Optical measuring device for electric porcelain insulator and method thereof

Abstract

The application discloses an optical measuring device for electric porcelain insulators and a method thereof, and relates to the technical field of insulator optical measurement. The device comprises a main frame, a measuring chamber installed on the outer wall of one side of the main frame, a calibration plate fixedly installed on the top of the measuring chamber, and a concave-shaped support plate installed at a lower position inside the main frame. A screw rod electric linear module is installed at the top end of the concave-shaped support plate. Two structured light three-dimensional scanners with lenses facing the calibration plate are installed at the driving end of the screw rod electric linear module. A rotating disc deceleration transposition assembly is installed at the bottom of the measuring chamber. The device combines double-station parallel scanning with rotating disc type continuous feeding. The rotating disc deceleration transposition assembly realizes batch pre-fixing and sequential switching of workpieces, reduces scanning deviation in manual operation, and thus makes the scanned track, data acquisition density and adjacent scanning band overlap rate of each electric porcelain insulator of the same type completely consistent.

Description

Technical Field

[0001] This invention relates to the field of optical measurement technology for insulators, specifically to an optical measurement device and method for porcelain insulators. Background Technology

[0002] Porcelain insulators play a crucial role in power systems, providing both mechanical support and electrical insulation. Surface defects such as cracks, flaws, deformation, or uneven glaze can significantly reduce insulation performance and even trigger major power accidents. Traditional manual visual or contact measurement methods are inefficient, subjective, and struggle to obtain comprehensive three-dimensional dimensional data. Optical measurement devices, through automated scanning and 3D reconstruction, can quickly and accurately capture the complete morphology of the insulator surface, enabling objective defect identification and quantitative assessment of dimensional deviations. These devices typically include a projection system, camera, computing unit, and support frame. The projection system projects light signals onto the insulator surface, the camera captures the deformation of the light signals, and the computing unit processes the acquired data to extract the insulator's three-dimensional information. During measurement, the insulator is first cleaned to ensure accuracy. The scanner's position and angle are then adjusted to capture surface information from all angles. After scanning, the data is transmitted to the computing unit for processing. Specialized software generates a 3D model, identifies defects, and measures dimensions. Finally, the measurement results are compared with standards to assess whether the insulator's appearance meets production requirements.

[0003] Currently, when performing optical measurements on long-sized porcelain insulators, the overall length of the insulator far exceeds the depth of field of a single scan, making it impossible to obtain the complete three-dimensional data in a single image. The entire length must be divided into multiple measurement segments and scanned segment by segment. In this case, the porcelain insulator must be fixed on a turntable, and the operator uses a structured light 3D scanner to scan along the length of the insulator until complete three-dimensional information is obtained. The entire process of fixing, aligning, segmented scanning, monitoring, and adjusting is time-consuming. Completing a complete scan of a porcelain insulator product may take tens of minutes or even longer, resulting in low detection efficiency. Furthermore, the precise control of the structured light scanner's movement distance, the judgment of overlapping areas, and the manual fine-tuning of the scanning angle all depend on the operator's experience, focus, and physical condition, inevitably introducing human fluctuations. Different personnel, or even the same person operating at different times, may cause differences in scanning path, data density, and splicing quality, resulting in insufficient consistency in measurement results. Summary of the Invention

[0004] The purpose of this invention is to provide an optical measurement device and method for porcelain insulators. Multiple porcelain insulator workpieces to be measured are fixed at their lower ends by rotary fixtures. A turntable speed reduction and positioning assembly rotates the workpieces by a certain angle, adjusting two of the rotary fixtures to be directly in front of two structured light 3D scanners. Then, an electrical control box drives a wedge-type double-position lifting shaft connection assembly. This assembly connects to the two rotary fixtures in position via a keyed shaft sprocket speed reduction transmission structure. When the lead screw electric linear module drives the two structured light 3D scanners upwards, the rotational power of the lead screw electric linear module is also transmitted to the rotary fixtures via the keyed shaft sprocket speed reduction transmission structure, causing the workpieces to rotate during the scanner's upward movement until the 3D information of the entire workpiece surface is acquired, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an optical measuring device for porcelain insulators, comprising a main frame, a measuring chamber mounted on the outer wall of one side of the main frame, a calibration plate fixedly mounted on the top of the measuring chamber, and a concave support plate mounted inside the main frame at a lower position. A lead screw electric linear module is mounted on the top of the concave support plate. Two structured light 3D scanners with lenses facing the calibration plate are mounted on the drive end of the lead screw electric linear module. A turntable deceleration and transposition assembly is mounted on the bottom of the measuring chamber. At least four rotary fixtures for clamping porcelain insulators are mounted on the drive end of the turntable deceleration and transposition assembly. The turntable deceleration and transposition assembly is used to move two of the rotary fixtures... Rotate to the front of the structured light 3D scanner. At the bottom of the concave support plate, a key shaft type sprocket reduction transmission structure is installed to maintain power connection with the lead screw electric linear module. At the bottom of the measuring chamber below the concave support plate, a wedge-type double-position lifting shaft connection assembly is installed. The wedge-type double-position lifting shaft connection assembly is used to enable the two rotary fixtures in front of the structured light 3D scanner to engage with the key shaft type sprocket reduction transmission structure when the lead screw electric linear module is working. An electrical control box is installed on one outer wall of the measuring chamber. The output end of the electrical control box is electrically connected to the input end of the lead screw electric linear module, the turntable reduction and positioning assembly, and the wedge-type double-position lifting shaft connection assembly, respectively.

[0006] Preferably, two CCD camera measurement components are installed on the upper part of one side of the outer wall of the main frame. The lenses of the CCD camera measurement components face downward and are coaxial with the rotating fixture directly in front of the structured light 3D scanner.

