Large workpiece strain measuring point auxiliary positioning system and method

Abstract

The invention discloses a large workpiece strain measuring point auxiliary positioning system and method, and the system comprises a professional software and automatic control system, and an industrial photogrammetry system, a car lifting system, a laser projection system and a three-dimensional scanning quantitative analysis system which are connected with the professional software and automatic control system. And a positioning target is arranged on the surface of the large workpiece product. According to the system, strain contact auxiliary lineation and laser guide assembly work of a large workpiece and quantitative analysis work of strain gauge pasting are achieved, the system takes a target arranged on a product as a positioning reference, the outline of a product model is extracted in a photogrammetry mode, the product model and a real object are matched and unified to the same coordinate system, and the product model and the real object are obtained. The position contour of the strain gauge needing to be pasted and auxiliary information are projected to the surface of a product through the laser projection technology, the current pasting position information can be efficiently and accurately reflected, and high-efficiency and high-precision assembly of the strain gauge is facilitated.

Description

Technical Field

[0001] The present invention relates to the technical field of auxiliary positioning of strain measuring points of large workpieces, and in particular to a system and method for auxiliary positioning of strain measuring points of large workpieces. Background Art

[0002] At present, the aerospace product development industry chain consists of three links: "design-manufacturing-testing". The design department has adopted a large number of advanced design tools such as 3D drawing, 3D collaboration, and 3D simulation to directly form 3D design products, forming an advanced digital design system, greatly shortening the design cycle and improving the design quality; similarly, the manufacturing department can also receive the 3D drawings of the design department to form 3D processes, and use CNC machine tools to directly perform 3D processing, forming an advanced 3D manufacturing system, greatly shortening the manufacturing cycle and improving the manufacturing quality. The test department currently still uses traditional test methods and test means, and the measurement point design still relies on paper documents or 2D drawings. It mainly relies on the calculation personnel to select points based on the approximate location of the test measurement points for comparison, which is inefficient, especially for the stress concentration area. The accuracy is not enough, and the strain measurement point process operation is all dependent on manual labor, which is inefficient and not accurate, and cannot be connected and matched with the 3D models of the design and manufacturing departments. With the shortening of the R&D cycle of the design and manufacturing departments, the test occupies an increasingly large part in the entire aerospace product development cycle, and has gradually become a bottleneck in the entire aerospace industry.

[0003] At present, there are many patches on the surface of tank-type cylinder workpieces and other products, and the positions of strain measurement points are unevenly distributed. The positioning adopts the traditional manual marking method, which will take up most of the time in the whole process, and the positioning depends on manual measurement and manual marking of the reference position. In this way, the overall positioning accuracy is affected by the measurement method and the human factors of marking. In the whole process, it is impossible to ensure that the strain gauge is accurately positioned at the designed position, and the position deviation cannot be measured and quantified. The invention patent CN 105179404 A "Pressure device for pasting and curing of low-temperature test strain gauges for large tanks" applied by Beijing Strength Environment Research Institute on June 13, 2014 discloses a pressure device for pasting and curing of low-temperature test strain gauges for large tanks, which realizes the pasting of large tank position test strain gauges, and provides a test basis for the design and assessment of the tank of the design department, but it does not mention the pasting positioning marking and quantitative analysis. The valve patent CN109505838A "A strain gauge push extrusion patch device and its use method" applied by Jiyuan Chaoguang Sensor System Engineering Co., Ltd. on October 22, 2018 discloses a strain gauge push extrusion patch device and its use method, which realizes the efficient curing and stabilization of strain gauge patches, but also does not mention the pasting positioning marking and quantitative analysis. The invention patent CN117182538A "A large workpiece laser projection assisted assembly system and method" applied by Beijing Aerospace Star Technology Co., Ltd. on July 13, 2023 discloses a large workpiece laser projection assisted assembly system and method, which can identify the target tooling for real-time positioning, adaptively track and calibrate according to the changes in the position of the target workpiece, and control the guide assembly to run to the preset position for projection assembly, realizing automated auxiliary assembly, but the system relies on the matching of the target tooling and the process file, and there is no quantitative analysis of the posture after installation. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention realizes the strain contact auxiliary marking and laser-guided assembly of large workpieces and the quantitative analysis of strain gauge pasting through an industrial photogrammetry system, a laser projection system, a three-dimensional scanning quantitative analysis system, a crane system, professional software and an automatic control system. The system uses a target arranged on the product as a positioning reference, extracts the product model contour through photogrammetry, matches the product model and the real object and unifies them into the same coordinate system, and projects the position contour and auxiliary information of the strain gauge to be pasted onto the product surface through laser projection technology, which can efficiently and accurately reflect the current assembly position information, and is conducive to the efficient and high-precision assembly of the strain gauge.

[0005] The present invention provides a large workpiece strain measurement point auxiliary positioning system, the system comprises: professional software and automatic control system and industrial photogrammetry system, frame system, laser projection system and three-dimensional scanning quantitative analysis system connected with the professional software and automatic control system. Positioning targets are arranged on the surface of the large workpiece product. The system is used for: Before patching, the industrial photogrammetry system, the professional software and the automatic control system are used to prepare target files and projection files based on the positioning targets on the large workpiece product, the three-dimensional model of the large workpiece product and the information of the preset strain gauges, and the gantry system is controlled by the professional software and the automatic control system to place the large workpiece product and the laser projection system at corresponding preset positions respectively; During the patching process, the carriage system is controlled by the professional software and automatic control system, the operation area of ​​the large workpiece product and the position of the laser projection system are adjusted according to the actual operation conditions, and the laser projection system is controlled by the professional software and automatic control system to project and patch the strain gauges in the current operation area of ​​the large workpiece product according to the target file and the projection file; After the patching is completed, the strain gauges pasted on the large workpiece product are three-dimensionally scanned by the three-dimensional scanning quantitative analysis system, the professional software and the automatic control system to obtain a three-dimensional scanning file. The patch quality of the pasted strain gauges is quantitatively analyzed based on the three-dimensional scanning file and the three-dimensional model in the projection file to generate a strain gauge pasting quality inspection report.

[0006] Preferably, the surface of the large workpiece product is provided with a plurality of coding points and target points of different positions and numbers; the large workpiece product includes a tank and a shell segment; the industrial photogrammetry system includes an industrial photogrammetry camera; the professional software and automatic control system include: a control cabinet, a computer is provided in the control cabinet, and a plurality of software are installed on the computer, and the plurality of software include: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software; The target file preparation process specifically includes: Pasting the positioning target on the target point on the surface of the large workpiece product and setting a scale; Acquiring the positioning target by means of the industrial photogrammetry camera to obtain a target image; Using the EZ-PhotoInspect software, based on the standard size of the coding points on the surface of the large workpiece product and the scale, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; Performing shape fitting on the identified and spliced ​​target images through the PDC software, creating a reference feature, creating a coordinate system based on the reference feature, obtaining a target point with the reference feature and the coordinate system, and generating a target file; The production process of the projection file specifically includes: Importing the three-dimensional model of the large workpiece product into the PDC software; By means of the PDC software, the information of the preset strain gauge is marked on the three-dimensional model according to the process requirements, and a projection file is prepared, wherein the information of the preset strain gauge includes the outline, number and projection sequence of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; The projection file is opened by the Iris software, the target file is imported, and the coordinate alignment between the three-dimensional model in the projection file and the actual large workpiece product is achieved through the reference features and coordinate system of the target point in the target file.

[0007] Preferably, the trolley system comprises: a trolley ground rail, an auxiliary ground rail is laid on both sides of the trolley ground rail, a rolling trolley is arranged at both ends of the trolley ground rail, namely a first rolling trolley and a second rolling trolley, an auxiliary support trolley is arranged in the middle of the trolley ground rail, the first rolling trolley and the second rolling trolley are connected to the tank through a rolling ring, the auxiliary support trolley is connected to the supporting device of the tank through a felt, and the shell segment is placed on the trolley ground rail; The tank is provided with a tank characteristic datum for realizing the characteristic positioning of the tank, and the shell segment is provided with a shell segment characteristic datum for realizing the characteristic positioning of the shell segment.

