hardwareObtaining the color deviation degree/>, based on the chromaticity dataFurther analyzing and obtaining the appearance conformity coefficient/>, of the industrial hardware。
And the deformation degree detection module is used for detecting the deformation degree of the industrial hardware in the axial direction, the radial direction and the step connection position under each pressure.
The compressive strength analysis module is used for analyzing and obtaining compressive strength evaluation coefficients of the industrial hardware according to the deformation degrees of the axial, radial and stepped connection parts of the industrial hardware under various pressures。
And the abrasion detection module is used for detecting the abrasion volume of the industrial hardware under each friction force.
The wear-resistant strength analysis module is used for obtaining the wear-resistant strength evaluation coefficient of the industrial hardware according to the analysis of the wear volume of the industrial hardware under each friction force。
The comprehensive evaluation index analysis module is used for analyzing and obtaining the comprehensive evaluation index of the industrial hardware according to the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, comparing the comprehensive evaluation index with a preset comprehensive evaluation index threshold value, and further obtaining the comprehensive evaluation condition of the industrial hardware and feeding back to the system.
And the management database is used for storing standard chromaticity value ranges of the surfaces of the industrial hardware.
Preferably, the dimension data of the industrial hardware comprises the appearance parameters and the thread parameters of the hardware, wherein the appearance parameters comprise bolt length, threaded hole radius and wall thickness uniformity, and the thread parameters comprise thread pitch uniformity and thread form fitness.
Preferably, the specific analysis process of the dimensional conformity of the industrial hardware is as follows: three-dimensional measurement is carried out on the industrial hardware by a laser scanning technology, a three-dimensional model is built for the industrial hardware, the three-dimensional model is recorded as the three-dimensional model of the industrial hardware, the bolt length and the radius of the threaded hole of the industrial hardware are read from the three-dimensional model, and the three-dimensional model is respectively recorded as the three-dimensional model of the industrial hardware、/>。
Determining the central axis of a threaded hole in a three-dimensional model of the industrial hardware, cutting the industrial hardware into a plurality of tangential planes, taking the tangential planes as threaded holes corresponding to all measurement planes, taking the intersection point of the central axis passing through all measurement planes as the circle center, taking the circle center of the threaded holes corresponding to all measurement planes as rays corresponding to the measurement planes, recording the rays as the circle center of all measurement planes, further obtaining the intersection point of the circle center rays of all measurement planes and the inner wall of the threaded holes and the intersection point of the outer wall of the threaded holes, respectively recording the rays as all inner wall measurement points and all outer wall measurement points, respectively measuring the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points, obtaining the distance between all inner wall measurement points and all outer wall measurement points by taking the difference between the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points as the wall thickness of all measurement pointsWherein/>Represents the/>Number of measurement points,/>The average wall thickness of each measuring point is obtained to obtain the average wall thickness/>, of the industrial hardwareSubstituting it into formulaObtaining the wall thickness uniformity/>, of the industrial hardware，/>Indicating the number of measurement points.
The method comprises the steps of obtaining an image of an industrial hardware by utilizing a laser scanning technology, focusing the image of the industrial hardware in a threaded hole, amplifying the image by adopting an amplifier to obtain a three-dimensional amplified image of the interior of the threaded hole of the industrial hardware, extracting the number of threads from the three-dimensional amplified image, respectively measuring the axial distance between each group of threads by taking two adjacent threads as a group, and marking the axial distance as，Represents the/>Numbering of group screw threads,/>Substituting it into the formula/>Obtain pitch uniformity/>Wherein/>Representing a preset standard pitch,/>Representing natural constants.
Selecting a thread gauge matched with a preset thread form, uniformly inserting the thread gauge into a threaded hole of an industrial hardware, respectively measuring the clearance between each thread line and the thread gauge, and marking asWherein/>Represents the/>The number of the thread line is the same as the number of the thread line,Simultaneously, two adjacent thread lines are taken as a group, the thread angle between each group of thread lines is measured by using a thread angle gauge, and the measured thread angle is recorded as/>Substituting it into formulaObtaining the thread form fitness/>, of the industrial hardwareWhereinIndicating the allowable clearance between the set thread and the gauge,/>Representing the set standard thread angle,/>Weight factors respectively representing clearance between thread line and thread gauge, and thread angleRepresenting the number of threads,/>The numbers of the thread groups are indicated.
The dimensional conformity of the industrial hardware is analyzed, and the formula is as follows: wherein/> Representing the preset standard bolt length and the screw hole radius,/>The weight factors of the bolt length, the radius of the threaded hole, the uniformity of the wall thickness of the industrial hardware, the uniformity of the thread pitch and the consistency of the thread teeth are respectively represented.