[0007] Preferably, the lead screw electric linear module includes a threaded shaft rotatably mounted on the top of a concave support plate, guide posts fixed on the top of the concave support plates on both sides of the threaded shaft, and a support plate slidably mounted between the two guide posts via a sleeve. A nut pair for threaded engagement with the threaded shaft is fixed inside the support plate. Two structured light 3D scanners are symmetrically mounted on both sides of the top of the support plate. A servo motor is mounted on the top of the main frame. Synchronous pulleys are fixed to the upper end of the output shaft of the servo motor and the upper end of the threaded shaft. A transmission belt is installed between the two synchronous pulleys. The lower end of the threaded shaft is connected to a keyed sprocket reduction transmission structure.

[0008] Preferably, the wedge-type double-position lifting shaft connection assembly includes a connecting plate fixed to the bottom of the measuring chamber, a U-shaped sliding arm slidably installed along the width direction of the measuring chamber via a track at the left and right positions of the top of the connecting plate, and a double-column elastic reset structure set on both sides of the top of the connecting plate. The movable end of the double-column elastic reset structure is fixed with a right-angle plate, and the lower end of the right-angle plate is fixed with an upper trapezoidal head. The top of the U-shaped sliding arm is equipped with a lower trapezoidal head that maintains a sliding fit with the upper trapezoidal head. The top of the right-angle plate is rotatably equipped with a vertically upward-extending external spline lower shaft. The external spline lower shaft and the key shaft type sprocket reduction transmission structure are connected for power connection and obtain rotational power from the threaded shaft. A cylinder is installed at the top of the connecting plate between the two double-column elastic reset structures. The piston rod of the cylinder is fixed with a middle plate. The middle plate is driven by the cylinder and slides along the length direction of the measuring chamber. A grooved wheel pushing structure is installed between the middle plate and the U-shaped sliding arm.

[0009] Preferably, the grooved wheel pushing structure includes an arc-shaped wedge groove in the middle plate and a protruding plate bolted to the top of the U-shaped sliding arm. A pin is rotatably installed at the bottom end of the protruding plate. The pin is located in the arc-shaped wedge groove. When the cylinder pushes the middle plate to move towards the opening of the measuring chamber, the middle plate drives the U-shaped sliding arms on both sides to move outward synchronously through the arc-shaped wedge groove and the pin.

[0010] Preferably, the double-column elastic reset structure includes two uprights fixed to one side of the top of the connecting plate and a support platform slidably installed on the two uprights. A helical spring coaxial with the uprights is fixed at the bottom of the support platform. A right-angle plate and an upper trapezoidal head are respectively fixed to the top and bottom of the support platform.

[0011] Preferably, the keyed sprocket reduction transmission structure includes a drive sprocket fixed to the lower end of the threaded shaft, two outer spherical bearing seats fixed symmetrically to the top of the concave support plate, and a hollow inner spline central shaft rotatably installed inside the outer spherical bearing seats. A reduction sprocket is fixed to one end of the surface of the hollow inner spline central shaft, and a transmission wheel is installed between the reduction sprocket and the drive sprocket. The upper end of the lower outer spline shaft passes through the hollow inner spline central shaft.

[0012] Preferably, the rotary tooling includes an outer spherical bearing housing II mounted on the drive end of the turntable reduction and shifting assembly, a hollow inner spline upper shaft that passes through and is rotatably mounted inside the outer spherical bearing housing II, and a chuck fixed at the top of the hollow inner spline upper shaft. The outer spline lower shaft is used to enter the hollow inner spline upper shaft when the cylinder piston rod is extended.

[0013] Preferably, the turntable reduction and transposition assembly includes a turntable frame fixed to the bottom of the measuring chamber, an external gear ring rotatably mounted on the top of the turntable frame, a support plate fixed to the top of the external gear ring, and a reduction motor mounted on the top of the turntable frame. The output axis of the reduction motor extends upward and is fixed with a drive gear that meshes with the external gear ring. The outer spherical bearing seat is fixed at the upper edge of the support plate. Detection tongues are fixed on both sides of the bottom end of the support plate. Slotted photoelectric switches for detecting the position of the detection tongues are installed on both sides of the top of the turntable frame.

[0014] The present invention also provides a method for optical measurement of porcelain insulators, using the above-described measuring device, comprising the following steps:

[0015] S101: The porcelain insulator workpiece is vertically clamped and fixed on the empty rotary fixture. After the loading is completed, the staff starts the measurement work through the human-machine interface of the control box. The turntable deceleration and positioning assembly starts to move under the command of the control box. The turntable deceleration and positioning assembly transports the two rotary fixtures with the new workpieces just clamped and positions them in front of the structured light 3D scanner.

[0016] S102: Once the workpiece is in place, the electrical control box issues a command to drive the wedge-type double-position lifting shaft connection assembly to operate. The wedge-type double-position lifting shaft connection assembly reliably docks with the input shaft ends of the two rotary toolings that have been rotated into place, completing the mechanical connection. After the power connection is established, the electrical control box controls the lead screw electric linear module to start. The lead screw electric linear module drives the two structured light 3D scanners fixed on it to start moving upward synchronously and at a constant speed along the vertical length direction of the workpiece. During this process, the rotational power of the lead screw electric linear module is not only used to lift the structured light 3D scanner, but also transmitted and converted into the rotational power of the two rotary toolings through the connected key shaft sprocket reduction transmission structure. Thus, while the structured light 3D scanner moves upward at a constant speed, the two porcelain insulator workpieces also rotate at a constant speed around their own axes, forming a spiral scanning trajectory. At the moment when the scanning data acquisition is completed, the host end connected to the structured light 3D scanner automatically compares the acquired 3D point cloud data with the pre-stored standard workpiece digital model to complete the preliminary verification of the outline and dimensions.

