Large casting surface cleaning robot system and method based on 3D vision

Abstract

The invention relates to the technical field of large casting surface cleaning, in particular to a large casting surface cleaning robot system and method based on 3D vision. According to the technical scheme, the large casting surface cleaning robot system comprises a rotary working platform, a rotary assembly, a robot and a processing assembly, and the processing assembly is arranged on a swing arm of the robot; the system further comprises a visual scanning assembly, a comparative analysis module and a control module, the robot drives the visual scanning assembly to scan a casting, and three-dimensional grid data of the casting to be machined are obtained; the contrastive analysis module receives the three-dimensional grid data and carries out contrastive analysis on the three-dimensional grid data to obtain processing path data, the control module receives the processing path data and forms a control signal based on the processing path data, and the control signal is sent to the rotating assembly, the robot and the processing assembly. The casting surface defect treatment method has the effect of improving the casting surface defect treatment efficiency and the casting surface defect treatment precision.

Description

Technical Field

[0001] The present invention relates to the technical field of large casting surface cleaning, and in particular to a large casting surface cleaning robot system and method based on 3D vision. Background Art

[0002] Large castings usually refer to metal parts that are larger in size and heavier in weight and are manufactured through casting processes. These castings are usually used in machinery manufacturing, aerospace, automobiles, ships, energy and infrastructure and other fields. For example, with the development of clean energy in recent years, wind power generation facilities have been promoted, and the construction of these facilities is inseparable from the use of large castings.

[0003] Among them, commonly used casting methods for castings include sand casting, resin sand casting, metal mold casting and precision casting. For the production of large castings, resin sand casting technology is usually used. The resin sand casting process usually goes through the steps of mold preparation, resin sand molding and core making, smelting and pouring, solidification and cooling, sand removal and cleaning, and inspection and post-processing. The resin sand casting process is widely used in the production of large castings because of its advantages such as high casting size accuracy, clear external contour and easy demolding.

[0004] However, there is still much room for improvement in the post-processing stage of castings. The surface defects of large castings mainly include sand adhesion, sand inclusion, burrs, seams, pouring nozzles, sand holes, pores and surface unevenness. The existing methods usually adopt manual processing, which makes the whole processing process time-consuming and labor-intensive. In addition, manual work may bring about the problem of uncontrollable processing accuracy. Therefore, it is necessary to improve the existing technology.

[0005] The above information is presented as background information only to assist with understanding the present disclosure and no determination or admission is made as to whether any of the above may be used as prior art with respect to the present disclosure. Summary of the invention

[0006] The present invention provides a large casting surface cleaning robot system and method based on 3D vision to solve the problems existing in the prior art.

[0007] In a first aspect, the present invention provides a large casting surface cleaning robot system based on 3D vision, including the following technical solutions:

[0008] A large casting surface cleaning robot system based on 3D vision, comprising:

[0009] Rotating work platform for placing castings;

[0010] A rotating assembly, used to drive the rotating working platform to drive the casting to rotate horizontally;

[0011] a robot, adjacent to the rotating assembly;

[0012] A processing component, disposed on the swing arm of the robot, for processing surface defects of the casting;

[0013] A visual scanning component is arranged on the swing arm of the robot, and the robot is used to drive the visual scanning component to scan the casting to obtain three-dimensional grid data of the casting to be processed;

[0014] A comparison and analysis module and a control module, wherein the comparison and analysis module is connected to the visual scanning component and the control module respectively, and the comparison and analysis module receives the three-dimensional mesh data collected by the visual scanning component, and is used to compare and analyze the three-dimensional mesh data of the casting to be processed with the three-dimensional mesh data of the finished part to obtain processing path data, and send the processing path data to the control module;

[0015] The control module is connected to the rotating component, the robot and the processing component respectively. The control module receives the processing path data and forms a control signal based on the processing path data, and is used to send the control signal to the rotating component, the robot and the processing component respectively, so that the rotating component, the robot and the processing component can process the surface defects of the casting along the processing path.

[0016] Preferably, the processing component comprises

[0017] A water jet head is arranged on the swing arm of the robot;

[0018] A high-pressure pump, connected to the water jet head, for pumping high-pressure water to the water jet head;

[0019] And a water treatment component, which has a water storage cavity inside, the high-pressure pump is arranged on the water treatment component and takes water through the water storage cavity.

[0020] Preferably, the water treatment component comprises:

[0021] A water storage tank, the interior of which is hollow to form a water storage cavity, one side of the water storage cavity is provided with a reflux port, the rotating working platform is provided with a flow channel for water to flow down, the flow channel is connected with the reflux port through a reflux pipe;

[0022] a partition plate, disposed in the water storage chamber, for dividing the water storage chamber into a first water storage portion and a second water storage portion, wherein the first water storage portion is connected to the reflux port, and the first water storage portion is used for precipitating impurities;

[0023] And a water pump, located in the first water storage part and connected to the second water storage part, is used to pump the supernatant located in the upper layer of the first water storage part into the second water storage part. The high-pressure pump is located in the second water storage part.