Preferably, the specific analysis process of the color deviation degree of the industrial hardware is as follows: and respectively scanning and expanding the inner surface and the outer surface of the industrial hardware by utilizing a laser scanning technology to generate a planar image, and recording the planar image as an outer surface image of the industrial hardware and an inner surface image of the industrial hardware.
Detecting the chromaticity value of each pixel point in the external surface image of the industrial hardware, extracting the standard chromaticity value range of the surface of the industrial hardware in the management database, comparing the chromaticity value with the chromaticity value of each pixel point in the external surface image of the industrial hardware, counting the number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, extracting the total number of pixel points of the external surface image of the industrial hardware, comparing the total number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, and obtaining the color deviation degree of the external surface of the industrial hardware, which is recorded as。
Analyzing the internal surface image of the industrial hardware according to the analysis method of the color deviation degree of the external surface of the industrial hardware to obtain the color deviation degree of the internal surface of the industrial hardwareBy the formulaObtaining the color deviation degree/>, of the industrial hardwareWherein/>Indicating a preset maximum allowable deviation degree of the color.
Preferably, the specific analysis method of the appearance conformity coefficient of the industrial hardware comprises the following steps: respectively reading the size conformity degree of industrial hardwareAnd degree of color deviation/>The appearance conformity coefficient of the industrial hardware is analyzed, and the formula is as follows:，/> Expressed as a natural constant.
Preferably, the specific analysis process of the deformation degree detection module is as follows: and (3) acquiring a three-dimensional image of the industrial hardware by utilizing a laser scanning technology, marking the three-dimensional image as an original image of the industrial hardware, applying preset different pressures to the industrial hardware along the central axis direction of the industrial hardware by utilizing a press machine, acquiring the three-dimensional image of the industrial hardware under the preset different pressures, and marking the three-dimensional image as an image of the industrial hardware under each pressure.
Comparing the industrial hardware image under each pressure with the industrial hardware original image, registering three-dimensional point cloud data of the industrial hardware image under each pressure and the industrial hardware original image by a point cloud registration algorithm to obtain each corresponding point between the industrial hardware image under each pressure and the industrial hardware original image, and calculating the distance between each corresponding point between the industrial hardware image under each pressure and the industrial hardware original imageWherein/>Represents the/>The number of the individual pressures is given,，/>Represents the/>Number of corresponding points,/>The maximum distance and the minimum distance between the image of the industrial hardware and the original image of the industrial hardware under each pressure are screened out from the image, and are respectively marked as/>、/>Substituting it into the formula/>Obtaining the axial deformation degree/>, of the industrial hardware under various pressures。
Making a vertical line on the central axis of the industrial hardware, applying preset different pressures on the industrial hardware along the radial direction by taking the vertical line direction as the radial direction, analyzing the radial deformation degree of the industrial hardware under each pressure according to the method for analyzing the axial deformation degree of the industrial hardware under each pressure, and recording as。
Applying preset different pressures to the step connection parts of the industrial hardware, analyzing the deformation degree of the step connection parts of the industrial hardware under each pressure according to a method for analyzing the axial deformation degree of the industrial hardware under each pressure, and marking the deformation degree as。
Preferably, the specific analysis method of the compressive strength evaluation coefficient of the industrial hardware comprises the following steps: reading the axial deformation degree of industrial hardware under various pressuresRadial deformation degree/>, of industrial hardware under various pressuresAnd the deformation degree/>, of the step connection part of the industrial hardware under various pressuresThe compressive strength evaluation coefficient of the industrial hardware is analyzed, and the formula is as follows: wherein/> Indicating a preset maximum allowable deformation degree.
Preferably, the specific analysis process of the wear detection module is as follows: the method comprises the steps of obtaining a three-dimensional model of industrial hardware, applying preset different friction forces to the industrial hardware, rubbing the industrial hardware on a specific abrasive according to preset time, obtaining a three-dimensional image of the industrial hardware under each preset friction force in preset time, constructing a three-dimensional model, and recording the three-dimensional image as the industrial hardware model under each friction force.
The industrial hardware model under each friction force is subjected to overlapping comparison with the industrial hardware three-dimensional model, the volume of the industrial hardware three-dimensional model is extracted, the volume of the non-overlapping area of the industrial hardware model under each friction force and the industrial hardware three-dimensional model is extracted by utilizing an edge detection technology, and the volume is recorded as the abrasion volume of the industrial hardware under each friction force, and the abrasion volume is recorded asWherein/>Represents the/>Number of friction force,/>。
Preferably, the specific analysis method of the wear resistance evaluation coefficient of the industrial hardware comprises the following steps: reading the abrasion volume of industrial hardware under each friction forceBringing it to the formula/>Obtaining the wear resistance evaluation coefficient/>, of the industrial hardwareWherein/>Representing the volume of a three-dimensional model of industrial hardware.