[0008] Preferably, the rolling frame vehicle comprises a rolling frame vehicle chassis, a rolling frame vehicle lifting mechanism fixing box, a rolling frame vehicle transverse shifting base, two rolling frame vehicle driving wheel axles, and a rolling frame vehicle arc frame. Four casters are installed under the rolling frame vehicle chassis, and a brake handwheel is installed on the casters. The rolling frame vehicle chassis is provided with a fixing box for the lifting mechanism of the rolling frame vehicle, and the rolling frame vehicle transverse shifting base is fixed above the fixing box for the lifting mechanism of the rolling frame vehicle and connected to each other through a lifting screw, and the lifting adjustment device enables the rolling frame vehicle transverse shifting base to be adjusted up and down along the lifting screw; A transverse moving slide rail is installed above the transverse moving base of the rolling frame, and a transverse moving slider is installed at the bottom of the arc frame of the rolling frame, so that the transverse horizontal adjustment of the arc frame of the rolling frame can be achieved under the action of the transverse moving adjustment device; Two driving axles of the rolling rack are installed on the upper part of the arc frame of the rolling rack. The two driving axles of the rolling rack are driven by a servo motor to realize the rolling of the tank products. The driving axles of the rolling rack are switched between automatic and manual by a clutch. The rolling rack can be manually rolled under the action of a manual rotating wheel. An encoder is installed in the middle of the two driving wheel axles of the rolling frame vehicles, and the encoder is used to realize the synchronous operation of the two driving wheel axles of the rolling frame vehicles through a control algorithm; The rolling frame vehicle is provided with a power interface panel and a control interface panel, and the control interface panel is connected to the control cabinet, and the automatic rolling of the rolling frame vehicle is realized through the control cabinet.

[0009] Preferably, the auxiliary support frame vehicle comprises an auxiliary support frame vehicle chassis, an auxiliary support frame vehicle lifting mechanism fixing box, an auxiliary support frame vehicle transverse shifting base, and an auxiliary support frame vehicle arc frame, the auxiliary support frame vehicle arc frame is installed above the auxiliary support frame vehicle transverse shifting base, and the auxiliary support frame vehicle arc frame adopts the form of arc surface support; An auxiliary support frame vehicle caster is installed below the auxiliary support frame vehicle chassis, and an auxiliary support frame vehicle brake handwheel is installed above the auxiliary support frame vehicle caster; The auxiliary support frame vehicle top lifting mechanism fixing box is fixed above the auxiliary support frame vehicle chassis, connected to the auxiliary support frame vehicle transverse displacement base through the auxiliary support frame vehicle lifting screw, and the up and down adjustment is achieved through the auxiliary support frame vehicle lifting adjustment device; A transverse moving slide rail block is fixed on the auxiliary support frame trolley transverse moving base, and transverse level adjustment is achieved through the auxiliary support frame trolley transverse moving adjustment device.

[0010] Preferably, the laser projection system comprises: five movable lifting brackets and five laser projectors, namely, a first movable lifting bracket and a first laser projector arranged thereon, a second movable lifting bracket and a second laser projector arranged thereon, a third movable lifting bracket and a third laser projector arranged thereon, a fourth movable lifting bracket and a fourth laser projector arranged thereon, and a fifth movable lifting bracket and a fifth laser projector arranged thereon; The first movable lifting support and the second movable lifting support are arranged on one side of the tank, the third movable lifting support and the fourth movable lifting support are arranged on the other side of the tank, and the fifth movable lifting support is arranged around the shell segment; The movable lifting bracket includes movable bracket casters, auxiliary casters, a mast-type lifting mechanism, and a laser projector fixing bracket. The movable bracket casters are used for assisting walking on the ground when the movable lifting bracket is in an extended state, and the auxiliary casters are used for assisting walking on the ground when the movable lifting bracket is in a retracted state. The mast-type lifting mechanism adjusts the lifting height through the adjustment hand wheel, and the laser projector fixing bracket fixes the laser projector arranged thereon through a tooling to achieve coverage of the projection area; The system also includes a climbing operation system. Before patching, the trolley system is controlled by the professional software and automatic control system to place the climbing operation system at a corresponding preset position, so that the entire operation area of ​​the large workpiece product can be covered by the climbing operation system. The aerial work system includes: a first aerial work vehicle, a second aerial work vehicle, a third aerial work vehicle, and a fourth aerial work vehicle. The first aerial work vehicle, the second aerial work vehicle, and the third aerial work vehicle are used to achieve full coverage of the tank operation area, and the fourth aerial work vehicle is used to achieve full coverage of the shell section operation area.

[0011] The present invention also provides a large workpiece strain measurement point auxiliary positioning method, based on the large workpiece strain measurement point auxiliary positioning system, the system includes: professional software and automatic control system and industrial photogrammetry system, frame system, laser projection system and three-dimensional scanning quantitative analysis system connected with the professional software and automatic control system, and a positioning target is set on the surface of the large workpiece product. The method includes: S1. Before patching, the industrial photogrammetry system, the professional software and the automatic control system are used to prepare target files and projection files based on the positioning targets on the large workpiece product, the three-dimensional model of the large workpiece product and the information of the preset strain gauges, and the gantry system is controlled by the professional software and the automatic control system to place the large workpiece product and the laser projection system at corresponding preset positions respectively; S2. During the patching process, the gantry system is controlled by the professional software and the automatic control system, the operation area of ​​the large workpiece product and the position of the laser projection system are adjusted according to the actual operation conditions, and the laser projection system is controlled by the professional software and the automatic control system to project and patch the strain gauges in the current operation area of ​​the large workpiece product according to the target file and the projection file; S3. After the patching is completed, the strain gauges pasted on the large workpiece product are three-dimensionally scanned by the three-dimensional scanning quantitative analysis system, the professional software and the automatic control system to obtain a three-dimensional scanning file. The patch quality of the pasted strain gauges is quantitatively analyzed according to the three-dimensional scanning file and the three-dimensional model in the projection file to generate a strain gauge pasting quality inspection report.

[0012] Preferably, the surface of the large workpiece product is provided with a plurality of coding points and target points of different positions and numbers; the large workpiece product includes a tank and a shell segment; the industrial photogrammetry system includes an industrial photogrammetry camera; the professional software and automatic control system include: a control cabinet, a computer is provided in the control cabinet, and a plurality of software are installed on the computer, and the plurality of software include: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software; In step S1, the target file preparation process specifically includes: Pasting the positioning target on the target point on the surface of the large workpiece product and setting a scale; Acquiring the positioning target by means of the industrial photogrammetry camera to obtain a target image; Using the EZ-PhotoInspect software, based on the standard size of the coding points on the surface of the large workpiece product and the scale, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; Performing shape fitting on the identified and spliced ​​target images through the PDC software, creating a reference feature, creating a coordinate system based on the reference feature, obtaining a target point with the reference feature and the coordinate system, and generating a target file; In step S1, the process of making the projection file specifically includes: Importing the three-dimensional model of the large workpiece product into the PDC software; By means of the PDC software, the information of the preset strain gauge is marked on the three-dimensional model according to the process requirements, and a projection file is prepared, wherein the information of the preset strain gauge includes the outline, number and projection sequence of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; The projection file is opened by the Iris software, the target file is imported, and the coordinate alignment between the three-dimensional model in the projection file and the actual large workpiece product is achieved through the reference features and coordinate system of the target point in the target file.

[0013] Preferably, in step S2, the crane system is controlled by the professional software and the automatic control system to adjust the operation area of ​​the large workpiece product and the position of the laser projection system according to the actual operation conditions, which specifically includes: If the patching of the current working area of ​​the large workpiece product has not been completed, the automatic control system controls the carriage system to move the laser projection system to the next projection area; if the patching of the current working area of ​​the large workpiece product has been completed, the automatic control system controls the carriage system to adjust the large workpiece product to the next working area and move the laser projection system to the initial projection area, and so on, until the patching of all working areas of the large workpiece product has been completed; In step S2, the laser projection system is controlled by the professional software and the automatic control system, and the strain gauges in the current working area of ​​the large workpiece product are projected and mounted according to the target file and the projection file, specifically including: The laser projection system is controlled by the professional software and automatic control system, and the positioning target in the current operating area of ​​the large workpiece product is automatically identified according to the target file. The outline, position and label of the strain gauge in the current operating area of ​​the large workpiece product are automatically projected in sequence according to the projection order in the projection file and the automatically identified positioning target, and the worker performs the strain gauge pasting operation according to the projection content.