[0017] S103: The lead screw electric linear module moves in the reverse direction, driving the structured light 3D scanner down to its original starting position. The wedge-type double-position lifting shaft connection assembly is reset, disengaging it from the input shaft end of the rotary fixture, disconnecting the power connection. The turntable deceleration and repositioning assembly restarts, rotating a certain angle to move the two workpieces that have just been scanned away from the scanning station to a position convenient for personnel to operate. At the same time, the rotary fixture with the next batch of two workpieces already clamped to be tested is sent to the front of the structured light 3D scanner.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: The optical measurement device and method for porcelain insulators are configured with a control box, a measurement chamber, a calibration plate, a lead screw electric linear module, two structured light 3D scanners, a turntable reduction and positioning assembly, a rotary fixture, a wedge-type double-position lifting shaft connection assembly, and a key shaft sprocket reduction transmission structure, etc., which cooperate with each other. The lower ends of multiple porcelain insulator workpieces to be measured are fixed by the rotary fixtures one by one. The turntable reduction and positioning assembly rotates a certain angle, so that two of the rotary fixtures holding the workpieces are adjusted to be directly in front of the two structured light 3D scanners. Then, the control box drives the wedge-type double-position lifting shaft connection assembly to move. The wedge-type double-position lifting shaft connection assembly connects with the two rotary fixtures that have been rotated into position through the key shaft sprocket reduction transmission structure. When the lead screw electric linear module drives the two structured light 3D scanners to move upward, the rotational power of the lead screw electric linear module will also be transmitted to the rotary fixture through the key shaft sprocket reduction transmission structure, so that the workpiece rotates during the upward movement of the scanner until the three-dimensional information of the entire workpiece surface is acquired and the data is compared. After the two workpieces are scanned, the electrical control box controls the wedge-type double-position lifting shaft connection assembly to reset and disconnects the power connection between the key shaft sprocket reduction transmission structure and the two rotary fixtures. Then the turntable reduction and positioning assembly adjusts the other two rotary fixtures with workpieces clamped to the front of the two structured light 3D scanners to repeat the above actions, thereby integrating the originally discrete scanning process that relies on manual step-by-step operation into a continuous and automated cyclic operation unit.

[0019] This solution combines dual-station parallel scanning with rotary continuous feeding. The rotary deceleration and switching assembly enables batch pre-fixation and sequential switching of workpieces. This allows operators to perform unloading of already measured workpieces and loading of new workpieces at other stations while two workpieces are being scanned, eliminating idle time while the equipment waits for manual operation. Simultaneously, when the lead screw electric linear module drives the two structured light 3D scanners upwards, it synchronously drives the workpiece rotation via a keyed shaft sprocket reduction transmission structure. This achieves the combined motion of the structured light 3D scanner's axial movement and the workpiece's circumferential rotation, thus completing the entire process in a single smooth continuous stroke. The spiral full-coverage scanning of the surface of each cylindrical workpiece eliminates the need for manual segmentation, pauses, and repositioning, thereby improving inspection efficiency. Secondly, the precise programming control by the electrical control box and the lead screw electric linear module eliminates speed inconsistencies and distance errors caused by manual hand-held or step-by-step movement. The wedge-type double-position lifting shaft connection assembly ensures the positional accuracy and repeatability of power connection and disconnection, avoiding deviations that may occur during manual docking. As a result, for each porcelain insulator of the same model, the scanned trajectory, data acquisition density, and overlap rate of adjacent scan zones are completely consistent, providing a highly consistent basis for subsequent dimensional comparison and defect judgment. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the main structure of the present invention;

[0021] Figure 2 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 1 ;

[0022] Figure 3 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 2 ;

[0023] Figure 4 This is a schematic diagram of the front cross-sectional structure of the present invention;

[0024] Figure 5 This is a three-dimensional cross-sectional structural diagram of the present invention;

[0025] Figure 6 This is a three-dimensional structural diagram of the main frame of the present invention with the left and right wall panels removed.

[0026] Figure 7 This is a three-dimensional structural diagram of the lead screw electric linear module of the present invention;

[0027] Figure 8 This is a schematic diagram of the three-dimensional cross-sectional structure of the wedge-type double-position lifting shaft connection assembly of the present invention;

[0028] Figure 9 For the present invention Figure 9 Enlarged structural diagram at point A in the middle;

[0029] Figure 10 This is a schematic diagram of the three-dimensional structure of the wedge-type double-position lifting shaft connection assembly of the present invention. Figure 1 ;

[0030] Figure 11 This is a schematic diagram of the three-dimensional structure of the wedge-type double-position lifting shaft connection assembly of the present invention. Figure 2 ;

[0031] Figure 12 This is a schematic diagram of the three-dimensional structure of the rotary table deceleration and transposition assembly of the present invention;

[0032] Figure 13 This is a three-dimensional cross-sectional structural diagram of the turntable deceleration and transposition assembly of the present invention.