Preferably, the specific analysis process of the comprehensive evaluation index analysis module is as follows: respectively reading out the appearance conformity coefficient of the industrial hardwareCompressive Strength evaluation coefficient of Industrial hardware/>And the wear resistance evaluation coefficient/>, of industrial hardwareBy the formula/>Obtaining a comprehensive evaluation index of the industrial hardware, whereinWeight factors respectively representing the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, and/>。
And comparing the comprehensive evaluation index of the industrial hardware with a preset comprehensive evaluation index threshold, if the comprehensive evaluation index of the industrial hardware is larger than or equal to the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is qualified, and if the comprehensive evaluation index of the industrial hardware is smaller than the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is unqualified, and feeding back the comprehensive evaluation of the hardware to the system.
Compared with the prior art, the industrial hardware detection MES data acquisition and analysis system has the following beneficial effects: 1. the system obtains the size conformity degree and the color deviation degree of the industrial hardware by analyzing the appearance parameters of the industrial hardware, further obtains the appearance conformity coefficient of the industrial hardware, provides an effective index for measuring the appearance conformity degree of the industrial hardware, can more accurately evaluate the appearance quality of products, detects the possible size deviation or color difference problem, and realizes objective evaluation of the appearance quality.
2. According to the system, the deformation degree of the axial, radial and stepped connection parts of the industrial hardware under each pressure is detected, the compressive strength evaluation coefficient of the industrial hardware is obtained through analysis, the stress state and the deformation condition of the product under the pressure are evaluated, the compressive capacity of the product when the product bears the pressure is reflected, the quality and the reliability of the product are improved, and the damage and accident risk of the product are reduced.
3. According to the system, the abrasion resistance evaluation coefficient of the industrial hardware is obtained by analyzing the abrasion volumes of the industrial hardware under various pressures, the abrasion resistance reduction condition of the product can be found in time through the abrasion resistance test of the industrial hardware under different pressures, and the production process is convenient to adjust and improve, so that the service life and the performance of the product are ensured.
4. The system analyzes the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the comprehensive industrial hardware to obtain the comprehensive evaluation index of the industrial hardware, so that the comprehensive evaluation condition of the industrial hardware is known, the comprehensive evaluation index is not limited to a single evaluation index, the quality condition of the industrial hardware can be more comprehensively known, the quality condition of a product can be timely known, potential problems are found, measures are timely taken to improve, and the quality stability of the product is improved.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed for the description of the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a diagram illustrating a system module connection according to the present invention.
Fig. 2 is a schematic view of the industrial hardware structure of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the invention provides an industrial hardware detection MES data acquisition and analysis system, which comprises an appearance parameter acquisition module, an appearance parameter analysis module, a deformation degree detection module, a compressive strength analysis module, a wear detection module, a wear resistance analysis module, a comprehensive evaluation index analysis module and a management database.
The management database is connected with the appearance parameter analysis module, the comprehensive evaluation index analysis module, the wear-resisting strength analysis module and the compressive strength analysis module, the appearance parameter analysis module is connected with the appearance parameter acquisition module and the comprehensive evaluation index analysis module, the wear-resisting strength analysis module is connected with the wear detection module and the comprehensive evaluation index analysis module, and the compressive strength analysis module is connected with the comprehensive evaluation index analysis module and the deformation degree detection module.
The appearance parameter acquisition module is used for acquiring appearance parameters of the industrial hardware, wherein the appearance parameters comprise size data and chromaticity data.
Referring to fig. 2, the dimension data of the industrial hardware includes the shape parameters and the thread parameters of the hardware, wherein the shape parameters include bolt length, radius of the threaded hole, uniformity of wall thickness, and the thread parameters include uniformity of thread pitch and consistency of thread profile.
Appearance parameter analysis module for obtaining dimension conformity according to dimension data of industrial hardwareObtaining the color deviation degree/>, based on the chromaticity dataFurther analyzing and obtaining the appearance conformity coefficient/>, of the industrial hardware。
The specific analysis process of the dimensional conformity of the industrial hardware comprises the following steps: three-dimensional measurement is carried out on the industrial hardware by a laser scanning technology, a three-dimensional model is built for the industrial hardware, the three-dimensional model is recorded as the three-dimensional model of the industrial hardware, the bolt length and the radius of the threaded hole of the industrial hardware are read from the three-dimensional model, and the three-dimensional model is respectively recorded as the three-dimensional model of the industrial hardware、/>; The laser scanning technology can provide high-precision three-dimensional measurement data, can accurately measure parameters such as bolt length, screw hole radius and the like, and can reduce artificial measurement errors and improve measurement precision compared with the traditional measurement method.