[0014] Preferably, step S3 specifically includes: S301, calibrating the X, Y, Z coordinate positions and rotation angles of the strain gauges attached to the large workpiece product by means of a tracker or a scanner; S302, scanning and meshing the strain gauges pasted on the large workpiece product by using the 3DViewer software and the scanner to form a mesh file; S303, importing the three-dimensional model in the projection file and the mesh file into the Control X 2020.0 software; S304, aligning the three-dimensional model in the projection file and the grid file according to the reference features and coordinate system of the target in the target file, wherein the reference features include point, line, and surface features, which are used to limit the X, Y, and Z coordinate positions and rotation angles to achieve coordinate alignment; S305, detecting the deviation between the X, Y, and Z coordinate positions and the rotation angles of the strain gauges pasted on the large workpiece product and the three-dimensional model in the projection file and the actual large workpiece product, and generating a strain gauge pasting quality inspection report, wherein the strain gauge pasting quality inspection report includes the offset of the X, Y, and Z coordinate positions and the deflection angle of the rotation angle.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention adopts a mobile solution for human-machine collaborative operation, and realizes the unification of the coordinate system of the real object and the model through industrial photogrammetry, without the need for precise positioning of assembly tooling; the trolley can move freely on the ground rail, and can be compatible with large workpieces of different lengths, so as to realize the fixation and rotation of the test piece during the marking process; the laser projection technology is used to accurately project the spatial position and serial number of the strain gauge, to assist workers in marking and labeling, and the workpiece position can be automatically tracked according to the change of the projected workpiece position for projection calibration without human intervention; the three-dimensional scanning quantitative analysis system is used to realize quantitative analysis of the position, angle, prying edge, etc. of the patch quality.

[0016] The system of the present invention is compatible with products of larger sizes and covers a wider range, which solves the problem that it is difficult to measure the position of the concentrated stress test site by manual marking. The system has high spatial positioning accuracy and a positioning accuracy of 0.5mm in a large space. It is compatible with tanks and shell segment products of different diameters within 40 meters, and can reduce the patch time by more than 50%. While reducing the labor intensity of workers, it can significantly improve work efficiency and assembly accuracy, further improve the test quality, and ensure the safety of equipment, personnel and products. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A schematic diagram of the framework of a large workpiece strain measurement point auxiliary positioning system provided by the present invention; Figure 2 A structural schematic diagram of a large workpiece strain measurement point auxiliary positioning system provided by the present invention; Figure 3 A schematic diagram of the auxiliary positioning work of the strain measuring point of the shell segment product provided by the present invention; Figure 4 A schematic diagram of the auxiliary positioning work of the strain measuring point of the tank product provided by the present invention; Figure 5 A schematic diagram of the structure of the rolling frame vehicle provided by the present invention; Figure 6 A schematic diagram of the transverse structure of the rolling frame vehicle provided by the present invention; Figure 7 A schematic diagram of the structure of the auxiliary support frame vehicle provided by the present invention; Figure 8 A schematic diagram of the structure of the movable lifting bracket provided by the present invention; Fig. 9 A schematic diagram of the structure of the movable lifting bracket provided by the present invention in a retracted state; Fig.10 A schematic diagram of the target file preparation process provided by the present invention; Fig.11 A schematic diagram of the projection file production process provided by the present invention; Fig.12 A schematic diagram of coding points provided by the present invention; Fig.13 A schematic diagram of the target provided by the present invention; Fig.14 A schematic diagram of a flow chart of a large workpiece strain measurement point auxiliary positioning method provided by the present invention; Fig.15 The present invention provides Fig.14 Schematic diagram of the step-by-step process of S3; Fig.16 A schematic diagram of the operation flow of the auxiliary positioning method for strain measurement points of a tank product provided by the present invention; Fig.17 A schematic diagram of the operation flow of the shell segment product strain measurement point auxiliary positioning method provided by the present invention; Markings and corresponding parts names in the attached drawings: 1-1: ground rail for carriage; 1-2: auxiliary ground rail; 1-3: first rolling carriage; 1-4: auxiliary support carriage; 1-5: second rolling carriage; 1-6: first movable lifting bracket; 1-7: first laser projector; 1-8: second movable lifting bracket; 1-9: second laser projector; 1-10: third movable lifting bracket; 1-11: third laser projector; 1-12: fourth movable lifting bracket; 1-13: fourth laser projector; 1-14: first high-altitude operation vehicle; 1-15 : The second high-altitude work vehicle; 1-16: The third high-altitude work vehicle; 1-17: The tank; 1-18: The rolling ring; 1-19: The tank characteristic datum; 1-20: The control cabinet; 1-21: The fifth movable lifting bracket; 1-22: The fourth high-altitude work vehicle; 1-23: The shell segment; 1-24: The shell segment characteristic datum; 1-25: The fifth laser projector; 1-26: The coding point; 1-27: The target point; 2-1: The chassis of the rolling frame vehicle; 2-2: The fixed box of the lifting mechanism of the rolling frame vehicle; 2-3: The horizontal Shift base; 2-4: Rolling frame driving wheel axle; 2-5: Rolling frame arc frame; 2-6: Caster; 2-7: Brake hand wheel; 2-8: Lateral adjustment device; 2-9: Lifting adjustment device; 2-10: Manual rotating wheel; 2-11: Encoder; 2-12: Control interface panel; 2-13: Power interface panel; 2-14: Lateral moving slide rail; 2-15: Lateral moving slider; 2-16: Lifting screw; 3-1: Auxiliary support frame chassis; 3-2: Auxiliary support frame top lifting mechanism fixing box; 3-3: Auxiliary support frame lateral shift base; 3-4: Auxiliary support frame arc frame; 3-5: Auxiliary support frame lateral shift adjustment device; 3-6: Auxiliary support frame lifting adjustment device; 3-7: Auxiliary support frame caster; 3-8: Auxiliary support frame brake handwheel; 3-9: Lateral moving slide block; 3-10: Auxiliary support frame lifting screw; 4-1: Movable bracket caster; 4-2: Auxiliary caster; 4-3: Mast-type lifting mechanism; 4-4: Laser projector fixed bracket; 4-5: Adjustment handwheel. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution 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 described embodiments are 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.

[0019] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0020] like Figure 1As shown, an embodiment of the present invention provides a large workpiece strain measurement point auxiliary positioning system, the system includes: professional software and automatic control system 100 and an industrial photogrammetry system 200, a crane system 300, a laser projection system 400 and a three-dimensional scanning quantitative analysis system 500 connected to the professional software and automatic control system 100.

[0021] The surface of the large workpiece product is provided with a positioning target, and the system is used for: before patching, the industrial photogrammetry system 200 and the professional software and automatic control system 100 are used to prepare a target file and a projection file based on the positioning target on the large workpiece product, the three-dimensional model of the large workpiece product and the preset strain gauge information, and the professional software and automatic control system 100 are used to control the carriage system 300 to place the large workpiece product and the laser projection system 400 at the corresponding preset positions respectively; during the patching process, the carriage system is controlled by the professional software and the automatic control system 100 to adjust the working area of ​​the large workpiece product and the position of the laser projection system 400 according to the actual working conditions, and the laser projection system is controlled by the professional software and the automatic control system 100 to project and patch the strain gauges in the current working area of ​​the large workpiece product according to the target file and the projection file; after the patching is completed, the strain gauges pasted on the large workpiece product are three-dimensionally scanned by the three-dimensional scanning quantitative analysis system 500 and the professional software and automatic control system 100 to obtain a three-dimensional scanning file, and the patch quality of the pasted strain gauges is quantitatively analyzed according to the three-dimensional scanning file and the three-dimensional model in the projection file, and a strain gauge pasting quality inspection report is generated.

[0022] The system of the embodiment of the present invention can simultaneously realize the coordinated patching operation of multiple large workpiece products such as tanks and shell segments, and arrange movable lifting brackets, aerial work vehicles, and laser projectors around the shell segments to realize the patching operation of the shell segments. Figure 2 As shown in the figure, the system includes a rack ground rail, an auxiliary ground rail, two rolling racks, one auxiliary support rack, four movable lifting brackets, four laser projectors, and four high-altitude operation vehicles, which can be freely combined to realize the auxiliary patching of strain gauges on the shell segment and the tank. The rack ground rail and the auxiliary ground rail adopt No. 50 load-bearing ground rails. Rolling racks are arranged at both ends of the rack ground rail, and auxiliary support racks are arranged in the middle. The rolling racks are connected to the product through rolling rings, and the auxiliary support racks are connected to the product tank support device through felt to realize the circumferential rolling of the product. Movable lifting brackets are arranged on both sides of the product on the auxiliary ground rail, and laser projectors are installed on the movable lifting brackets. The system adopts a movable solution. The movable lifting brackets can be moved on the auxiliary ground rail. The laser projector can be adjusted to rise and fall and pitch as needed to cover the product operation area. Climbing operation vehicles are set on both sides of the product to cover the operation area. They can be freely combined according to the length of the product and the number of workers. They can be operated in a single station or in multiple stations.