[0024] Preferably, the water treatment component further comprises a sewage pump connected to the bottom of the first water storage part for sucking out precipitated impurities.

[0025] Preferably, the processing component comprises:

[0026] A plasma cutter is arranged on the swing arm of the robot;

[0027] A plasma generator connected to the plasma cutter and used to drive the plasma cutter to spray a plasma jet;

[0028] And a control element is connected to the plasma generator and the plasma cutter and is used to control the plasma generator and the plasma cutter to generate a plasma arc.

[0029] Preferably, the processing component further comprises an alloy grinding wheel grinder, and the alloy grinding wheel grinder is arranged on the swing arm of the robot.

[0030] Preferably, the processing component and the visual scanning component are connected to the robot via a switching component, and the switching component comprises:

[0031] A bracket, fixedly arranged on the swing arm of the robot;

[0032] At least two rotating racks, for mounting the processing assembly and the visual scanning assembly respectively, and rotatably disposed on one side of the bracket;

[0033] and a driving component, wherein the driving component is used to drive the rotating frame to rotate, and the rotating frame includes at least two states:

[0034] In the first state, one group of the rotating frames drives the processing components to be folded relative to the bracket, and another group of the rotating frames drives the visual scanning components to be opened relative to the bracket and perform a scanning operation on the casting;

[0035] In the second state, one group of the rotating frames drives the visual scanning assembly to be folded relative to the bracket, and another group of the rotating frames drives the processing assembly to be opened relative to the bracket and performs processing operations on the casting.

[0036] Preferably, the bracket has a first step surface and a second step surface respectively abutting and limiting the rotating frame. When the first step surface abuts against the rotating frame, the rotating frame is opened compared to the bracket, and when the second step surface abuts against the rotating frame, the rotating frame is folded compared to the bracket.

[0037] In a second aspect, the present invention provides a processing method comprising the following technical solutions:

[0038] A surface cleaning method using a large casting surface cleaning robot system based on 3D vision includes the following steps:

[0039] Loading castings: hoisting the castings to the middle of the rotating working platform;

[0040] Scanning modeling: the rotating work platform is driven by the rotating component to rotate the casting, and the visual scanning component scans the casting in all directions along the circumference of the workpiece and generates three-dimensional mesh data. The number of complete scans is at least two times;

[0041] Analysis and comparison: the comparison and analysis module compares and analyzes the three-dimensional mesh data of the casting to be processed with the three-dimensional mesh data of the finished part to obtain processing path data, and sends the processing path data to the control module;

[0042] Surface treatment, the control module generates a control signal based on the processing path data, and sends the control signal to the rotating component, the robot and the processing component, the rotating component drives the rotating work platform to rotate to adjust the processing position, and the robot drives the processing component to perform one or more of sand removal, cutting and grinding on the surface defects, and a separate scanning modeling step and an analysis and comparison step are performed before performing a cleaning;

[0043] The castings are unloaded and hoisted after processing.

[0044] Preferably, when the processing component processes the surface defects, the processing is carried out in the order of sand cleaning, cutting and grinding.

[0045] Compared with the prior art, the present invention has the following beneficial effects: the visual scanning component automatically scans the casting to be processed to form three-dimensional grid data, and the processing path can be quickly obtained through the contrast effect of the comparison analysis module. At this time, based on the automatic control effect of the control module, the rotating component, the robot and the processing component can be controlled to operate together. The rotating component drives the casting to rotate to adjust the processing angle, and the robot drives the processing component to move along the processing path, so that the processing component automatically processes the defects on the surface of the casting. The whole process is quick and convenient with a high degree of automation. The overall processing accuracy can be well maintained during long-term processing, thereby well solving the time-consuming, labor-intensive and uncontrollable precision problems caused by manual processing.

[0046] The present invention has other features and advantages, which will be apparent from or will be described in detail in the accompanying drawings and the following detailed description incorporated herein, which together serve to explain the specific principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0048] Figure 1 It is a structural schematic diagram of a large casting surface cleaning robot system based on 3D vision provided by a preferred embodiment of the present invention;

[0049] Figure 2 It is a structural schematic diagram of a rotating working platform, a rotating assembly and a casting provided by a preferred embodiment of the present invention;

[0050] Figure 3 It is a structural schematic diagram of a rotating working platform, a robot and a water treatment component provided by a preferred embodiment of the present invention;

[0051] Figure 4 It is a structural schematic diagram of a switching component and a processing component provided by a preferred embodiment of the present invention;

[0052] Figure 5 It is a structural schematic diagram of a switching component and a processing component from another perspective provided by a preferred embodiment of the present invention.