Determining the central axis of a threaded hole in a three-dimensional model of the industrial hardware, cutting the industrial hardware into a plurality of tangential planes, taking the tangential planes as threaded holes corresponding to all measurement planes, taking the intersection point of the central axis passing through all measurement planes as the circle center, taking the circle center of the threaded holes corresponding to all measurement planes as rays corresponding to the measurement planes, recording the rays as the circle center of all measurement planes, further obtaining the intersection point of the circle center rays of all measurement planes and the inner wall of the threaded holes and the intersection point of the outer wall of the threaded holes, respectively recording the rays as all inner wall measurement points and all outer wall measurement points, respectively measuring the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points, obtaining the distance between all inner wall measurement points and all outer wall measurement points by taking the difference between the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points as the wall thickness of all measurement pointsWherein/>Represents the/>Number of measurement points,/>The average wall thickness of each measuring point is obtained to obtain the average wall thickness/>, of the industrial hardwareSubstituting it into formulaObtaining the wall thickness uniformity/>, of the industrial hardware，/>Representing the number of measurement points; the wall thickness uniformity of the industrial hardware can be accurately estimated by collecting wall thickness data of a plurality of measuring points and calculating an average value, so that the quality of the industrial hardware is judged.
The method comprises the steps of obtaining an image of an industrial hardware by utilizing a laser scanning technology, focusing the image of the industrial hardware in a threaded hole, amplifying the image by adopting an amplifier to obtain a three-dimensional amplified image of the interior of the threaded hole of the industrial hardware, extracting the number of threads from the three-dimensional amplified image, respectively measuring the axial distance between each group of threads by taking two adjacent threads as a group, and marking the axial distance as，Represents the/>Numbering of group screw threads,/>Substituting it into the formula/>Obtain pitch uniformity/>Wherein/>Representing a preset standard pitch,/>Representing natural constants; by measuring the axial distance between the sets of threads, pitch uniformity information can be obtained for assessing thread manufacturing quality and consistency.
Selecting a thread gauge matched with a preset thread form, uniformly inserting the thread gauge into a threaded hole of an industrial hardware, respectively measuring the clearance between each thread line and the thread gauge, and marking asWherein/>Represents the/>The number of the thread line is the same as the number of the thread line,Simultaneously, two adjacent thread lines are taken as a group, the thread angle between each group of thread lines is measured by using a thread angle gauge, and the measured thread angle is recorded as/>Substituting it into formulaObtaining the thread form fitness/>, of the industrial hardwareWhereinIndicating the allowable clearance between the set thread and the gauge,/>Representing the set standard thread angle,/>Weight factors respectively representing clearance between thread line and thread gauge, and thread angleRepresenting the number of threads,/>A number indicating the thread group; the number of the threads is extracted by amplifying the image, and the gaps and angles between the threads are measured, so that the thread form fitness of the industrial hardware, namely the difference between the thread size and the thread gauge, can be analyzed, and the qualification degree of the industrial hardware can be determined.
The dimensional conformity of the industrial hardware is analyzed, and the formula is as follows: wherein/> Representing the preset standard bolt length and the screw hole radius,/>Weight factors respectively representing the bolt length, the radius of the threaded hole, the uniformity of the wall thickness of industrial hardware, the uniformity of the thread pitch and the consistency of thread teeth; by comprehensively considering the factors such as the length of the bolt, the radius of the threaded hole, the uniformity of the wall thickness, the uniformity of the thread pitch, the consistency of the thread profile and the like, the size and the shape of the industrial hardware can be accurately estimated, the quality of products is improved, and the quality of the products is ensured to meet the preset standard.
The specific analysis process of the color deviation degree of the industrial hardware comprises the following steps: respectively scanning and expanding the inner surface and the outer surface of the industrial hardware by utilizing a laser scanning technology to generate a planar image, and recording the planar image as an outer surface image of the industrial hardware and an inner surface image of the industrial hardware; the laser scanning technology is utilized to analyze the inner and outer surfaces of the industrial hardware, so that the whole industrial hardware can be comprehensively scanned, and a high-precision plane image can be generated.
Detecting the chromaticity value of each pixel point in the external surface image of the industrial hardware, extracting the standard chromaticity value range of the surface of the industrial hardware in the management database, comparing the chromaticity value with the chromaticity value of each pixel point in the external surface image of the industrial hardware, counting the number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, extracting the total number of pixel points of the external surface image of the industrial hardware, comparing the total number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, and obtaining the color deviation degree of the external surface of the industrial hardware, which is recorded as; By detecting the chromaticity value of the pixel points, the surface color of the industrial hardware can be accurately analyzed, so that the color difference of the workpiece can be accurately estimated.
Analyzing the internal surface image of the industrial hardware according to the analysis method of the color deviation degree of the external surface of the industrial hardware to obtain the color deviation degree of the internal surface of the industrial hardwareBy the formulaObtaining the color deviation degree/>, of the industrial hardwareWherein/>Representing a preset maximum allowable deviation degree of the color; the color of the industrial hardware is accurately detected and analyzed, the color consistency of the product can be effectively controlled, the color difference is reduced, unqualified products can be screened and adjusted by quantifying the color deviation degree, and accordingly comprehensive assessment and monitoring of the color deviation of the industrial hardware are achieved, and the overall quality and appearance effect of the product are improved.