[0023] like Figure 2-4 As shown in 12-13, the large workpiece products include tank 1-17 and shell segment 1-23. Code points 1-26 and target points 1-27 are arranged irregularly on the tank 1-17 and shell segment 1-23. The code points 1-26 and the scale are used for reverse modeling and image stitching by industrial photography camera recognition, and the target points 1-27 are used for the position and number in the projection file after the laser projector projection alignment is completed. The tank 1-17 is provided with a tank feature datum 1-19 for realizing the feature positioning of the tank 1-17, and the shell segment 1-23 is provided with a shell segment feature datum 1-24 for realizing the feature positioning of the shell segment 1-23, so as to realize the unified alignment of the three-dimensional model and the physical model, and can be directly imported into the CAD digital model, supporting igs and stp formats. The professional software and automatic control system 100 in the embodiment of the present invention includes: a control cabinet 1-20, in which a computer, a UPS power supply and a switch are installed to realize the collaborative operation of multiple laser projectors, and multiple software are installed on the computer, including: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software. The industrial photogrammetry system 200 includes an industrial photogrammetry camera, which can fit features such as straight lines, planes, circles, spheres, cylinders and paraboloids according to measurement points, and can measure parameters such as distance, angle, length, benchmark-actual comparison, etc.

[0024] like Fig.10 As shown, the production process of the target file in the embodiment of the present invention specifically includes: pasting the positioning target on the target point 1-27 on the surface of the large workpiece product and setting the scale; collecting the positioning target through an industrial photogrammetry camera to obtain a target image; using the EZ-PhotoInspect software, based on the standard size and scale of the coding points 1-26 on the surface of the large workpiece product, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; using the PDC software to perform shape fitting on the identified and spliced ​​target image, create a reference feature, create a coordinate system based on the reference feature, obtain the target point 1-27 with the reference feature and the coordinate system, and generate a target file (CAL format).

[0025] like Fig.11As shown, the production process of the projection file in the embodiment of the present invention specifically includes: importing the three-dimensional model of the large workpiece product into the PDC software, supporting three-dimensional models in multiple formats such as DWG, DXF, CATIA, NX, and Creo; using the PDC software, marking the information of the preset strain gauge on the three-dimensional model according to the process requirements, and producing a projection file, the information of the preset strain gauge includes the outline, number and projection order of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; opening the projection file through the Iris software, importing the target file in the CAL format, and realizing the coordinate alignment of the three-dimensional model in the projection file with the actual large workpiece product through the reference features and coordinate system of the target points 1-27 in the target file.

[0026] like Figure 2-4 As shown, the trolley system includes: a trolley rail 1-1, an auxiliary rail 1-2 is laid on both sides of the trolley rail 1-1, a rolling trolley is arranged at each end of the trolley rail 1-1, namely, the first rolling trolley 1-3 and the second rolling trolley 1-5, an auxiliary support trolley 1-4 is arranged in the middle of the trolley rail 1-1, the first rolling trolley 1-3 and the second rolling trolley 1-5 are connected to the tank 1-17 through a rolling ring 1-18, the auxiliary support trolley 1-4 is connected to the supporting device of the tank 1-17 through a felt, and the shell segment 1-23 is placed on the trolley rail 1-1. Figure 2-4 As shown, the system provided by the embodiment of the present invention also includes a climbing operation system. Before the patch, the climbing operation system is placed in a corresponding preset position by controlling the trolley system 300 through professional software and the automatic control system 100, and the climbing operation system is used to achieve full coverage of the operation area of ​​the large workpiece product. The climbing operation system includes: a first climbing operation vehicle 1-14, a second climbing operation vehicle 1-15, a third climbing operation vehicle 1-16, and a fourth climbing operation vehicle 1-22. The first climbing operation vehicle 1-14, the second climbing operation vehicle 1-15, and the third climbing operation vehicle 1-16 are used to achieve full coverage of the operation area of ​​the tank 1-17, and the fourth climbing operation vehicle 1-22 is used to achieve full coverage of the operation area of ​​the shell segment 1-23.

[0027] like Figure 5-6As shown, the rolling frame vehicle comprises a rolling frame vehicle chassis 2-1, a rolling frame vehicle top lifting mechanism fixing box 2-2, a rolling frame vehicle transverse shifting base 2-3, two rolling frame vehicle driving wheel shafts 2-4, and a rolling frame vehicle arc frame 2-5. Four casters 2-6 are installed under the rolling frame vehicle chassis 2-1, and brake hand wheels 2-7 are installed on the casters 2-6; a rolling frame vehicle top lifting mechanism fixing box 2-2 is installed on the rolling frame vehicle chassis 2-1, and a brake hand wheel 2-7 is installed on the casters 2-6. A rolling frame trolley lateral shifting base 2-3 is fixed on the side and connected to each other through a lifting screw 2-16. Under the action of the lifting adjustment device 2-9, the rolling frame trolley lateral shifting base 2-3 is adjusted up and down along the lifting screw 2-16, and the moving distance is 100mm; a lateral moving slide rail 2-14 is installed on the top of the rolling frame trolley lateral shifting base 2-3, and a lateral moving slider 2-15 is installed on the lower part of the rolling frame trolley arc frame 2-5. Under the action of the lateral shift adjustment device 2-8, the rolling frame trolley arc frame 2 -5 horizontal adjustment, moving distance 200mm; two roller rack driving axles 2-4 are installed on the upper part of the roller rack arc frame 2-5, the two roller rack driving axles 2-4 are driven by servo motors to realize the rolling of the storage box product 1-17, the roller rack driving axles 2-4 are switched between automatic and manual by a clutch, and the roller rack can realize manual rolling under the action of the manual rotating wheel 2-10; encoders 2-11 are installed in the middle of the two roller rack driving axles 2-4, the encoders 2-11 are used to realize the synchronous operation of the two roller rack driving axles 2-4 through the control algorithm, so as to reduce the torque on the product; the roller rack has a power interface panel 2-13, which provides power supply through a movable solution; at the same time, it has a control interface panel 2-12, with a running light, a servo drive network interface, an emergency stop button, etc., and the automatic rolling of the roller rack is realized through the control cabinet 1-20, with speed adjustment, position adjustment and fixed angle rolling functions. The rolling frame has two specifications, which are compatible with products with diameters of 5000mm and 3500mm.

[0028] like Figure 7As shown, the auxiliary support frame 1-4 serves as a load-bearing support component, which can reduce the axial deflection of the product and does not rotate with the product when rotating. The auxiliary support frame 1-4 includes an auxiliary support frame chassis 3-1, an auxiliary support frame lifting mechanism fixing box 3-2, an auxiliary support frame transverse base 3-3, and an auxiliary support frame arc frame 3-4. The auxiliary support frame arc frame 3-4 is installed above the auxiliary support frame transverse base 3-3. The auxiliary support frame arc frame 3-4 adopts the form of arc support, and the surface is covered with felt, which fits the product surface. The arc support is designed as a modular combination, which is easy to disassemble and replace; auxiliary support frame casters 3-7 are installed below the auxiliary support frame chassis 3-1, and auxiliary support frame casters 3-7 are installed above the auxiliary support frame casters 3-7. The auxiliary support frame trolley is equipped with a brake hand wheel 3-8, which can realize the fixation of the auxiliary support frame trolley 1-4; the auxiliary support frame trolley top lifting mechanism fixing box 3-2 is fixed on the auxiliary support frame trolley chassis 3-1, which is connected to the auxiliary support frame trolley transverse base 3-3 through the auxiliary support frame trolley lifting screw 3-10, and the up and down adjustment is realized through the auxiliary support frame trolley lifting adjustment device 3-6, and the adjustment distance is 100mm; the auxiliary support frame trolley transverse base 3-3 is fixed with a transverse moving slide rail slider 3-9, and the transverse horizontal adjustment is realized through the auxiliary support frame trolley transverse adjustment device 3-5, and the adjustment distance is 200mm. The auxiliary support frame trolley 1-4 has 2 specifications, which are compatible with two products with diameters of 5000mm and 3500mm. The rolling frame trolley and the auxiliary support frame trolley can carry a maximum of 40 tons of products, and have a safety factor of 2.5 times.