[0033] In the diagram: 1. Main frame; 2. Measuring chamber; 3. Lead screw electric linear module; 301. Threaded shaft; 302. Guide post; 303. Support plate; 304. Nut pair; 305. Servo motor; 306. Synchronous pulley; 4. CCD camera measuring assembly; 5. Turntable reduction and transposition assembly; 501. Turntable frame; 502. Gear motor; 503. External gear ring; 504. Support plate; 505. Slotted photoelectric switch; 506. Detector tongue; 507. Drive gear; 6. Rotary fixture; 601. Second outer spherical bearing seat; 602. Hollow internal spline upper shaft; 603. Chuck; 7. Concave support plate; 8. Structured light. 3D scanner; 9. Wedge-type double-position lifting shaft connection assembly; 901. Connecting plate; 902. Middle plate; 903. Arc-shaped wedge groove; 904. Cylinder; 905. U-shaped sliding arm; 906. Lower trapezoidal head; 907. Double-column elastic reset structure; 908. Right-angle plate; 909. Lower external spline shaft; 910. Upper trapezoidal head; 911. Convex plate; 912. Pin; 10. Key shaft type sprocket reduction transmission structure; 1001. Outer spherical bearing seat one; 1002. Hollow internal spline central shaft; 1003. Reduction sprocket; 1004. Transmission wheel; 1005. Drive sprocket; 11. Electrical control box; 12. Calibration plate. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0035] Example 1, by Figures 1 to 7The present invention includes a main frame 1, a measuring chamber 2 installed on the outer wall of one side of the main frame 1, a calibration plate 12 fixedly installed on the top of the measuring chamber 2, and a concave support plate 7 installed at a lower position inside the main frame 1. A lead screw electric linear module 3 is installed at the top of the concave support plate 7. Two structured light 3D scanners 8 with lenses facing the calibration plate 12 are installed at the drive end of the lead screw electric linear module 3. The measuring chamber 2 provides a physically isolated and stable measuring environment. Before the calibration plate 12 is measured, the structured light 3D scanners 8 establish a unified coordinate system by scanning the precise positioning points with known dimensions and positions on the calibration plate 12.

[0036] A turntable reduction and transposition assembly 5 is installed at the bottom of the measuring chamber 2. At least four rotary fixtures 6 for clamping porcelain insulators are installed on the drive end of the turntable reduction and transposition assembly 5. The turntable reduction and transposition assembly 5 is used to rotate two of the rotary fixtures 6 to the front of the structured light 3D scanner 8. A key shaft sprocket reduction transmission structure 10 is installed at the bottom of the concave support plate 7 to maintain power connection with the lead screw electric linear module 3. The bottom of the measuring chamber 2 below the concave support plate 7 is equipped with... There is a wedge-type double-position lifting shaft connection assembly 9, which is used to enable the two rotary tooling 6 in front of the structure light 3D scanner 8 to engage with the key shaft type sprocket reduction transmission structure 10 when the lead screw electric linear module 3 is working. An electrical control box 11 is installed on one side of the outer wall of the measuring chamber 2. The output end of the electrical control box 11 is electrically connected to the input end of the lead screw electric linear module 3, the turntable reduction and shifting assembly 5, and the wedge-type double-position lifting shaft connection assembly 9 respectively.

[0037] Two CCD camera measurement components 4 are installed on the upper part of one side of the outer wall of the main frame 1. The lens of the CCD camera measurement component 4 faces downward and is coaxial with the rotating fixture 6 in front of the structured light 3D scanner 8. The CCD camera measurement component 4 can detect the top-view plane data of the electric porcelain insulator during its rotation process from above the workpiece.

[0038] The lead screw electric linear module 3 includes a threaded shaft 301 rotatably mounted on the top of a concave support plate 7, guide posts 302 fixed on the top of the concave support plates 7 on both sides of the threaded shaft 301, and a support plate 303 slidably mounted between the two guide posts 302 via a sleeve. A nut pair 304 for threaded engagement with the threaded shaft 301 is fixed inside the support plate 303. Two structured light 3D scanners 8 are symmetrically mounted on both sides of the top of the support plate 303. A servo motor 305 is mounted on the top of the main frame 1. Synchronous pulleys 306 are fixed to the upper end of the output shaft of the servo motor 305 and the upper end of the threaded shaft 301. A transmission belt is installed between them. The lower end of the threaded shaft 301 is connected to the key shaft type sprocket reduction transmission structure 10. When the lead screw electric linear module 3 is working, it controls the servo motor 305 to work through the electrical control box 11. The output shaft of the servo motor 305 drives the threaded shaft 301 to rotate through the synchronous pulley 306 and the transmission belt. Then, the threaded shaft 301 drives the servo motor 305 and the two structured light 3D scanners 8 to move up and down along the vertical axis of the guide post 302 through the nut pair 304, so as to realize the high-precision and high-stability linear motion of the structured light 3D scanner 8, replacing the unstable manual hand-held or stepping movement.

[0039] This embodiment provides a method for optical measurement of porcelain insulators, using the aforementioned measuring device, and includes the following steps:

[0040] S101: The porcelain insulator workpiece is vertically clamped and fixed on the empty rotary fixture 6. After the loading is completed, the staff starts the measurement work through the human-machine interface of the control box 11. The turntable deceleration and transposition assembly 5 starts to move under the command of the control box 11. The turntable deceleration and transposition assembly 5 transports the two rotary fixtures 6 that have just clamped the new workpieces to the front of the structured light 3D scanner 8.

[0041] S102: After the workpiece is in place, the electrical control box 11 issues a command to drive the wedge-type double-position lifting shaft connection assembly 9 to operate. The wedge-type double-position lifting shaft connection assembly 9 reliably docks with the input shaft ends of the two rotary tooling 6 that have been rotated into place, completing the mechanical connection. After the power connection is established, the electrical control box 11 controls the lead screw electric linear module 3 to start. The lead screw electric linear module 3 drives the two structured light 3D scanners 8 fixed on it to start moving upward synchronously and at a uniform speed along the vertical length direction of the workpiece. During this process, the rotation of the lead screw electric linear module 3... The power is not only used to lift the structured light 3D scanner 8, but also transmitted and converted into the rotational power of the two rotary tooling 6 through the connected key shaft sprocket reduction transmission structure 10. As the structured light 3D scanner 8 moves upward at a constant speed, the two porcelain insulator workpieces also rotate around their own axes at a constant speed, forming a spiral scanning trajectory. At the moment the scanning data acquisition is completed, the host terminal connected to the structured light 3D scanner 8 automatically compares the acquired 3D point cloud data with the pre-stored standard workpiece digital model to complete the preliminary verification of the shape and size.