[0053] Reference numerals:

[0054] 1. Rotating work platform; 11. Flow channel; 2. Rotating assembly; 21. Speed ​​reduction motor; 22. Gear; 23. Ring gear; 3. Robot;

[0055] 4. Processing components;

[0056] 41. Water cutter head; 42. High-pressure pump; 43. Water treatment component; 431. Water storage tank; 4311. Return port; 432. Baffle; 433. Water pump; 434. Sewage pump;

[0057] 44. Plasma cutter;

[0058] 45. Alloy grinding wheel grinder;

[0059] 5. Visual scanning component;

[0060] 6. Switching assembly; 61. Bracket; 611. Threading hole; 612. First step surface; 613. Second step surface; 62. Rotating frame; 63. Driving component. DETAILED DESCRIPTION

[0061] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0062] In the description of the present invention, it is to be understood that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally disposed component. When a component is considered to be "disposed on" another component, it may be directly disposed on the other component or there may be a centrally disposed component.

[0063] In addition, terms such as "long", "short", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings and are only used to facilitate the description of the present invention. They do not indicate or imply that the device or component referred to must have this specific direction or operate with a specific direction structure, and should not be understood as a limitation of the present invention.

[0064] The following is combined with Figure 1-5 The technical solution of the present invention is further illustrated by specific implementation methods.

[0065] Reference Figure 1The present embodiment discloses a large casting surface cleaning robot system based on 3D vision, including a rotating work platform 1, a rotating component 2, a robot 3 and a processing component 4. The rotating work platform 1, the rotating component 2, the robot 3 and the processing component 4 cooperate with each other to process the surface defects of the casting. It can be understood that the surface defects of the casting include but are not limited to surface defects such as seams and pouring risers. The rotating work platform 1, the rotating component 2, the robot 3 and the processing component 4 are first used to process the above two defects.

[0066] Among them, the rotating work platform 1 can be rotatably installed on the ground. Specifically, the rotating work platform 1 in this embodiment is a circular platform structure, and a base is pre-buried in the ground. The rotating work platform 1 has a rotating shaft arranged in the vertical direction, and a bearing is installed on the base. The rotating shaft is connected to the bearing. Under the support of the base and with the mutual cooperation of the rotating shaft and the bearing, the rotating work platform 1 can rotate horizontally. At this time, the casting to be processed can be hoisted to the middle of the rotating work platform 1.

[0067] On the one hand, the rotating work platform 1 can place the casting, and on the other hand, the rotating work platform 1 can drive the casting to rotate horizontally during its rotation, which is beneficial for adjusting the processing angle during the subsequent surface treatment process.

[0068] It is understandable that the casting is preferably placed in the middle of the rotating work platform 1. In some other embodiments, a fixture structure can also be installed on the top of the rotating work platform 1 to position the casting through the fixture structure to ensure that it is located in the middle of the rotating work platform 1. When the casting is located in the middle of the rotating work platform 1, the eccentric rotation of the casting during rotation can be reduced to facilitate the smooth processing action.

[0069] Reference Figure 2 Furthermore, the rotating assembly 2 is adjacent to the rotating working platform 1 and connected to the rotating working platform 1. The rotating assembly 2 is used to drive the rotating working platform 1 to rotate horizontally, thereby driving the casting to rotate horizontally.

[0070] Specifically, the rotating assembly 2 mainly includes a reduction motor 21, a gear 22, a ring gear 23 and other component structures, wherein the reduction motor 21 can be assembled on the ground and set adjacent to the rotating work platform 1, and the ring gear 23 is fixed at the periphery of the rotating work platform 1. At this time, the gear 22 is fixedly installed on the output shaft of the reduction motor 21, and the gear 22 is meshed with the ring gear 23; based on the above arrangement, the reduction motor 21 can stably output torque to drive the gear 22 to rotate, and then can accurately drive the rotating work platform 1 to rotate through the ring gear 23, so as to achieve the effect of adjusting the processing angle of the casting.

[0071] Further, look back Figure 1 The surface treatment of the casting surface is mainly achieved through the robot 3 and the processing component 4, wherein the robot 3 is arranged on one side of the rotating work platform 1. In the present embodiment, the robot 3 adopts a five-axis robot 3, which has excellent freedom of movement, can perform relatively complex processing actions, and can well meet the actual processing needs; at the same time, the processing component 4 adopts one or more of plasma elements, water jet cutting elements and grinding elements. The processing component 4 is arranged on the swing arm of the robot 3, and its main function is to cut or grind surface defects such as seams and pouring risers. The specific setting method is not limited here, and the elements that can achieve the above-mentioned removal effect should be included in the interpretation scope of the processing component 4.

[0072] Here, based on the above settings, the robot 3 can drive the processing component 4 to process the surface defects of the casting along a certain contour, and continuously adjust the processing angle of the casting in combination with the rotating working platform 1, and gradually complete the surface treatment of the entire casting.

[0073] It is understandable that it is difficult to achieve fully automated defect processing actions by relying solely on the above mechanical structure. Therefore, in order to improve the overall processing efficiency and processing accuracy, the system also includes a visual scanning component 5, a comparison and analysis module, and a control module.