[0029] like Figure 2-4 As shown, the laser projection system 400 includes: five movable lifting brackets and five laser projectors, namely, the first movable lifting bracket 1-6 and the first laser projector 1-7 arranged thereon, the second movable lifting bracket 1-8 and the second laser projector 1-9 arranged thereon, the third movable lifting bracket 1-10 and the third laser projector 1-11 arranged thereon, the fourth movable lifting bracket 1-12 and the fourth laser projector 1-13 arranged thereon, the fifth movable lifting bracket 1-21 and the fifth laser projector 1-25 arranged thereon; the first movable lifting bracket 1-6 and the second movable lifting bracket 1-8 are arranged on one side of the tank 1-17, the third movable lifting bracket 1-10 and the fourth movable lifting bracket 1-12 are arranged on the other side of the tank 1-17, and the fifth movable lifting bracket 1-21 is arranged around the shell segment 1-23. Figure 8-9As shown, the movable lifting bracket includes a movable bracket caster 4-1, an auxiliary caster 4-2, a mast-type lifting mechanism 4-3, and a laser projector fixed bracket 4-4. The movable bracket caster 4-1 is used for ground auxiliary walking when the movable lifting bracket is extended, and the auxiliary caster 4-2 is used for ground auxiliary walking when the movable lifting bracket is retracted. The mast-type lifting mechanism 4-3 adjusts the lifting height by adjusting the hand wheel 4-5, and the maximum lifting height is 6.5 meters. The laser projector fixed bracket 4-4 fixes the laser projector arranged thereon by tooling to achieve coverage of the projection area. The laser projector fixed bracket 4-4 can adjust the pitch angle of the laser. The movable lifting bracket has a rated load of 300kg and a wind resistance level of 4. The laser projector of the embodiment of the present invention has an automatic tracking projection function. When the position of the projected workpiece changes, the workpiece position can be automatically tracked for projection calibration without manual intervention; the laser projector has a local fine projection function. Local fine projection in key areas can make the projection clearer and the positioning more accurate; the laser projector has a missing installation detection function. When a product is missing, an obvious warning will be projected in the area, and it has an automatic focusing function to ensure the optimal projection line width at different distances.

[0030] like Fig.14 As shown, the embodiment of the present invention also provides a large workpiece strain measurement point auxiliary positioning method, based on the large workpiece strain measurement point auxiliary positioning system, the system includes: professional software and automatic control system and the industrial photogrammetry system connected with the professional software and automatic control system, the frame system, the laser projection system and the three-dimensional scanning quantitative analysis system, the large workpiece product surface is provided with a positioning target, the method includes: S1. Before patching, the industrial photogrammetry system, professional software and automatic control system are used to prepare target files and projection files based on the positioning targets on the large workpiece products, the three-dimensional model of the large workpiece products and the preset strain gauge information. The professional software and automatic control system are used to control the carriage system to place the large workpiece products and the laser projection system in the corresponding preset positions respectively; The surface of the large workpiece product is provided with multiple coding points 1-26 and target points 1-27 of different positions and quantities; the large workpiece product includes a storage tank 1-17 and a shell segment 1-23; the industrial photogrammetry system includes an industrial photogrammetry camera; the professional software and automatic control system include: a control cabinet 1-20, a computer is provided in the control cabinet 1-20, and multiple software are installed on the computer, including: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software. The target file production process specifically includes: pasting the positioning target on the target point 1-27 on the surface of the large workpiece product and setting the scale; collecting the positioning target through the industrial photogrammetry camera to obtain the target image; using the EZ-PhotoInspect software, based on the standard size and scale of the coding points 1-26 on the surface of the large workpiece product, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; using the PDC software to perform shape fitting on the identified and spliced ​​target image, create a reference feature, create a coordinate system based on the reference feature, obtain the target point 1-27 with the reference feature and the coordinate system, and generate a target file. The production process of the projection file specifically includes: importing the three-dimensional model of the large workpiece product into the PDC software; using the PDC software, marking the information of the preset strain gauge on the three-dimensional model according to the process requirements, and producing a projection file, wherein the information of the preset strain gauge includes the outline, number and projection order of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; opening the projection file through the Iris software, importing the target file, and realizing the coordinate alignment of the three-dimensional model in the projection file with the actual large workpiece product through the reference features and coordinate system of the target points 1-27 in the target file.

[0031] S2. During the patching process, the carriage system is controlled by professional software and automatic control system, and the operation area of ​​large workpiece products and the position of the laser projection system are adjusted according to the actual operation conditions. The laser projection system is controlled by professional software and automatic control system, and the strain gauges in the current operation area of ​​large workpiece products are projected and patched according to the target file and projection file; The carriage system is controlled by professional software and automatic control system to adjust the working area of ​​large workpiece products and the position of the laser projection system according to the actual working conditions. Specifically, if the current working area of ​​the large workpiece product has not been patched, the carriage system is controlled by the automatic control system to move the laser projection system to the next projection area; if the current working area of ​​the large workpiece product has been patched, the carriage system is controlled by the automatic control system to adjust the large workpiece product to the next working area and move the laser projection system to the initial projection area, and so on, until all working areas of the large workpiece product have been patched; The laser projection system is controlled by professional software and automatic control system, and the strain gauges in the current operating area of ​​the large workpiece product are projected and pasted according to the target file and the projection file. Specifically, the laser projection system is controlled by professional software and automatic control system, and the positioning target in the current operating area of ​​the large workpiece product is automatically identified according to the target file. The outline, position and number of the strain gauge in the current operating area of ​​the large workpiece product are automatically projected in sequence according to the projection sequence in the projection file and the automatically identified positioning target, and the workers implement the strain gauge pasting operation according to the projection content.

[0032] S3. After the patching is completed, the strain gauges pasted on the large workpiece products are scanned in three dimensions through the three-dimensional scanning quantitative analysis system, professional software and automatic control system to obtain a three-dimensional scanning file. The quality of the pasted strain gauges is quantitatively analyzed based on the three-dimensional scanning file and the three-dimensional model in the projection file to generate a strain gauge pasting quality inspection report.

[0033] like Fig.15 As shown, step S3 specifically includes: S301, calibrating the X, Y, Z coordinate position and rotation angle of the strain gauge pasted on the large workpiece product through a tracker or scanner; S302, scanning and meshing the strain gauges pasted on the large workpiece product by using 3DViewer software and a scanner to form a mesh file; S303. Import the 3D model and mesh file in the projection file into Control X 2020.0 software; S304, aligning the three-dimensional model in the projection file and the grid file according to the reference features and coordinate system of the target in the target file, wherein the reference features include point, line, and surface features, which are used to limit the X, Y, and Z coordinate positions and rotation angles to achieve coordinate alignment; S305. Detect the deviation between the X, Y, and Z coordinate positions and the rotation angles of the strain gauges pasted on the large workpiece product in the projection file and the three-dimensional model and the actual large workpiece product, and generate a strain gauge pasting quality inspection report. The strain gauge pasting quality inspection report includes the offset of the X, Y, and Z coordinate positions and the deflection angle of the rotation angle.

[0034] The system of the embodiment of the present invention adopts a movable solution, and the system operation is mainly divided into a tank operation process and a shell segment operation process for the workpiece, and the spatial positioning accuracy is 0.5mm. Table 1 describes the various parameters of the system components and their index values.

[0035] Table 1 Serial number Parameter name Index value 1 Spatial positioning accuracy 0.5mm 2 System Features The system has 3D scanning and point positioning functions, and can locate points through 3D models 3 Overall equipment The system has multi-tasking capabilities, allowing a single computer to control multiple devices 4 Covering product diameter 3350mm、5000mm 5 Covering product length 40m 6 Carriage load 40 tons 7 Lifting height 6.5m 8 Industrial photogrammetry accuracy 4um+4um / m 9 Laser projector accuracy 0.38mm 10 Laser projector projection angle Not less than 80° 11 3D Scanner Accuracy 0.025mm Embodiment 1