[0042] S103: The lead screw electric linear module 3 moves in the reverse direction, driving the structured light 3D scanner 8 to descend to its original starting position, and the wedge-type double-position lifting shaft connection assembly 9 is reset, disengaging it from the input shaft end of the rotary fixture 6, disconnecting the power connection, and the turntable deceleration and repositioning assembly 5 starts again, rotating at a certain angle to move the two workpieces that have just been scanned away from the scanning station to a position convenient for personnel to operate, while the next batch of two rotary fixtures 6 with the workpieces to be measured already clamped are continued to be sent to the front of the structured light 3D scanner 8.

[0043] Example 2, based on Example 1, is... Figure 8 , Figure 9 , Figure 10 and Figure 11The wedge-type double-position lifting shaft connection assembly 9 includes a connecting plate 901 fixed to the bottom of the measuring chamber 2, a U-shaped sliding arm 905 slidably mounted along the width direction of the measuring chamber 2 via a track at the left and right positions of the top of the connecting plate 901, and a double-column elastic reset structure 907 provided on both sides of the top of the connecting plate 901. A right-angle plate 908 is fixed to the movable end of the double-column elastic reset structure 907, and an upper trapezoidal head 910 is fixed to the lower end of the right-angle plate 908. A lower trapezoidal head 900, which slides in cooperation with the upper trapezoidal head 910, is mounted on the top of the U-shaped sliding arm 905. 6. A vertically extending external spline lower shaft 909 is rotatably mounted on the top of the right-angle plate 908. The external spline lower shaft 909 and the key shaft type sprocket reduction transmission structure 10 are connected to each other and obtain rotational power from the threaded shaft 301. A cylinder 904 is mounted on the top of the connecting plate 901 between the two double column elastic reset structures 907. The piston rod of the cylinder 904 is fixed to the middle plate 902. The middle plate 902 is driven by the cylinder 904 and slides along the length direction of the measuring chamber 2. A grooved wheel pushing structure is installed between the middle plate 902 and the U-shaped sliding arm 905.

[0044] After the rotary table reduction and repositioning assembly 5 drives two rotary fixtures 6 to rotate to the front of the structured light 3D scanner 8, the cylinder 904 in the wedge-type double-position lifting shaft connection assembly 9 is controlled by the electrical control box 11 and works. That is, the cylinder 904 pushes the middle plate 902 to move linearly towards the opening of the measuring chamber 2. Since the middle plate 902 and the U-shaped sliding arms 905 on both sides are connected through the grooved wheel pushing structure, the two U-shaped sliding arms 905 will move away from each other during the sliding of the middle plate 902. Then, the U-shaped sliding arms 905 force the upper trapezoidal head 910 and the right angle plate 908 to move upward through the lower trapezoidal head 906. That is, the upper end of the lower external spline shaft 909 is connected to the power input shaft end of the lower end of the rotary fixture 6, thereby establishing a rigid power transmission link. At this time, the rotary fixture 6 can obtain the rotational power from the lead screw electric linear module 3 through the key shaft type sprocket reduction transmission structure 10.

[0045] The grooved wheel pushing structure includes an arc-shaped wedge groove 903 set in the middle plate 902 and a protruding plate 911 bolted to the top of the U-shaped sliding arm 905. A pin 912 is rotatably installed at the bottom end of the protruding plate 911. The pin 912 is located in the arc-shaped wedge groove 903. When the cylinder 904 pushes the middle plate 902 to move towards the opening of the measuring chamber 2, the middle plate 902 drives the U-shaped sliding arms 905 on both sides to move outward synchronously through the arc-shaped wedge groove 903 and the pin 912. The double-column elastic reset structure 907 includes two uprights fixed to one side of the top of the connecting plate 901 and a support platform slidably installed on the two uprights. A helical spring that is coaxial with the uprights is fixed at the bottom end of the support platform. The right-angle plate 908 and the upper trapezoidal head 910 are respectively fixed to the top and bottom ends of the support platform.

[0046] When the middle plate 902 moves toward the opening of the measuring chamber 2, the middle plate 902 will force the convex plate 911 and the U-shaped sliding arm 905 to slide outward through the arc-shaped wedge groove 903 and the pin 912. That is, the convex plate 911, the U-shaped sliding arm 905 and the lower trapezoidal head 906 move toward the upper trapezoidal head 910. At this time, the two lower external spline shafts 909 on the left and right sides can move upward and complete the power connection.

[0047] When the piston rod of cylinder 904 is reset to disconnect the power transmission between key shaft type sprocket reduction transmission structure 10 and rotary tooling 6, the lower trapezoidal head 906 no longer touches the upper trapezoidal head 910. Then the right angle plate 908, the upper trapezoidal head 910, and the lower external spline shaft 909 reset themselves under the action of gravity. During this process, the helical spring in the double column elastic reset structure 907 also returns to its initial shape from the original stretched state.

[0048] The key shaft type sprocket reduction transmission structure 10 includes a drive sprocket 1005 fixed at the lower end of the threaded shaft 301, two outer spherical bearing seats 1001 fixed mirror-symmetrically at the top of the concave support plate 7, and a hollow inner spline central shaft 1002 rotatably installed inside the outer spherical bearing seats 1001. A reduction sprocket 1003 is fixed at one end of the surface of the hollow inner spline central shaft 1002. A transmission wheel 1004 is installed between the reduction sprocket 1003 and the drive sprocket 1005. The upper end of the outer spline lower shaft 909 passes through the hollow inner spline central shaft 1002. The reduction wheel group formed by the drive sprocket 1005 and the reduction sprocket 1003 ensures that the rotation speed of the workpiece matches the upward or downward speed of the structured light 3D scanner 8 to form an ideal spiral scanning trajectory.