[0074] Among them, the visual scanning component 5 mainly adopts a 3D contour scanning camera. The visual scanning component 5 is installed on the swing arm of the robot 3. First, the working platform 1 is rotated to drive the casting to be processed to rotate. During this process, the robot 3 can drive the visual scanning component 5 toward the casting and drive the visual scanning component 5 to scan the casting until the visual scanning component 5 performs a 360-degree multi-angle scan on the casting to obtain the three-dimensional grid data of the casting to be processed.

[0075] At the same time, the comparison and analysis module can use a computer device, and processing software is installed on the computer device. At this time, the comparison and analysis module is electrically connected to the visual scanning component 5 so that the comparison and analysis module can receive the three-dimensional grid data collected by the visual scanning component 5, and process the three-dimensional grid data collected by the visual scanning component 5 through the processing software, and finally obtain the processing path.

[0076] It can be understood that, usually when processing data, the three-dimensional mesh data of the finished parts can be entered into the processing software in advance, and then the three-dimensional mesh data of the casting to be processed is compared and analyzed with the three-dimensional mesh data of the finished parts. According to the Boolean subtraction method, the overlapping parts of the two are removed, and the remaining part is the contour of surface defects such as seams or pouring nozzles. Then, the root contour of the surface defect is selected as a reference to obtain the processing path of the surface defect, and further obtain the processing path data.

[0077] Then, the control module is electrically connected to the comparison and analysis module, and the control module is electrically connected to the rotating component 2, the robot 3 and the processing component 4 respectively; here, the control module mainly performs control actions, and preferably, the control module can adopt a PLC control module.

[0078] Under the above-mentioned setting conditions, the comparison and analysis module sends the processing path data to the control module; the control module receives the processing path data and forms a control signal based on the processing path data, and then the control module sends the control signal to the rotating component 2, the robot 3 and the processing component 4 respectively, so that the rotating component 2, the robot 3 and the processing component 4 process the surface defects of the casting along the processing path.

[0079] Based on the above implementation, the automated processing of castings can be achieved by combining 3D scanning with automated control, so that the processing efficiency and accuracy of surface defects are optimized and improved, solving the time-consuming and labor-intensive problem in manual processing.

[0080] Reference Figure 3 and Figure 4 In one embodiment, the processing component 4 can use a water jet cutting method to remove surface defects. Water jet cutting is a cold cutting method. It does not produce thermal effects, deformation, slag, or ablation during cutting, and does not change the physical and chemical properties of the material. Therefore, the cutting accuracy is relatively high.

[0081] Specifically, the processing component 4 mainly includes two parts: a water cutter head 41 and a high-pressure pump 42. The water cutter head 41 can be directly installed on the swing arm of the robot 3, and the robot 3 drives the water cutter head 41 to move along the processing path. In addition, the high-pressure pump 42 is connected to the water cutter head 41 through a pipeline, and the high-pressure pump 42 is connected to the water source. At this time, the high-pressure pump 42 can pump high-pressure water to the water cutter head 41, and then the water cutter head 41 can achieve cutting. The setting is simple and convenient, and can well meet the actual use needs.

[0082] Furthermore, in order to reduce the waste of water resources, the processing component 4 also includes a water treatment component 43. For the sake of distinction, the water body required in the cutting process is referred to as cutting fluid. At this time, the water treatment component 43 has a water storage cavity for storing the cutting fluid inside, which can form a water source for the high-pressure pump 42. The high-pressure pump 42 is arranged on the water treatment component 43 and takes water through the water storage cavity. The key point is that in this solution, the water treatment component 43 can not only store the cutting fluid, but also collect the cutting fluid flowing out during the water jet cutting process to achieve the effect of recycling.

[0083] Specifically, the water treatment component 43 includes a water tank 431, a partition 432 and a water pump 433. The water tank 431 can be pre-buried under the ground and set below the horizontal position of the rotating working platform 1; at the same time, the interior of the water tank 431 is hollow to form a water storage cavity, one side of the water storage cavity has a return port 4311, and the rotating working platform 1 has a flow channel 11 for water flow to fall (combined with Figure 2 ), the flow channel 11 passes through the rotating working platform 1 in the vertical direction for water flow; furthermore, a drainage ditch may be provided on the ground below the rotating working platform 1, the drainage ditch is inclined, the lower end of the drainage ditch is connected to a return pipe, and the other end of the return pipe is connected to the return port 4311.

[0084] Based on the above arrangement, the cutting fluid in the water jet cutting process can enter the drain ditch from the flow channel 11, and flow back to the water storage chamber through the drain ditch and the reflux pipe, and then be pumped to the water jet head 41 by the high-pressure pump 42 to realize the recycling of the cutting fluid.