[0036] Figure 4 A schematic diagram of the auxiliary positioning of the strain measurement points of the tank product is provided. The auxiliary positioning system for the strain measurement points of the tank product includes: a frame rail 1-1, an auxiliary ground rail 1-2, a first rolling frame 1-3 and a second rolling frame 1-5, an auxiliary support frame 1-4, the first rolling frame 1-3 and the second rolling frame 1-5 are connected to the tank 1-17 through a rolling ring 1-18, and the auxiliary support frame 1-4 is connected to the supporting device of the tank 1-17 through a felt; it also includes a first climbing work vehicle 1-14, a second climbing work vehicle 1-15 and a third climbing work vehicle 1-16 to achieve full coverage of the working area of ​​the tank 1-17; it also includes a first movable lifting vehicle The bracket 1-6 and the first laser projector 1-7 arranged thereon, the second movable lifting bracket 1-8 and the second laser projector 1-9 arranged thereon, the third movable lifting bracket 1-10 and the third laser projector 1-11 arranged thereon, the fourth movable lifting bracket 1-12 and the fourth laser projector 1-13 arranged thereon, the first movable lifting bracket 1-6 and the second movable lifting bracket 1-8 are arranged on one side of the storage tank 1-17, and the third movable lifting bracket 1-10 and the fourth movable lifting bracket 1-12 are arranged on the other side of the storage tank 1-17. The storage tank product 1-17 can be rolled under the action of the first rolling rack 1-3 and the second rolling rack 1-5, ensuring that the workers only work in the most suitable area; the first rolling rack 1-3, the auxiliary support rack 1-4, and the second rolling rack 1-5 move freely on the ground rail 1-1 to be compatible with products of different lengths, and can support products of up to 40m in length. On the tank 1-17, coding points 1-26 and target points 1-27 are arranged irregularly, wherein coding points 1-26 and scales are used together for industrial camera recognition for reverse modeling and image stitching, and target points 1-27 are used for the position and number in the projection file after the laser projector projection alignment is completed. A tank feature reference 1-19 is provided on the tank 1-17, which is used to realize the feature positioning of the tank 1-17, realize the unified alignment of the three-dimensional model of the tank and the physical model of the tank, and can be directly imported into the CAD digital model, supporting igs and stp formats. It also includes a control cabinet 1-20, which is equipped with a computer, a UPS power supply and a switch to realize the collaborative operation of multiple laser projectors. Multiple software are installed on the computer, including: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software. It also includes an industrial photogrammetry system and a three-dimensional scanning quantitative analysis system.

[0037] Fig.16 An operation flow chart of the auxiliary positioning method for strain measurement points of tank products is provided.

[0038] S1: Target file production: According to the target file production process, the target file (xx.cal) is produced to achieve the unification of theoretical model and physical coordinates and feature alignment; through the target file and the actual target position, the laser projector can accurately project the outline, position and label of the strain gauge.

[0039] S2: Projection file production: Import the 3D model through the software, support DWG, DXF, CATIA, NX, Creo and other 3D models, add the outline, number and projection order of the strain gauge in sequence according to the process requirements, save it after completion, and import the target file (xx.cal) produced in step S1 into the projection model; S3: On-site arrangement: According to the length of the product, the rack is moved to the appropriate position on the ground rail. Figure 1 Place the two ends as shown, place the rolling support trolley in the middle support position, place the product on the trolley, move the laser projector and its movable bracket to the appropriate position, and connect the control cabinet to the laser projector; S4: Turn on the projection, connect the laser projector and start projection. The Iris software automatically identifies the target in the area and automatically projects the strain gauge outline, label, etc. in the projection file in the area in the projection order. S5: During the operation, workers polish and apply glue according to the projection content and prompts, and select appropriate strain gauges for pasting, and use the aerial work vehicle to achieve full coverage of the operation area; S6: Switch the projection content, and switch the projection content in order and verify the strain gauge by pressing the button; if the construction of the area is completed, enter S7, otherwise continue the projection; S7: Carriage rolling: The product is rolled circumferentially to the next operation area by means of a carriage; If all circumferential operations of the product are completed, then enter S8, otherwise continue with projection; S8: Laser projector movement: moving the laser projector to the next area along the length direction of the product; If all operations in the product length direction are completed, enter S9, otherwise continue projection; S9: Product operation completed: After the operation is completed, the station will transfer to the next product operation; S10: 3D scanning: After the patch is completed, calibration, scanning, packaging and file saving are achieved through 3DViewer software and 3D scanner; Calibration is divided into tracker calibration and scanner calibration. Follow the instructions and move the calibration stick to the corresponding X, Y, and Z positions and postures for calibration. After the calibration is passed, the indicator will turn green and automatically jump to the next step. There are 30 steps in the tracker calibration and 32 steps in the scanner calibration. After the calibration is completed, the calibration accuracy and whether it is passed are improved. Scanning refers to the scanning of physical objects by a person holding a scanner. Set the resolution and laser exposure parameters according to the actual situation. Click the Start Scan button to scan and control the selection of dynamic markers. Follow the prompts. Red represents the markers that the current tracker is identifying, and white markers represent the markers that have been collected. The punctuation is used to splice different physical objects; until all the punctuation points are collected and all scans are completed, the 3D model collected by the system is consistent with the physical object. Packaging is a one-step operation of the 3DViewer software. After all scans are completed, click Stop Scan, click to exit dynamic tracking, click Mesh to encapsulate the grid, form a grid file and save it to the specified location, which is convenient for subsequent analysis through Control X2020.0 software and digital modeling.

[0040] S11: Generate reports through quantitative analysis, import 3D scan files and models, align and detect through Control X 2020.0 software, analyze height, position and angle, and produce strain gauge pasting quality inspection reports.

[0041] The 3D model and the scanned mesh file were imported through Control X 2020.0 software, and the mesh file and the model were aligned according to the feature benchmark. The feature benchmark includes limiting the X, Y, and Z spatial positions and rotation directions through point, line, and surface features to achieve spatial alignment, detect the deviation between the theoretical and actual X, Y, and Z spatial positions of the strain gauge center, and the deviation of the rotation angle of the strain gauge, and can provide quantitative analysis data such as offset and deflection angle, determine whether there is warping, etc., and provide analysis reports for more than 4,000 strain gauges. Embodiment 2

[0042] Figure 3 A schematic diagram of the auxiliary positioning of the strain measurement points of shell segment products is provided. The auxiliary positioning system for the strain measurement points of shell segment products includes: a frame vehicle ground rail 1-1, an auxiliary ground rail 1-2, a shell segment 1-23 placed on the frame vehicle ground rail 1-1, a fourth aerial work vehicle 1-22, and a fifth movable lifting bracket 1-21 and a fifth laser projector 1-25 arranged thereon. The fifth movable lifting bracket 1-21 and the fifth laser projector are arranged around the shell segment 1-23, and the alignment of the three-dimensional model and the physical model is achieved through the shell segment feature reference 1-24. The CAD digital model can be directly imported, and the igs and stp formats are supported. The fourth aerial work vehicle 1-22 is used to achieve coverage of the operating area for the pasting of strain gauges, and the fifth movable lifting bracket 1-21 and the fifth laser projector are arranged thereon. Figure 3The difference is that the tank 1-17 is rolled by the first rolling frame 1-3 and the second rolling frame 1-5, and the shell segment 1-23 covers the working area by the movement of the fifth movable bracket 1-21. Furthermore, the first laser projector 1-7, the second laser projector 1-9, the third laser projector 1-11, the fourth laser projector 1-13, the fifth laser projector and the first movable lifting bracket 1-6, the second movable lifting bracket 1-8, the third movable lifting bracket 1-10, the fourth movable lifting bracket 1-12, and the fifth movable lifting bracket 1-21 can be switched freely. The coding points 1-26 and the target points 1-27 are arranged irregularly on the shell segment 1-23 product, wherein the coding points 1-26 and the scale are used in combination for industrial photography camera recognition for reverse modeling and image stitching, and the target points 1-27 are used for the position and number in the projection file after the laser projector projection alignment is completed. It also includes a control cabinet 1-20, which is equipped with a computer, a UPS power supply and a switch to achieve the collaborative operation of multiple laser projectors. Multiple software are installed on the computer, including: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software. It also includes an industrial photogrammetry system and a three-dimensional scanning quantitative analysis system.

[0043] Fig.17 An operation flow chart of the auxiliary positioning method of strain measurement points for shell segment products is provided.

[0044] S1: Target file preparation: According to the target file preparation process, prepare the target file (xx.cal) to achieve the unification of theoretical model and physical coordinates and feature alignment; S2: Projection file production: Import the 3D model through the software, support DWG, DXF, CATIA, NX, Creo and other 3D models, add the outline, number and projection order of the strain gauge in sequence according to the process requirements, save it after completion, and import the target file (xx.cal) produced in step S1 into the projection model; S3: On-site arrangement work: according to the product placement on the bracket, move the laser projector and its movable bracket to the appropriate position, and connect the control cabinet to the laser projector; S4: Turn on the projection, connect the laser projector and start projection. The software automatically identifies the target in the area and automatically projects the strain gauge outline, number, etc. in the projection file in the area in the projection order. S5: During the operation, workers polish and apply glue according to the projection content and prompts, and select appropriate strain gauges for pasting, and use the aerial work vehicle to achieve full coverage of the operation area; S6: Switch the projection content, and switch the projection content in order and verify the strain gauge by pressing the button; if the construction of the area is completed, enter S7, otherwise continue the projection; S7: Moving the laser projector: moving the laser projector to the next area along the circumferential direction of the product; if all the operations in the circumferential direction of the product are completed, enter S8, otherwise continue projection; S8: Product operation completed: After the operation is completed, the station will transfer to the next product operation; S9: 3D scanning: After the patch is completed, calibration, scanning, packaging and file saving are achieved through 3DViewer software and 3D scanner; S10: Generate reports through quantitative analysis, import 3D scan files and models, align and detect through Control X 2020.0 software, analyze height, position and angle, and produce strain gauge pasting quality inspection reports.