[0049] When the lower external spline shaft 909 in the wedge-type double-position lifting shaft connection assembly 9 moves upward and completes the power connection with the input shaft end of the rotary tooling 6, the lower end of the threaded shaft 301 in the lead screw electric linear module 3 drives the drive sprocket 1005 to rotate. The drive sprocket 1005 drives the hollow internal spline shaft 1002 in the outer spherical bearing housing 1001 to rotate. Since the hollow internal spline shaft 1002 and the lower external spline shaft 909 are always keyway connected, the drive sprocket 1005 can use the transmission wheel 1004 to drive the reduction sprocket 1003, the hollow internal spline shaft 1002, and the lower external spline shaft 909 to rotate, thereby distributing the rotational power to the two connected rotary tooling 6, driving them to rotate precisely and uniformly.

[0050] Example 3, based on Example 2, by Figure 12 and Figure 13The rotary tooling 6 includes an outer spherical bearing housing 601 mounted on the drive end of the turntable reduction and transposition assembly 5, a hollow inner spline upper shaft 602 that passes through and rotatably mounts inside the outer spherical bearing housing 601, and a chuck 603 fixed at the top of the hollow inner spline upper shaft 602. The outer spline lower shaft 909 is used to enter the hollow inner spline upper shaft 602 when the piston rod of the cylinder 904 is extended.

[0051] The chuck 603 fixes the lower end of the porcelain insulator to ensure the stability of the porcelain insulator; the upper end of the lower external spline shaft 909 can enter the upper hollow internal spline shaft 602, so that the screw electric linear module 3 can transmit rotational power to the upper hollow internal spline shaft 602 and the chuck 603 through the key shaft type sprocket reduction transmission structure 10.

[0052] To ensure that the hollow internal spline upper shaft 602 can be poweredly connected to the external spline lower shaft 909, a planar magnetic coupling can also be installed at the opposite ends of the external spline lower shaft 909 and the hollow internal spline upper shaft 602. In this case, the external spline lower shaft 909 no longer needs to be fully inserted into the hollow internal spline upper shaft 602.

[0053] The rotary table reduction and transposition assembly 5 includes a table frame 501 fixed to the bottom of the measuring chamber 2, an external gear ring 503 rotatably mounted on the top of the table frame 501, a support plate 504 fixed to the top of the external gear ring 503, and a reduction motor 502 mounted on the top of the table frame 501. The output shaft of the reduction motor 502 extends upward and is fixed with a drive gear 507 that meshes with the external gear ring 503. The outer spherical bearing seat 601 is fixed at the upper edge of the support plate 504. Detection tongues 506 are fixed on both sides of the bottom end of the support plate 504. Slotted photoelectric switches 505 for detecting the position of the detection tongues 506 are installed on both sides of the top of the table frame 501. When the rotary table reduction and transposition assembly 5 is working, the reduction motor 502 drives the drive gear 507 to rotate, and the drive gear 507 drives the external gear ring 503 and the support plate 504 to rotate, thereby sending the workpiece to be measured to the scanning station and sending the measured workpiece to the loading and unloading station for easy manual operation.

[0054] During each rotation of the support plate 504, the two detector tongues 506, which are mirror-symmetrically installed at the bottom of the support plate 504, reach the position of the slotted photoelectric switch 505. The slotted photoelectric switch 505 determines whether the support plate 504 has rotated to the correct position, thereby ensuring that the turntable deceleration and transposition assembly 5 can stop accurately and smoothly at the predetermined position each time it performs a transposition action.

[0055] In the prior art, the electrical control box 11 needs to use an industrial programmable logic controller or an industrial computer equipped with control software to execute preset programs and coordinate the logical sequence and decision-making of all actions. For example, it is responsible for high-precision speed, position and trajectory control of the lifting motor of the lead screw electric linear module 3 and the rotary drive motor of the turntable reduction and transposition assembly 5. In order to drive these motors, corresponding motor power units are also required.

[0056] For the acquisition of measurement data, the electrical control box 11 also needs to be equipped with a scanner control and data acquisition interface. The communication module sends synchronous commands to the two structured light 3D scanners 8, and receives the massive image data acquired by them through interfaces such as high-speed Ethernet. In order to handle a large number of switching signals, relays and I / O modules also need to be equipped. Finally, solenoid valves for controlling the action of the wedge-type double-position lifting shaft connection assembly 9 are also required.