[0085] In addition, in the actual application process, debris and impurities may be generated during cutting. If these impurities are sucked into the high-pressure pump 42, they may cause certain damage to the high-pressure pump 42. In order to overcome the above technical obstacles, the present embodiment arranges the partition 432 in the water storage chamber; specifically, the partition 432 is arranged in the vertical direction and is fixedly connected to the water tank 431. At this time, the partition 432 separates the water storage chamber into a first water storage part and a second water storage part, wherein the first water storage part is connected to the reflux port 4311, and the refluxed cutting fluid first flows into the first water storage part through the reflux port 4311. Impurities can be precipitated in the first water storage part, and the liquid located in the upper part of the water body is generally clear liquid at this time.

[0086] At the same time, the water pump 433 is used to pump the water in the upper part of the first water storage part to the second water storage part. Specifically, the water pump 433 is located in the first water storage part and is connected to the second water storage part; in the specific setting, the first aspect can install an air bag on the water pump 433 so that the water pump 433 can rise and fall with the liquid level to facilitate the absorption of the cutting liquid. Under this condition, the water pump 433 can give priority to the supernatant to meet the actual working conditions.

[0087] Secondly, a pipeline structure connected to the second water storage part is also installed on the water pump 433. The water pump 433 pumps the supernatant liquid to the second water storage part through the pipeline. Based on this, the high-pressure pump 42 is arranged in the second water storage part, and then the clear liquid can be pumped to the water knife head 41, overcoming the destructive effects of impurities and solving the technical obstacles mentioned above.

[0088] Continue to refer to Figure 3During long-term use, impurities may accumulate more and more in the first water storage part, which will affect the quality of the supernatant in the long run. Based on this, the water treatment component 43 also includes a sewage pump 434, and a sewage outlet is opened at the bottom of the first water storage part. The sewage pump 434 is connected to the sewage outlet through a pipe, and then connected to the bottom of the first water storage part. Starting the sewage pump 434 can suck out the precipitated impurities and achieve a regular sewage discharge effect.

[0089] Optionally, an electromagnetic valve may be provided at the sewage outlet to facilitate control of the opening and closing of the sewage outlet.

[0090] Reference Figure 4 In another embodiment, the processing component 4 can also adopt a plasma cutting method. The difference from water jet cutting is that the plasma cutting method has a greater energy density and a higher cutting rate. In addition, because plasma cutting adopts a plasma jet injection method, while achieving a cutting effect, it can also heat and clean the sand layer remaining on the surface of the casting after demolding, and has a higher energy efficiency.

[0091] Specifically, in this embodiment, the processing component 4 includes a plasma cutter 44, a plasma generator, and a control element. The plasma cutter 44 is installed on the swing arm of the robot 3, and the plasma cutter 44 is responsible for spraying plasma and oxidant onto the metal material for cutting; specifically, the plasma cutter 44 includes a nozzle and an electrode, and the electrode is used to generate an arc.

[0092] At the same time, the plasma generator is connected to the plasma cutter 44. The plasma generator is used to heat the gas to a high temperature state. Under the action of the electrode, high-frequency arc discharge is used to excite the gas molecules into ions with positive and negative charges, thereby forming a plasma beam. The plasma cutter 44 can spray a plasma jet with the assistance of the plasma generator.

[0093] The control element is connected to the plasma generator and the plasma cutter 44 respectively to control the plasma generator to generate a plasma arc. The control element mainly includes a gas control part, also known as a gas control system. The gas control system is responsible for controlling the flow and pressure of the gas to ensure the stability and effect during the cutting process. The gas control system can adjust the type and flow of the gas as needed to meet the cutting requirements of different materials.

[0094] At this time, the control element, the plasma cutter 44 and the plasma generator are connected to a power source, and the jet injection and control are achieved under the action of the electric energy provided by the power source.

[0095] It is understandable that during the plasma cutting process, due to the high-energy heat in the plasma jet, the body of the casting may be heated. Based on this, a portion of margin space can be reserved during cutting, such as a margin spacing of 3mm to 10mm, to reduce damage to the body of the casting.

[0096] Further, continue to refer to Figure 4 Regardless of whether water jet cutting or plasma cutting is used, there will be some burrs at the cutting position of the surface defects. In order to improve the overall processing effect, the processing component 4 also includes an alloy grinding wheel grinder 45. The alloy grinding wheel grinder 45 is also on the swing arm of the robot 3. The alloy grinding wheel grinder 45 can supplement the grinding of the burr structure based on the processing path, and the processing quality is further optimized and improved.

[0097] In practical applications, in order to further improve the cutting progress, it is preferred to install the processing component 4 and the visual scanning component 5 on the swing arm of the robot 3 at the same time, so that different components can obtain the same installation reference, which can effectively reduce the motion errors of different components in the process of connecting different actions.

[0098] However, the installation position of the swing arm of the robot 3 is limited. In order to overcome this problem, the processing component 4 and the visual scanning component 5 are connected to the robot 3 through a switching component 6. The switching component 6 is used to switch the processing component 4 and the visual scanning component 5 to solve the problem of installation difficulties.