The specific analysis method of the appearance conformity coefficient of the industrial hardware comprises the following steps: respectively reading the size conformity degree of industrial hardwareAnd degree of color deviation/>The appearance conformity coefficient of the industrial hardware is analyzed, and the formula is as follows:，/> Expressed as a natural constant.
And the deformation degree detection module is used for detecting the deformation degree of the industrial hardware in the axial direction, the radial direction and the step connection position under each pressure.
The specific analysis process of the deformation degree detection module is as follows: and (3) acquiring a three-dimensional image of the industrial hardware by utilizing a laser scanning technology, marking the three-dimensional image as an original image of the industrial hardware, applying preset different pressures to the industrial hardware along the central axis direction of the industrial hardware by utilizing a press machine, acquiring the three-dimensional image of the industrial hardware under the preset different pressures, and marking the three-dimensional image as an image of the industrial hardware under each pressure.
Comparing the industrial hardware image under each pressure with the industrial hardware original image, registering three-dimensional point cloud data of the industrial hardware image under each pressure and the industrial hardware original image by a point cloud registration algorithm to obtain each corresponding point between the industrial hardware image under each pressure and the industrial hardware original image, and calculating the distance between each corresponding point between the industrial hardware image under each pressure and the industrial hardware original imageWherein/>Represents the/>The number of the individual pressures is given,，/>Represents the/>Number of corresponding points,/>The maximum distance and the minimum distance between the image of the industrial hardware and the original image of the industrial hardware under each pressure are screened out from the image, and are respectively marked as/>、/>Substituting it into the formula/>Obtaining the axial deformation degree/>, of the industrial hardware under various pressures; The performance of the industrial hardware under different pressures can be known by comparing the deformation degree between the image of the industrial hardware and the original image under different pressures, and the pressure deformation characteristic of the industrial hardware can be evaluated and the load limit and the application condition thereof can be determined by analyzing the maximum distance and the minimum distance under each pressure.
Making a vertical line on the central axis of the industrial hardware, applying preset different pressures on the industrial hardware along the radial direction by taking the vertical line direction as the radial direction, analyzing the radial deformation degree of the industrial hardware under each pressure according to the method for analyzing the axial deformation degree of the industrial hardware under each pressure, and recording as。
Applying preset different pressures to the step connection parts of the industrial hardware, analyzing the deformation degree of the step connection parts of the industrial hardware under each pressure according to a method for analyzing the axial deformation degree of the industrial hardware under each pressure, and marking the deformation degree as; By adopting a point cloud registration algorithm to register three-dimensional point cloud data of the industrial hardware image and the original image under each pressure, accurate corresponding point matching can be realized, and therefore the axial deformation degree, the radial deformation degree and the deformation degree of the step connection position are calculated.
The compressive strength analysis module is used for analyzing and obtaining compressive strength evaluation coefficients of the industrial hardware according to the deformation degrees of the axial, radial and stepped connection parts of the industrial hardware under various pressures。
The specific analysis method of the compressive strength evaluation coefficient of the industrial hardware comprises the following steps: reading the axial deformation degree of industrial hardware under various pressuresRadial deformation degree/>, of industrial hardware under various pressuresAnd the deformation degree/>, of the step connection part of the industrial hardware under various pressuresThe compressive strength evaluation coefficient of the industrial hardware is analyzed, and the formula is as follows: wherein/> Representing a preset maximum allowable deformation degree value; by analyzing the compressive strength evaluation coefficient of the industrial hardware, the compressive strength evaluation method can help evaluate the compressive strength of the industrial hardware, judge whether the compressive strength meets the design requirement, avoid human errors possibly existing in the traditional measurement method and provide more accurate deformation information.
And the abrasion detection module is used for detecting the abrasion volume of the industrial hardware under each friction force.
The specific analysis process of the wear detection module is as follows: the method comprises the steps of obtaining a three-dimensional model of industrial hardware, applying preset different friction forces to the industrial hardware, rubbing the industrial hardware on a specific abrasive according to preset time, obtaining a three-dimensional image of the industrial hardware under each preset friction force in preset time, constructing a three-dimensional model, and recording the three-dimensional image as the industrial hardware model under each friction force.
The industrial hardware model under each friction force is subjected to overlapping comparison with the industrial hardware three-dimensional model, the volume of the industrial hardware three-dimensional model is extracted, the volume of the non-overlapping area of the industrial hardware model under each friction force and the industrial hardware three-dimensional model is extracted by utilizing an edge detection technology, and the volume is recorded as the abrasion volume of the industrial hardware under each friction force, and the abrasion volume is recorded asWherein/>Represents the/>Number of friction force,/>; By acquiring the three-dimensional model of the industrial hardware, performing overlapping comparison and abrasion volume extraction, the friction and abrasion conditions of the industrial hardware under different pressures can be estimated more accurately, the product design is improved, and the abrasion resistance and the service life of the product are improved.