[0045] Compared with the prior art, the present invention provides a large-scale workpiece strain measurement point auxiliary positioning system and method, which adopts a mobile solution to realize human-machine collaborative operation, realizes the unification of the coordinate system of the real object and the model through industrial photogrammetry, and does not require precise positioning of assembly tooling; the frame car moves freely on the ground rail to be compatible with large workpieces of different lengths, realizes the fixation and rotation of the test piece during the marking process, and is equipped with a high-altitude work vehicle to achieve full coverage of the working area of ​​the large workpiece, and personnel only need to be in the most reasonable position; the laser projector accurately projects the spatial position and serial number of the strain gauge according to the projection file, assists workers in marking and labeling, and can automatically track the workpiece position according to the change of the projected workpiece position for projection calibration without manual intervention; finally, a three-dimensional scanning quantitative analysis system is used to realize quantitative analysis of the position, angle, prying edge, etc. of the patch quality.

[0046] The system is compatible with larger products and covers a wider range, solving the problem of difficult measurement of the position of concentrated stress test parts by manual marking. The system has high spatial positioning accuracy, ≯0.5mm in large spaces, and is compatible with tanks and shell products of different diameters within 40 meters. It can reduce patch time by more than 50%, and while reducing the labor intensity of workers, it can significantly improve work efficiency and assembly accuracy, further improve test quality, and ensure the safety of equipment, personnel and products.

[0047] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A large workpiece strain measurement point auxiliary positioning system, characterized in that: The system includes: professional software and automatic control system, and industrial photogrammetry system, crane system, laser projection system and 3D scanning quantitative analysis system connected with the professional software and automatic control system. Positioning targets are set on the surface of large workpiece products. The system is used for: Before patching, the industrial photogrammetry system, the professional software and the automatic control system are used to prepare target files and projection files based on the positioning targets on the large workpiece product, the three-dimensional model of the large workpiece product and the information of the preset strain gauges, and the gantry system is controlled by the professional software and the automatic control system to place the large workpiece product and the laser projection system at corresponding preset positions respectively; During the patching process, the carriage system is controlled by the professional software and automatic control system, the operation area of ​​the large workpiece product and the position of the laser projection system are adjusted according to the actual operation conditions, and the laser projection system is controlled by the professional software and automatic control system to project and patch the strain gauges in the current operation area of ​​the large workpiece product according to the target file and the projection file; After the patching is completed, the strain gauges pasted on the large workpiece product are three-dimensionally scanned by the three-dimensional scanning quantitative analysis system, the professional software and the automatic control system to obtain a three-dimensional scanning file. The patch quality of the pasted strain gauges is quantitatively analyzed based on the three-dimensional scanning file and the three-dimensional model in the projection file to generate a strain gauge pasting quality inspection report.

2. The large workpiece strain measurement point auxiliary positioning system according to claim 1 is characterized in that: The surface of the large workpiece product is provided with a plurality of encoding points (1-26) and target points (1-27) at different positions and numbers; the large workpiece product comprises a storage tank (1-17) and a shell segment (1-23); the industrial photogrammetry system comprises an industrial photogrammetry camera; the professional software and automatic control system comprises: a control cabinet (1-20), a computer is arranged in the control cabinet (1-20), and a plurality of software are installed on the computer, the plurality of software comprises: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software; The target file preparation process specifically includes: Pasting a positioning target on a target point (1-27) on the surface of the large workpiece product and setting a scale; Acquiring the positioning target by means of the industrial photogrammetry camera to obtain a target image; Using the EZ-Photo Inspect software, based on the standard size of the coded points (1-26) on the surface of the large workpiece product and the scale, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; Performing shape fitting on the identified and spliced ​​target images through the PDC software to create a reference feature, creating a coordinate system based on the reference feature, obtaining a target point (1-27) having a reference feature and a coordinate system, and generating a target file; The production process of the projection file specifically includes: Importing the three-dimensional model of the large workpiece product into the PDC software; By means of the PDC software, the information of the preset strain gauge is marked on the three-dimensional model according to the process requirements, and a projection file is prepared, wherein the information of the preset strain gauge includes the outline, number and projection sequence of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; The projection file is opened by the Iris software, the target file is imported, and the coordinate alignment between the three-dimensional model in the projection file and the actual large workpiece product is achieved through the reference features and coordinate system of the target points (1-27) in the target file.

3. The large workpiece strain measurement point auxiliary positioning system according to claim 2 is characterized in that: The trolley system comprises: a trolley ground rail (1-1), an auxiliary ground rail (1-2) is laid on both sides of the trolley ground rail (1-1), a rolling trolley is arranged at each end of the trolley ground rail (1-1), namely a first rolling trolley (1-3) and a second rolling trolley (1-5), an auxiliary support trolley (1-4) is arranged in the middle of the trolley ground rail (1-1), the first rolling trolley (1-3) and the second rolling trolley (1-5) are connected to the storage tank (1-17) through a rolling ring (1-18), the auxiliary support trolley (1-4) is connected to the support device of the storage tank (1-17) through a felt, and the shell segment (1-23) is placed on the trolley ground rail (1-1); The tank (1-17) is provided with a tank characteristic datum (1-19) for realizing characteristic positioning of the tank (1-17), and the shell segment (1-23) is provided with a shell segment characteristic datum (1-24) for realizing characteristic positioning of the shell segment (1-23).

4. The large workpiece strain measurement point auxiliary positioning system according to claim 3 is characterized in that: The rolling frame vehicle comprises a rolling frame vehicle chassis (2-1), a rolling frame vehicle top lifting mechanism fixing box (2-2), a rolling frame vehicle transverse shifting base (2-3), two rolling frame vehicle driving wheel shafts (2-4), and a rolling frame vehicle arc frame (2-5); four casters (2-6) are installed below the rolling frame vehicle chassis (2-1); and a brake handwheel (2-7) is installed on the casters (2-6); The rolling frame vehicle chassis (2-1) is provided with a rolling frame vehicle lifting mechanism fixing box (2-2); the rolling frame vehicle transverse shifting base (2-3) is fixed above the rolling frame vehicle lifting mechanism fixing box (2-2) and the two are connected to each other via a lifting screw (2-16); and the rolling frame vehicle transverse shifting base (2-3) is adjusted up and down along the lifting screw (2-16) under the action of a lifting adjustment device (2-9); A transverse moving slide rail (2-14) is installed above the rolling frame vehicle transverse shifting base (2-3), and a transverse moving slider (2-15) is installed below the rolling frame vehicle circular arc frame (2-5), so that the transverse horizontal adjustment of the rolling frame vehicle circular arc frame (2-5) is achieved under the action of the transverse shifting adjustment device (2-8); Two driving wheel shafts (2-4) of the rolling frame are installed on the upper part of the rolling frame arc frame (2-5); the two driving wheel shafts (2-4) of the rolling frame are driven by a servo motor to realize the rolling of the storage box product (1-17); the driving wheel shafts (2-4) of the rolling frame are switched between automatic and manual by a clutch; the rolling frame can realize manual rolling under the action of a manual rotating wheel (2-10); An encoder (2-11) is installed in the middle of the two driving wheel shafts (2-4) of the rolling frame vehicle, and the encoder (2-11) is used to realize the synchronous operation of the two driving wheel shafts (2-4) of the rolling frame vehicle through a control algorithm; The rolling frame vehicle is provided with a power interface panel (2-13) and a control interface panel (2-12); the control interface panel (2-12) is connected to the control cabinet (1-20), and automatic rolling of the rolling frame vehicle is achieved through the control cabinet (1-20).

5. The large workpiece strain measurement point auxiliary positioning system according to claim 4 is characterized in that: The auxiliary support frame vehicle (1-4) comprises an auxiliary support frame vehicle chassis (3-1), an auxiliary support frame vehicle lifting mechanism fixing box (3-2), an auxiliary support frame vehicle transverse shifting base (3-3), and an auxiliary support frame vehicle arc frame (3-4); the auxiliary support frame vehicle arc frame (3-4) is installed above the auxiliary support frame vehicle transverse shifting base (3-3); and the auxiliary support frame vehicle arc frame (3-4) adopts the form of arc surface support; An auxiliary support vehicle caster (3-7) is installed below the auxiliary support vehicle chassis (3-1), and an auxiliary support vehicle brake handwheel (3-8) is installed above the auxiliary support vehicle caster (3-7); The auxiliary support frame vehicle top lifting mechanism fixing box (3-2) is fixed above the auxiliary support frame vehicle chassis (3-1), connected to the auxiliary support frame vehicle transverse displacement base (3-3) via an auxiliary support frame vehicle lifting screw (3-10), and is adjusted up and down via an auxiliary support frame vehicle lifting adjustment device (3-6); A transverse moving slide rail slider (3-9) is fixed on the auxiliary support frame trolley transverse moving base (3-3), and transverse horizontal adjustment is achieved through the auxiliary support frame trolley transverse moving adjustment device (3-5).