[0099] Reference Figure 4 and Figure 5 The switching assembly 6 includes a bracket 61, a rotating frame 62 and a driving component 63. The bracket 61 is fixedly mounted on the swing arm of the robot 3, and the rotating frame 62 is rotatably mounted on one side of the bracket 61. Specifically, the rotating frame 62 is rotatably mounted on the peripheral side of the bracket 61. At this time, the rotating frame 62 can be opened outward and folded inward compared to the bracket 61.

[0100] In addition, the specific number of rotating racks 62 is at least two, wherein the two rotating racks 62 are respectively used to install the processing component 4 and the visual scanning component 5. By adjusting the relative positions of different rotating racks 62, the switching action of the processing component 4 and the visual scanning component 5 is realized.

[0101] It should be explained that, in the process of setting the processing assembly 4, different specific combinations can be selected according to different processing requirements. In this case, the number of rotating racks 62 needs to correspond to the number of different functions.

[0102] For example, in this embodiment, in order to perform more complex processing functions, the processing component 4 also includes a water jet head 41, a plasma cutter 44 and an alloy grinding wheel grinder 45. Correspondingly, the number of rotating frames 62 is four. The water jet head 41, the plasma cutter 44 and the alloy grinding wheel grinder 45 are correspondingly installed on three of the rotating frames 62, and the visual scanning component 5 is installed on the remaining rotating frame 62.

[0103] At the same time, the switching action of the rotating frame 62 is mainly realized by the driving component 63. The number of the driving component 63 is also adapted to the rotating frame 62. No specific details are given here. The driving component 63 mainly includes a motor. The output shaft of the motor is connected to the rotating frame 62, thereby controlling the rotating frame 62 to rotate.

[0104] It should be noted that when the rotating frames 62 are specifically set, they need to be evenly spaced along the circumference of the bracket 61. Due to limited space, during the specific operation, one of the rotating frames 62 needs to be driven to open separately, and the other rotating frames 62 need to be folded compared to the bracket 61 to avoid interference between the structures.

[0105] At this time, during the scanning or processing operation, the plurality of rotating racks 62 include at least two states:

[0106] In the first state, one set of rotating frames 62 drives the processing assembly 4 to be folded relative to the bracket 61, and the other set of rotating frames 62 drives the visual scanning assembly 5 to be opened relative to the bracket 61 and perform a scanning operation on the casting;

[0107] In the second state, one group of rotating frames 62 drives the visual scanning component 5 to fold relative to the bracket 61, and the other group of rotating frames 62 drives the processing component 4 to open relative to the bracket 61 and perform processing operations on the casting. The processing action can be one of cutting or grinding. The type of processing action depends on the type of component on the rotating frame 62 in the open state, which will not be elaborated here.

[0108] Optionally, a threading hole 611 is also provided in the middle of the bracket 61, and the threading hole 611 is used for passing pipes or wires of components such as the water supply head 41, the plasma cutter 44 and the alloy grinding wheel grinder 45, so as to meet the actual use requirements of each component without affecting the structural layout.

[0109] Reference Figure 5In order to control the stopping position of the rotating frame 62 when it is opened and folded, and thus improve the position accuracy of each component during operation, the bracket 61 is respectively provided with a first step surface 612 and a second step surface 613 which are abutted and limited with the rotating frame 62, wherein the first step surface 612 is located on the inner side of the bracket 61, and when the first step surface 612 abuts against the rotating frame 62, the rotating frame 62 is opened compared to the bracket 61, and the second step surface 613 is close to the outer side of the bracket 61, and when the second step surface 613 abuts against the rotating frame 62, the rotating frame 62 is folded compared to the bracket 61.

[0110] Optionally, electromagnet elements may be provided on the first step surface 612 and the second step surface 613 to further optimize the stability of the rotating frame 62 when it is opened and folded by magnetic attraction.

[0111] In addition, this embodiment also discloses a surface cleaning method for treating surface defects on castings, which uses the large casting surface cleaning robot system based on 3D vision described above, and specifically includes the following steps:

[0112] The casting is loaded and hoisted to the middle of the rotating work platform 1. Specifically, the casting can be hoisted by a gantry crane. In the process of placing the casting on the rotating work platform 1, in order to ensure that the casting is placed more stably and accurately, a jig can be installed on the rotating work platform 1 to fix and position the casting.

[0113] After the casting is loaded, scanning and modeling are then carried out. Specifically, the rotating component 2 can be started, and the rotating work platform 1 can be driven by the rotating component 2 to rotate, so that the casting rotates; at the same time, the robot 3 is started, so that the visual scanning component 5 is facing the casting, and a starting point is selected. The starting point is rotated 360 degrees as a cycle, so that the visual scanning component 5 scans the casting in all directions along the circumference of the workpiece and generates three-dimensional mesh data. The number of complete scans is at least two, preferably three. Through multiple scans, more accurate three-dimensional mesh data can be obtained.

[0114] After obtaining the three-dimensional mesh data, the data is then analyzed and compared. Specifically, the comparison and analysis module performs comparison and analysis based on the three-dimensional mesh data of the casting to be processed and the three-dimensional mesh data of the finished part. During the comparison process, computer equipment and computer software can be used to perform comparison calculations, and a non-overlapping graphic contour is obtained through Boolean subtraction. Based on the contour, its root path is selected to obtain the final processing path data, which is then sent to the control module.