[0057] In this embodiment, the operator first manually loads the long porcelain insulator workpiece to be measured in the non-working area of ​​the rotary deceleration and transposition assembly 5. The workpiece is vertically clamped and fixed on the empty rotary fixture 6, ensuring that its lower end is firmly locked and its upper end is left hanging naturally. At least four rotary fixtures 6 are arranged on the rotary deceleration and transposition assembly 5. While two stations are scanning, the other stations can simultaneously perform loading or unloading operations, achieving parallelization of the production cycle. After loading is completed, the operator starts the measurement through the human-machine interface of the control box 11. During operation, the rotary table deceleration and transposition assembly 5 begins to move under the command of the electrical control box 11, precisely rotating by a certain angle, such as 180 degrees. The specific rotation angle depends on the number of rotary fixtures 6, thereby transporting and positioning the two rotary fixtures 6, which have just clamped the new workpieces, to the scanning station in the measuring chamber 2, that is, directly in front of the two structured light 3D scanners 8. After the workpieces are in place, the electrical control box 11 issues a command to drive the wedge-type double-position lifting shaft connection assembly 9 to move. The wedge-type double-position lifting shaft connection assembly 9 reliably connects with the lower ends of the two rotary fixtures 6 that have been rotated into place. The input shaft ends are docked to complete the mechanical connection, so that the key shaft type sprocket reduction transmission structure 10 can guide the power for the subsequent lifting and lowering movement of the structured light 3D scanner 8 to the workpiece, causing it to rotate. After the power connection is established, the electrical control box 11 controls the start of the lead screw electric linear module 3. The lead screw electric linear module 3 drives the two structured light 3D scanners 8 fixed on it to start moving upward synchronously and at a uniform speed along the vertical length direction of the workpiece. During this process, the rotational power of the lead screw electric linear module 3 is not only used to lift the structured light 3D scanner 8, but also through the connected key shaft type sprocket reduction transmission structure 10 to the workpiece. The wheel reduction transmission structure 10 is transmitted and converted into the rotational power of the two rotary tooling 6. As the structure light 3D scanner 8 moves upward at a constant speed, the two porcelain insulator workpieces also rotate around their own axes at a constant speed. By using the spiral scanning trajectory, the structure light projected by the structure light 3D scanner 8 can continuously and without omission cover the entire outer surface of the workpiece, including the complex umbrella skirt and the root. After the structure light 3D scanner 8 has acquired the 3D point cloud information of the entire surface of the workpiece or after the structure light 3D scanner 8 moves upward to the top of the workpiece, the lead screw electric linear module 3 automatically stops.At the instant the scanning data acquisition is completed, the host unit connected to the structured light 3D scanner 8 automatically and quickly compares the acquired 3D point cloud data with the pre-stored standard workpiece digital model to complete the preliminary verification of the shape contour and dimensions. Then, the lead screw electric linear module 3 reverses its movement, driving the structured light 3D scanner 8 to descend to its original starting position. Simultaneously, the wedge-type double-position lifting shaft connection assembly 9 resets, disengaging it from the input shaft end of the rotary fixture 6, disconnecting the power connection. The turntable deceleration and repositioning assembly 5 restarts, rotating a certain angle to move the two scanned workpieces from the scanning station to a position convenient for personnel operation. At the same time, the rotary fixture 6, with two workpieces already clamped for testing, continues to be delivered to the front of the structured light 3D scanner 8. The operator can then unload the scanned workpieces and, as needed, load them, preparing for the next cycle.

[0058] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0059] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An optical measuring device for porcelain insulators, comprising a main frame (1), a measuring chamber (2) installed on the outer wall of one side of the main frame (1), a calibration plate (12) fixedly installed on the top of the measuring chamber (2), and a concave support plate (7) installed at a lower position inside the main frame (1), wherein a lead screw electric linear module (3) is installed at the top of the concave support plate (7), characterized in that: The drive end of the lead screw electric linear module (3) is equipped with two structured light 3D scanners (8) with their lenses facing the calibration plate (12). The bottom of the measuring chamber (2) is equipped with a turntable reduction and transposition assembly (5). The drive end of the turntable reduction and transposition assembly (5) is equipped with at least four rotary fixtures (6) for clamping porcelain insulators. The turntable reduction and transposition assembly (5) is used to rotate two of the rotary fixtures (6) to the front of the structured light 3D scanners (8). The bottom end of the concave support plate (7) is equipped with a key shaft type sprocket reduction transmission structure (1) for always maintaining power connection with the lead screw electric linear module (3). 0), The bottom of the measuring chamber (2) below the concave support plate (7) is equipped with a wedge-type double-position lifting shaft connection assembly (9). The wedge-type double-position lifting shaft connection assembly (9) is used to enable the two rotary fixtures (6) in front of the structure light 3D scanner (8) to engage with the key shaft type sprocket reduction transmission structure (10) when the screw electric linear module (3) is working. An electric control box (11) is installed on one side of the outer wall of the measuring chamber (2). The output end of the electric control box (11) is electrically connected to the input end of the screw electric linear module (3), the turntable reduction and shifting assembly (5), and the wedge-type double-position lifting shaft connection assembly (9).

2. The optical measuring device for porcelain insulators according to claim 1, characterized in that: Two CCD camera measurement components (4) are installed on the upper part of one side of the outer wall of the main frame (1). The lens of the CCD camera measurement component (4) faces downward and is coaxial with the rotary fixture (6) in front of the structured light 3D scanner (8).

3. The optical measuring device for porcelain insulators according to claim 1, characterized in that: The lead screw electric linear module (3) includes a threaded shaft (301) rotatably mounted on the top of a concave support plate (7), guide posts (302) fixed on the top of the concave support plate (7) on the left and right sides of the threaded shaft (301), and a support plate (303) slidably mounted between the two guide posts (302) through a sleeve. The support plate (303) has a nut pair (304) fixed inside for threaded engagement with the threaded shaft (301). Two structured light 3D scanners (8) are symmetrically mounted on both sides of the top of the support plate (303). A servo motor (305) is mounted on the top of the main frame (1). The upper end of the output shaft of the servo motor (305) and the upper end of the threaded shaft (301) are both fixed with synchronous pulleys (306). A transmission belt is installed between the two synchronous pulleys (306). The lower end of the threaded shaft (301) is connected to a key shaft type sprocket reduction transmission structure (10).

4. The optical measuring device for porcelain insulators according to claim 3, characterized in that: The wedge-type double-position lifting shaft connection assembly (9) includes a connecting plate (901) fixed to the bottom of the measuring chamber (2), a U-shaped sliding arm (905) slidably installed along the width direction of the measuring chamber (2) via a track at the left and right positions of the top of the connecting plate (901), and a double-column elastic reset structure (907) provided on both sides of the top of the connecting plate (901). The movable end of the double-column elastic reset structure (907) is fixed with a right-angle plate (908), and the lower end of the right-angle plate (908) is fixed with an upper trapezoidal head (910). The top of the U-shaped sliding arm (905) is equipped with a lower trapezoidal head (905) that maintains a sliding fit with the upper trapezoidal head (910). 6) The top of the right-angle plate (908) is rotatably mounted with a vertically upward-extending external spline lower shaft (909). The external spline lower shaft (909) and the key shaft type sprocket reduction transmission structure (10) are connected to each other and obtain rotational power from the threaded shaft (301). The top of the connecting plate (901) between the two double-column elastic reset structures (907) is equipped with a cylinder (904). The piston rod of the cylinder (904) is fixed with a middle plate (902). The middle plate (902) is driven by the cylinder (904) and slides along the length direction of the measuring chamber (2). A grooved wheel pushing structure is installed between the middle plate (902) and the U-shaped sliding arm (905).