The wear-resistant strength analysis module is used for obtaining the wear-resistant strength evaluation coefficient of the industrial hardware according to the analysis of the wear volume of the industrial hardware under each friction force。
The specific analysis method of the wear resistance evaluation coefficient of the industrial hardware comprises the following steps: reading the abrasion volume of industrial hardware under each friction forceBringing it to the formula/>Obtaining the wear resistance evaluation coefficient/>, of the industrial hardwareWherein/>Representing a volume of the three-dimensional model of the industrial hardware; the service life and the loss condition of the industrial hardware can be estimated more accurately by extracting the abrasion volume of the industrial hardware under each pressure, the product design quality is improved, the process flow is optimized, the trial-and-error cost is reduced, and the maintenance plan is optimized, so that the performance and the service life of the industrial hardware are improved, and the production cost and the risk are reduced.
The comprehensive evaluation index analysis module is used for analyzing and obtaining the comprehensive evaluation index of the industrial hardware according to the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, comparing the comprehensive evaluation index with a preset comprehensive evaluation index threshold value, and further obtaining the comprehensive evaluation condition of the industrial hardware and feeding back to the system.
The specific analysis process of the comprehensive evaluation index analysis module is as follows: respectively reading out the appearance conformity coefficient of the industrial hardwareCompressive Strength evaluation coefficient of Industrial hardware/>And the wear resistance evaluation coefficient/>, of industrial hardwareBy the formula/>Obtaining a comprehensive evaluation index of the industrial hardware, wherein/>Weight factors respectively representing the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, and/>; The quality of the hardware can be objectively evaluated by respectively reading the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware and combining the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient into the comprehensive evaluation index, so that subjectivity and unilateral property evaluated by only one index are avoided.
Comparing the comprehensive evaluation index of the industrial hardware with a preset comprehensive evaluation index threshold, if the comprehensive evaluation index of the industrial hardware is larger than or equal to the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is qualified, and if the comprehensive evaluation index of the industrial hardware is smaller than the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is unqualified, and feeding back the comprehensive evaluation of the hardware to the system; for unqualified hardware of comprehensive evaluation, the result is fed back to the system, so that quality problems can be found in time and corresponding corrective measures can be taken, the occurrence of product quality problems can be reduced, and safety risks and cost losses caused by low-quality hardware can be reduced.
And the management database is used for storing standard chromaticity value ranges of the surfaces of the industrial hardware.
The system obtains the appearance conformity coefficient of the industrial hardware through the size conformity degree and the color deviation degree analysis of the industrial hardware, obtains the compressive strength evaluation coefficient of the industrial hardware through the axial, radial and stepped joint deformation degree analysis of the industrial hardware under various pressures, obtains the wear resistance evaluation coefficient of the industrial hardware through the wear volume analysis of the industrial hardware under various friction forces, and further obtains the comprehensive evaluation index of the industrial hardware, thereby judging the quality condition of the product, improving the objective evaluation capability of the quality of the industrial hardware, reducing the quality risk, and improving the consistency and the stability of the product.
The foregoing is merely illustrative and explanatory of the principles of this invention, as various modifications and additions may be made to the specific embodiments described, or similar arrangements may be substituted by those skilled in the art, without departing from the principles of this invention or beyond the scope of this invention as defined in the claims.