[0115] Then, the surface treatment step is performed. Specifically, the control module can adopt a PLC control module. The control module generates a control signal based on the processing path data, and sends the control signal to the rotating component 2, the robot 3 and the processing component 4. The rotating component 2 drives the rotating work platform 1 to rotate to adjust the processing position, and the robot 3 drives the processing component 4 to process the surface defects.

[0116] It should be noted that this processing method can execute multiple processing forms through programming. For example, the sand layer adhered to the surface of the casting can be cleaned first, and then the scanning modeling and comparative analysis steps can be performed again, and then the cutting action can be performed, and then the scanning modeling and comparative analysis steps can be performed again, and finally the polishing can be performed. The cutting and polishing processes can also be performed separately according to actual conditions. In other words, the robot drives the processing components to perform one or more of the sand cleaning, cutting and polishing processes on the surface defects. Before performing any cleaning, a separate scanning modeling step and an analysis and comparison process step are performed. No matter what combination is adopted, it should be regarded as within the scope of the interpretation of this plan.

[0117] In this embodiment, when the processing component 4 processes the surface defects, it processes them in the order of sand cleaning, cutting and grinding. This processing sequence is more reasonable, can effectively reduce the repeated execution of steps, and has a higher processing efficiency.

[0118] After the surface treatment is completed, the casting is finally unloaded. Accordingly, a gantry crane can be used for hoisting and unloading, thus completing the entire processing cycle.

[0119] It can be understood that when performing the cutting process, water jet cutting or plasma cutting is mainly used, and the processing action is achieved through the water jet head 41 and the high-pressure pump 42, which is mainly used to remove burrs, seams, pouring nozzles and other defects; and when performing the grinding process, the action is mainly completed by the alloy grinding wheel grinder 45, which is mainly used to deal with defects such as sand holes, pores and surface unevenness.

[0120] What needs further explanation is that regarding the cleaning of surface defects such as sand adhesion and sand wrapping, because most large castings use the resin sand casting process, after demolding, some residual material will remain on the surface of the casting, which forms the sand adhesion layer mentioned above. This part of the residue will also affect the subsequent processing steps of the casting, so it also needs to be removed.

[0121] For example, in the scanning modeling step, the three-dimensional mesh data of the sand-bonding layer on the surface of the casting can be obtained, and the thickness and contour processing data of the sand-bonding layer can be obtained by comparing and analyzing the three-dimensional mesh data of the finished part. At this time, the sand cleaning process is different from the cutting and grinding paths. The sand-bonding layer also involves the surface cleaning dimension, so the thickness and area contour are important data in the cleaning process. This method also adopts the Boolean subtraction method, which will not be repeated here.

[0122] Then, the thickness and contour processing data of the sand-bonding layer are sent to the control module, and the control module forms a control signal based on the thickness and contour processing data of the sand-bonding layer. The rotating component 2, the robot 3 and the processing component 4 clean the sand-bonding layer based on the control signal.

[0123] Here, in the process of cleaning the sticky sand layer, the resin sand is mainly heated by plasma jet, and the surface heating action is realized by sweeping, so it is necessary to use the plasma cutter 44, the plasma generator and the control element to realize the above-mentioned surface cleaning action, and then achieve the purpose of making it disappear, so that the surface sticky sand layer can be removed more quickly. Accordingly, when heating the sticky sand layer, it is necessary to adjust the distance between the plasma cutter and the casting to keep a certain distance between the two and avoid the two from approaching each other to avoid burning and damaging the casting.

[0124] So far, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A large casting surface cleaning robot system based on 3D vision, characterized in that: include: A rotating working platform (1) for placing castings; A rotating assembly (2) is used to drive the rotating working platform (1) to drive the casting to rotate horizontally; A robot (3) adjacent to the rotating assembly (2); A processing component (4), arranged on the swing arm of the robot (3), for processing surface defects of the casting; A visual scanning component (5) is arranged on the swing arm of the robot (3), and the robot (3) is used to drive the visual scanning component (5) to scan the casting to obtain three-dimensional grid data of the casting to be processed; a comparison and analysis module and a control module, wherein the comparison and analysis module is connected to the visual scanning component (5) and the control module respectively, and receives the three-dimensional mesh data collected by the visual scanning component (5), and is used to compare and analyze the three-dimensional mesh data of the casting to be processed with the three-dimensional mesh data of the finished part to obtain processing path data, and sends the processing path data to the control module; The control module is connected to the rotating component (2), the robot (3) and the processing component (4) respectively. The control module receives the processing path data and forms a control signal based on the processing path data, and is used to send the control signal to the rotating component (2), the robot (3) and the processing component (4) respectively, so that the rotating component (2), the robot (3) and the processing component (4) process the surface defects of the casting along the processing path.