6. The large workpiece strain measurement point auxiliary positioning system according to any one of claims 3 to 5, characterized in that: The laser projection system comprises: five movable lifting brackets and five laser projectors, namely, a first movable lifting bracket (1-6) and a first laser projector (1-7) arranged thereon, a second movable lifting bracket (1-8) and a second laser projector (1-9) arranged thereon, a third movable lifting bracket (1-10) and a third laser projector (1-11) arranged thereon, a fourth movable lifting bracket (1-12) and a fourth laser projector (1-13) arranged thereon, and a fifth movable lifting bracket (1-21) and a fifth laser projector (1-25) arranged thereon; The first movable lifting bracket (1-6) and the second movable lifting bracket (1-8) are arranged on one side of the tank (1-17), the third movable lifting bracket (1-10) and the fourth movable lifting bracket (1-12) are arranged on the other side of the tank (1-17), and the fifth movable lifting bracket (1-21) is arranged around the shell segment (1-23); The movable lifting bracket comprises movable bracket casters (4-1), auxiliary casters (4-2), a mast-type lifting mechanism (4-3), and a laser projector fixed bracket (4-4); the movable bracket casters (4-1) are used for assisting the movable lifting bracket to walk on the ground when the movable lifting bracket is in an extended state; the auxiliary casters (4-2) are used for assisting the movable lifting bracket to walk on the ground when the movable lifting bracket is in a retracted state; the mast-type lifting mechanism (4-3) adjusts the lifting height through the adjustment hand wheel (4-5); and the laser projector fixed bracket (4-4) fixes the laser projector arranged thereon through a tool to cover the projection area; The system also includes a climbing operation system. Before patching, the trolley system is controlled by the professional software and automatic control system to place the climbing operation system at a corresponding preset position, so that the entire operation area of ​​the large workpiece product can be covered by the climbing operation system. The climbing work system comprises: a first climbing work vehicle (1-14), a second climbing work vehicle (1-15), a third climbing work vehicle (1-16), and a fourth climbing work vehicle (1-22); the first climbing work vehicle (1-14), the second climbing work vehicle (1-15), and the third climbing work vehicle (1-16) are used to achieve full coverage of the operation area of ​​the tank (1-17); and the fourth climbing work vehicle (1-22) is used to achieve full coverage of the operation area of ​​the shell section (1-23).

7. A large workpiece strain measurement point auxiliary positioning method, based on the large workpiece strain measurement point auxiliary positioning system according to any one of claims 1 to 6, characterized in that: The system includes: professional software and automatic control system, and an industrial photogrammetry system, a crane system, a laser projection system and a three-dimensional scanning quantitative analysis system connected to the professional software and automatic control system. A positioning target is set on the surface of a large workpiece product. The method includes: S1. Before patching, the industrial photogrammetry system, the professional software and the automatic control system are used to prepare target files and projection files based on the positioning targets on the large workpiece product, the three-dimensional model of the large workpiece product and the information of the preset strain gauges, and the gantry system is controlled by the professional software and the automatic control system to place the large workpiece product and the laser projection system at corresponding preset positions respectively; S2. During the patching process, the gantry system is controlled by the professional software and the automatic control system, the operation area of ​​the large workpiece product and the position of the laser projection system are adjusted according to the actual operation conditions, and the laser projection system is controlled by the professional software and the automatic control system to project and patch the strain gauges in the current operation area of ​​the large workpiece product according to the target file and the projection file; S3. After the patching is completed, the strain gauges pasted on the large workpiece product are three-dimensionally scanned by the three-dimensional scanning quantitative analysis system, the professional software and the automatic control system to obtain a three-dimensional scanning file. The patch quality of the pasted strain gauges is quantitatively analyzed according to the three-dimensional scanning file and the three-dimensional model in the projection file to generate a strain gauge pasting quality inspection report.

8. The large workpiece strain measurement point auxiliary positioning method according to claim 7 is characterized in that: The surface of the large workpiece product is provided with a plurality of encoding points (1-26) and target points (1-27) at different positions and numbers; the large workpiece product comprises a storage tank (1-17) and a shell segment (1-23); the industrial photogrammetry system comprises an industrial photogrammetry camera; the professional software and automatic control system comprises: a control cabinet (1-20), a computer is arranged in the control cabinet (1-20), and a plurality of software are installed on the computer, the plurality of software comprises: Iris software, 3DViewer software, Control X2020.0 software, EZ-PhotoInspect software and PDC software; In step S1, the target file preparation process specifically includes: Pasting a positioning target on a target point (1-27) on the surface of the large workpiece product and setting a scale; Acquiring the positioning target by means of the industrial photogrammetry camera to obtain a target image; Using the EZ-Photo Inspect software, based on the standard size of the coded points (1-26) on the surface of the large workpiece product and the scale, the target image is identified and spliced ​​to obtain the identified and spliced ​​target image; Performing shape fitting on the identified and spliced ​​target images through the PDC software to create a reference feature, creating a coordinate system based on the reference feature, obtaining a target point (1-27) having a reference feature and a coordinate system, and generating a target file; In step S1, the process of making the projection file specifically includes: Importing the three-dimensional model of the large workpiece product into the PDC software; By means of the PDC software, the information of the preset strain gauge is marked on the three-dimensional model according to the process requirements, and a projection file is prepared, wherein the information of the preset strain gauge includes the outline, number and projection sequence of the strain gauge, and the projection file includes the marked three-dimensional model and the information of the preset strain gauge; The projection file is opened by the Iris software, the target file is imported, and the coordinate alignment between the three-dimensional model in the projection file and the actual large workpiece product is achieved through the reference features and coordinate system of the target points (1-27) in the target file.

9. The large workpiece strain measurement point auxiliary positioning method according to claim 8, characterized in that: In step S2, the crane system is controlled by the professional software and the automatic control system to adjust the operation area of ​​the large workpiece product and the position of the laser projection system according to the actual operation conditions, which specifically includes: If the patching of the current working area of ​​the large workpiece product has not been completed, the automatic control system controls the carriage system to move the laser projection system to the next projection area; if the patching of the current working area of ​​the large workpiece product has been completed, the automatic control system controls the carriage system to adjust the large workpiece product to the next working area and move the laser projection system to the initial projection area, and so on, until the patching of all working areas of the large workpiece product has been completed; In step S2, the laser projection system is controlled by the professional software and the automatic control system, and the strain gauges in the current working area of ​​the large workpiece product are projected and mounted according to the target file and the projection file, specifically including: The laser projection system is controlled by the professional software and automatic control system, and the positioning target in the current operating area of ​​the large workpiece product is automatically identified according to the target file. The outline, position and label of the strain gauge in the current operating area of ​​the large workpiece product are automatically projected in sequence according to the projection order in the projection file and the automatically identified positioning target, and the worker performs the strain gauge pasting operation according to the projection content.

10. The large workpiece strain measurement point auxiliary positioning method according to claim 8 or 9, characterized in that: Step S3 specifically includes: S301, calibrating the X, Y, Z coordinate positions and rotation angles of the strain gauges attached to the large workpiece product by means of a tracker or a scanner; S302, scanning and meshing the strain gauges pasted on the large workpiece product by using the 3DViewer software and the scanner to form a mesh file; S303, importing the three-dimensional model in the projection file and the mesh file into the Control X 2020.0 software; S304, aligning the three-dimensional model in the projection file and the grid file according to the reference features and coordinate system of the target points (1-27) in the target file, wherein the reference features include point, line, and surface features, which are used to limit the X, Y, and Z coordinate positions and rotation angles to achieve coordinate alignment; S305, detecting the deviation between the X, Y, and Z coordinate positions and the rotation angles of the strain gauges pasted on the large workpiece product and the three-dimensional model in the projection file and the actual large workpiece product, and generating a strain gauge pasting quality inspection report, wherein the strain gauge pasting quality inspection report includes the offset of the X, Y, and Z coordinate positions and the deflection angle of the rotation angle.

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