Claims (1)
1. An industrial hardware detects MES data acquisition analysis system, characterized by comprising:
The appearance parameter acquisition module is used for acquiring appearance parameters of the industrial hardware, wherein the appearance parameters comprise size data and chromaticity data;
appearance parameter analysis module for obtaining dimension conformity according to dimension data of industrial hardware Obtaining the color deviation degree/>, based on the chromaticity dataFurther analyzing and obtaining the appearance conformity coefficient/>, of the industrial hardware；
The deformation degree detection module is used for detecting the deformation degree of the industrial hardware in the axial direction, the radial direction and the step connection position under each pressure;
the compressive strength analysis module is used for analyzing and obtaining compressive strength evaluation coefficients of the industrial hardware according to the deformation degrees of the axial, radial and stepped connection parts of the industrial hardware under various pressures ；
The abrasion detection module is used for detecting the abrasion volume of the industrial hardware under each friction force;
The wear-resistant strength analysis module is used for obtaining the wear-resistant strength evaluation coefficient of the industrial hardware according to the analysis of the wear volume of the industrial hardware under each friction force ；
The comprehensive evaluation index analysis module is used for analyzing and obtaining the comprehensive evaluation index of the industrial hardware according to the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, comparing the comprehensive evaluation index with a preset comprehensive evaluation index threshold value, and further obtaining the comprehensive evaluation condition of the industrial hardware and feeding back to the system;
The management database is used for storing a standard chromaticity value range of the surface of the industrial hardware;
The dimension data of the industrial hardware comprises the appearance parameters and the thread parameters of the hardware, wherein the appearance parameters comprise bolt length, threaded hole radius and wall thickness uniformity, and the thread parameters comprise thread pitch uniformity and thread form fitness;
the specific analysis process of the dimensional conformity of the industrial hardware comprises the following steps:
Three-dimensional measurement is carried out on the industrial hardware by a laser scanning technology, a three-dimensional model is built for the industrial hardware, the three-dimensional model is recorded as the three-dimensional model of the industrial hardware, the bolt length and the radius of the threaded hole of the industrial hardware are read from the three-dimensional model, and the three-dimensional model is respectively recorded as the three-dimensional model of the industrial hardware 、/>；
Determining the central axis of a threaded hole in a three-dimensional model of the industrial hardware, cutting the industrial hardware into a plurality of tangential planes, taking the tangential planes as threaded holes corresponding to all measurement planes, taking the intersection point of the central axis passing through all measurement planes as the circle center, taking the circle center of the threaded holes corresponding to all measurement planes as rays corresponding to the measurement planes, recording the rays as the circle center of all measurement planes, further obtaining the intersection point of the circle center rays of all measurement planes and the inner wall of the threaded holes and the intersection point of the outer wall of the threaded holes, respectively recording the rays as all inner wall measurement points and all outer wall measurement points, respectively measuring the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points, obtaining the distance between all inner wall measurement points and all outer wall measurement points by taking the difference between the horizontal distances from the circle center to all inner wall measurement points and all outer wall measurement points as the wall thickness of all measurement pointsWherein/>Represents the/>Number of measurement points,/>The average wall thickness of each measuring point is obtained to obtain the average wall thickness/>, of the industrial hardwareSubstituting it into formulaObtaining the wall thickness uniformity/>, of the industrial hardware，/>Representing the number of measurement points;
The method comprises the steps of obtaining an image of an industrial hardware by utilizing a laser scanning technology, focusing the image of the industrial hardware in a threaded hole, amplifying the image by adopting an amplifier to obtain a three-dimensional amplified image of the interior of the threaded hole of the industrial hardware, extracting the number of threads from the three-dimensional amplified image, respectively measuring the axial distance between each group of threads by taking two adjacent threads as a group, and marking the axial distance as ，/>Represents the/>Numbering of group screw threads,/>Substituting it into the formula/>Obtain pitch uniformity/>Wherein/>Representing a preset standard pitch,/>Representing natural constants;
selecting a thread gauge matched with a preset thread form, uniformly inserting the thread gauge into a threaded hole of an industrial hardware, respectively measuring the clearance between each thread line and the thread gauge, and marking as Wherein/>Represents the/>The number of the thread line is the same as the number of the thread line,Simultaneously, two adjacent thread lines are taken as a group, the thread angle between each group of thread lines is measured by using a thread angle gauge, and the measured thread angle is recorded as/>Substituting it into formulaObtaining the thread form fitness/>, of the industrial hardwareWhereinIndicating the allowable clearance between the set thread and the gauge,/>Representing the set standard thread angle,/>Weight factors respectively representing clearance between thread line and thread gauge, and thread angleRepresenting the number of threads,/>A number indicating the thread group;
the dimensional conformity of the industrial hardware is analyzed, and the formula is as follows: wherein/> Representing the preset standard bolt length and the screw hole radius,/>Weight factors respectively representing the bolt length, the radius of the threaded hole, the uniformity of the wall thickness of industrial hardware, the uniformity of the thread pitch and the consistency of thread teeth;
the specific analysis process of the color deviation degree of the industrial hardware comprises the following steps:
Respectively scanning and expanding the inner surface and the outer surface of the industrial hardware by utilizing a laser scanning technology to generate a planar image, and recording the planar image as an outer surface image of the industrial hardware and an inner surface image of the industrial hardware;