2. The large casting surface cleaning robot system based on 3D vision according to claim 1 is characterized in that: The processing component (4) comprises A water jet head (41) is arranged on the swing arm of the robot (3); A high-pressure pump (42) is connected to the water knife head (41) and is used to pump high-pressure water to the water knife head (41); and a water treatment component (43) having a water storage chamber inside, wherein the high-pressure pump (42) is arranged on the water treatment component (43) and takes water through the water storage chamber.

3. The large casting surface cleaning robot system based on 3D vision according to claim 2 is characterized in that: The water treatment component (43) comprises: A water storage tank (431) is hollow inside to form a water storage chamber, one side of the water storage chamber is provided with a return port (4311), the rotating working platform (1) is provided with a flow channel (11) for water to flow downward, the flow channel (11) is connected to the return port (4311) via a return pipe; a partition (432) disposed in the water storage chamber, used to separate the water storage chamber into a first water storage portion and a second water storage portion, wherein the first water storage portion is in communication with the reflux port (4311), and the first water storage portion is used to precipitate impurities; and a water pump (433), which is located in the first water storage part and is connected to the second water storage part, and is used to pump the supernatant located in the upper layer of the first water storage part into the second water storage part. The high-pressure pump (42) is located in the second water storage part.

4. The large casting surface cleaning robot system based on 3D vision according to claim 3 is characterized in that: The water treatment component (43) further comprises a sewage pump (434) which is connected to the bottom of the first water storage part and is used for sucking out precipitated impurities.

5. The large casting surface cleaning robot system based on 3D vision according to claim 1 is characterized in that: The processing component (4) comprises: A plasma cutter (44) is arranged on the swing arm of the robot (3); A plasma generator connected to the plasma cutter (44) and used to drive the plasma cutter (44) to spray a plasma jet; and a control element connected to the plasma generator and the plasma cutter (44) and used for controlling the plasma generator and the plasma cutter (44) to generate a plasma arc.

6. The large casting surface cleaning robot system based on 3D vision according to claim 1 is characterized in that: The processing component (4) also includes an alloy grinding wheel grinder (45), and the alloy grinding wheel grinder (45) is arranged on the swing arm of the robot (3).

7. The large casting surface cleaning robot system based on 3D vision according to claim 1 is characterized in that: The processing component (4) and the visual scanning component (5) are connected to the robot (3) via a switching component (6), and the switching component (6) comprises: A bracket (61) fixedly mounted on the swing arm of the robot (3); At least two rotating racks (62) are used to install the processing component (4) and the visual scanning component (5) respectively, and are rotatably arranged on one side of the bracket (61); and a driving component (63), wherein the driving component (63) is used to drive the rotating frame (62) to rotate, and the rotating frame (62) includes at least two states: In a first state, one group of the rotating frames (62) drives the processing assembly (4) to be folded relative to the bracket (61), and another group of the rotating frames (62) drives the visual scanning assembly (5) to be opened relative to the bracket (61) and perform a scanning operation on the casting; In the second state, one group of the rotating frames (62) drives the visual scanning component (5) to be folded relative to the bracket (61), and another group of the rotating frames (62) drives the processing component (4) to be opened relative to the bracket (61) and perform processing operations on the casting.

8. The large casting surface cleaning robot system based on 3D vision according to claim 7 is characterized in that: The bracket (61) is provided with a first step surface (612) and a second step surface (613) respectively abutting against the rotating frame (62) for limiting position; when the first step surface (612) abuts against the rotating frame (62), the rotating frame (62) is opened relative to the bracket (61); when the second step surface (613) abuts against the rotating frame (62), the rotating frame (62) is folded relative to the bracket (61).

9. A surface cleaning method, using the large casting surface cleaning robot system based on 3D vision as described in any one of claims 1 to 8, characterized in that: The steps include: Casting loading: hoisting the casting to the middle of the rotating working platform (1); Scanning modeling, driving the rotating work platform (1) to rotate by the rotating component (2) to rotate the casting, while the visual scanning component (5) performs a full-scale scan of the casting along the circumference of the workpiece and generates three-dimensional mesh data, and the number of complete scans is at least two times; Analysis and comparison: the comparison and analysis module compares and analyzes the three-dimensional mesh data of the casting to be processed with the three-dimensional mesh data of the finished part to obtain processing path data, and sends the processing path data to the control module; Surface treatment, the control module generates a control signal based on the processing path data, and sends the control signal to the rotating component (2), the robot (3) and the processing component (4), the rotating component (2) drives the rotating work platform (1) to rotate to adjust the processing position, and the robot (3) drives the processing component (4) to perform one or more of sand removal, cutting and grinding on the surface defects, and before performing a cleaning process, a separate scanning modeling step and an analysis and comparison process step are performed; The castings are unloaded and hoisted after processing.

10. A surface cleaning method according to claim 9, characterized in that: When the processing component (4) processes the surface defects, the processing is carried out in the order of sand cleaning, cutting and grinding.

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