5. The optical measuring device for porcelain insulators according to claim 4, characterized in that: The grooved wheel pushing structure includes an arc-shaped wedge groove (903) set in the middle plate (902) and a convex plate (911) bolted to the top of the U-shaped sliding arm (905). A pin (912) is rotatably installed at the bottom end of the convex plate (911). The pin (912) is located in the arc-shaped wedge groove (903). When the cylinder (904) pushes the middle plate (902) to move towards the opening of the measuring chamber (2), the middle plate (902) drives the U-shaped sliding arms (905) on both sides to move outward synchronously through the arc-shaped wedge groove (903) and the pin (912).

6. The optical measuring device for porcelain insulators according to claim 4, characterized in that: The double-column elastic reset structure (907) includes two uprights fixed to one side of the top of the connecting plate (901) and a support platform slidably installed on the two uprights. The bottom end of the support platform is fixed with a helical spring that is coaxial with the uprights. The right-angle plate (908) and the upper trapezoidal head (910) are respectively fixed to the top and bottom of the support platform.

7. The optical measuring device for porcelain insulators according to claim 4, characterized in that: The key shaft type sprocket reduction transmission structure (10) includes a drive sprocket (1005) fixed at the lower end of the threaded shaft (301), two outer spherical bearing seats (1001) fixed symmetrically at the top of the concave support plate (7), and a hollow inner spline shaft (1002) rotatably installed inside the outer spherical bearing seats (1001). A reduction sprocket (1003) is fixed at one end of the surface of the hollow inner spline shaft (1002). A transmission wheel (1004) is installed between the reduction sprocket (1003) and the drive sprocket (1005). The upper end of the outer spline lower shaft (909) passes through the hollow inner spline shaft (1002).

8. The optical measuring device for porcelain insulators according to claim 7, characterized in that: The rotary tooling (6) includes an outer spherical bearing housing (601) installed on the drive end of the turntable deceleration and transposition assembly (5), a hollow inner spline upper shaft (602) that passes through and is rotatably installed inside the outer spherical bearing housing (601), and a chuck (603) fixed at the top of the hollow inner spline upper shaft (602). The outer spline lower shaft (909) is used to enter the hollow inner spline upper shaft (602) when the piston rod of the cylinder (904) is extended.

9. The optical measuring device for porcelain insulators according to claim 8, characterized in that: The turntable deceleration and transposition assembly (5) includes a turntable frame (501) fixed at the bottom of the measuring chamber (2), an external gear ring (503) rotatably mounted on the top of the turntable frame (501), a support plate (504) fixed on the top of the external gear ring (503), and a deceleration motor (502) mounted on the top of the turntable frame (501). The output axis of the deceleration motor (502) extends upward and is fixed with a drive gear (507) that meshes with the external gear ring (503). The outer spherical bearing seat (601) is fixed at the upper edge of the support plate (504). Both sides of the bottom end of the support plate (504) are fixed with detection tongues (506). Both sides of the top of the turntable frame (501) are equipped with slotted photoelectric switches (505) for detecting the position of the detection tongues (506).

10. A method for optical measurement of porcelain insulators, using the measuring device as described in any one of claims 1-9, characterized in that: Includes the following steps: S101: The porcelain insulator workpiece is vertically clamped and fixed on the empty rotary fixture (6). After the loading is completed, the staff starts the measurement work through the human-machine interface of the control box (11). The turntable deceleration and repositioning assembly (5) starts to move under the instruction of the control box (11). The turntable deceleration and repositioning assembly (5) transports and positions the two rotary fixtures (6) with the new workpieces just clamped to the front of the structured light 3D scanner (8). S102: After the workpiece is in place, the electrical control box (11) issues a command to drive the wedge-type double-position lifting shaft connection assembly (9) to move. The wedge-type double-position lifting shaft connection assembly (9) reliably docks with the input shaft ends of the two rotary tooling (6) that have been rotated into place, completing the mechanical connection. After the power connection is established, the electrical control box (11) controls the lead screw electric linear module (3) to start. The lead screw electric linear module (3) drives the two structured light 3D scanners (8) fixed on it to start moving upward synchronously and at a uniform speed along the vertical length direction of the workpiece. During this process, the lead screw electric linear module (3) The rotational power of the structure light 3D scanner (8) is not only used to lift the structure light 3D scanner (8), but also transmitted and converted into the rotational power of the two rotary tooling (6) through the key shaft sprocket reduction transmission structure (10) that has been connected. As the structure light 3D scanner (8) moves upward at a constant speed, the two porcelain insulator workpieces also rotate around their own axes at a constant speed, forming a spiral scanning trajectory. At the moment when the scanning data acquisition is completed, the host end connected to the structure light 3D scanner (8) automatically compares the acquired 3D point cloud data with the pre-stored standard workpiece digital model to complete the preliminary verification of the outline and size. S103: The lead screw electric linear module (3) moves in the opposite direction, driving the structured light 3D scanner (8) down to the original starting position, and the wedge-type double-position lifting shaft connection assembly (9) is reset, so that it is disengaged from the input shaft end of the rotary fixture (6), disconnecting the power connection. The turntable deceleration and repositioning assembly (5) starts again, rotates a certain angle, and moves the two workpieces that have just been scanned away from the scanning station to a position that is convenient for personnel to operate. At the same time, the rotary fixture (6) with the next batch of two workpieces that have been clamped to be tested continues to be sent to the front of the structured light 3D scanner (8).

Images