Detecting the chromaticity value of each pixel point in the external surface image of the industrial hardware, extracting the standard chromaticity value range of the surface of the industrial hardware in the management database, comparing the chromaticity value with the chromaticity value of each pixel point in the external surface image of the industrial hardware, counting the number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, extracting the total number of pixel points of the external surface image of the industrial hardware, comparing the total number of pixel points with the chromaticity value not in the standard chromaticity value range of the surface of the industrial hardware, and obtaining the color deviation degree of the external surface of the industrial hardware, which is recorded as ；
Analyzing the internal surface image of the industrial hardware according to the analysis method of the color deviation degree of the external surface of the industrial hardware to obtain the color deviation degree of the internal surface of the industrial hardwareBy the formulaObtaining the color deviation degree/>, of the industrial hardwareWherein/>Representing a preset maximum allowable deviation degree of the color;
the specific analysis method of the appearance conformity coefficient of the industrial hardware comprises the following steps:
Respectively reading the size conformity degree of industrial hardware And degree of color deviation/>The appearance conformity coefficient of the industrial hardware is analyzed, and the formula is as follows: /(I)，/>Expressed as natural constants;
The specific analysis process of the deformation degree detection module is as follows:
The method comprises the steps of obtaining three-dimensional images of industrial hardware by utilizing a laser scanning technology, marking the three-dimensional images as original images of the industrial hardware, applying preset different pressures to the industrial hardware along the central axis direction of the industrial hardware by utilizing a press machine, obtaining the three-dimensional images of the industrial hardware under the preset different pressures, and marking the three-dimensional images as images of the industrial hardware under each pressure;
comparing the industrial hardware image under each pressure with the industrial hardware original image, registering three-dimensional point cloud data of the industrial hardware image under each pressure and the industrial hardware original image by a point cloud registration algorithm to obtain each corresponding point between the industrial hardware image under each pressure and the industrial hardware original image, and calculating the distance between each corresponding point between the industrial hardware image under each pressure and the industrial hardware original image Wherein/>Represents the/>The number of the individual pressures is given,，/>Represents the/>Number of corresponding points,/>The maximum distance and the minimum distance between the image of the industrial hardware and the original image of the industrial hardware under each pressure are screened out from the image, and are respectively marked as/>、/>Substituting it into the formula/>Obtaining the axial deformation degree of the industrial hardware under various pressures；
Making a vertical line on the central axis of the industrial hardware, applying preset different pressures on the industrial hardware along the radial direction by taking the vertical line direction as the radial direction, analyzing the radial deformation degree of the industrial hardware under each pressure according to the method for analyzing the axial deformation degree of the industrial hardware under each pressure, and recording as；
Applying preset different pressures to the step connection parts of the industrial hardware, analyzing the deformation degree of the step connection parts of the industrial hardware under each pressure according to a method for analyzing the axial deformation degree of the industrial hardware under each pressure, and marking the deformation degree as；
The specific analysis method of the compressive strength evaluation coefficient of the industrial hardware comprises the following steps:
reading the axial deformation degree of industrial hardware under various pressures Radial deformation degree of industrial hardware under various pressuresAnd the deformation degree/>, of the step connection part of the industrial hardware under various pressuresThe compressive strength evaluation coefficient of the industrial hardware is analyzed, and the formula is as follows: /(I)Wherein/>Representing a preset maximum allowable deformation degree value;
the specific analysis process of the wear detection module is as follows:
Acquiring a three-dimensional model of the industrial hardware, applying preset different friction forces to the industrial hardware, rubbing the industrial hardware on a specific abrasive according to preset time length, acquiring a three-dimensional image of the industrial hardware under each preset friction force of the preset time length, constructing a three-dimensional model, and marking the three-dimensional model as the industrial hardware model under each friction force;
The industrial hardware model under each friction force is subjected to overlapping comparison with the industrial hardware three-dimensional model, the volume of the industrial hardware three-dimensional model is extracted, the volume of the non-overlapping area of the industrial hardware model under each friction force and the industrial hardware three-dimensional model is extracted by utilizing an edge detection technology, and the volume is recorded as the abrasion volume of the industrial hardware under each friction force, and the abrasion volume is recorded as Wherein/>Represent the firstNumber of friction force,/>；
The specific analysis method of the wear resistance evaluation coefficient of the industrial hardware comprises the following steps:
Reading the abrasion volume of industrial hardware under each friction force Bringing it into the formulaObtaining the wear resistance evaluation coefficient/>, of the industrial hardwareWherein/>Representing a volume of the three-dimensional model of the industrial hardware;
the specific analysis process of the comprehensive evaluation index analysis module is as follows:
respectively reading out the appearance conformity coefficient of the industrial hardware Compressive Strength evaluation coefficient of Industrial hardware/>And the wear resistance evaluation coefficient/>, of industrial hardwareBy the formula/>Obtaining a comprehensive evaluation index of the industrial hardware, wherein/>Weight factors respectively representing the appearance conformity coefficient, the compressive strength evaluation coefficient and the wear resistance evaluation coefficient of the industrial hardware, and/>；
And comparing the comprehensive evaluation index of the industrial hardware with a preset comprehensive evaluation index threshold, if the comprehensive evaluation index of the industrial hardware is larger than or equal to the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is qualified, and if the comprehensive evaluation index of the industrial hardware is smaller than the preset comprehensive evaluation index threshold, indicating that the comprehensive evaluation of the hardware is unqualified, and feeding back the comprehensive evaluation of the hardware to the system.
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