Surface image acquisition system based on 3D visual path planning

Abstract

The utility model discloses a steam turbine blade surface image acquisition system based on 3D visual path planning, which comprises an industrial robot unit, a product tooling platform unit, a surface data acquisition unit and a geometrical optics unit, and is characterized in that the surface data acquisition unit comprises a 3D sensor and a 2D industrial camera; the geometrical optical unit is formed by combining a plurality of optical light sources and illuminates the blade at different angles and under different illumination conditions, so that details and features of the surface of the blade can be highlighted, and the contrast ratio and definition of an image are improved. The system utilizes 3D visual path planning to guide the data acquisition unit to perform steam turbine blade surface image acquisition, can be widely applied to industrial detection and maintenance, can dynamically adjust the position and the angle of acquisition equipment, and can realize accurate path planning and multi-visual-angle fusion through accurate path planning and multi-visual-angle fusion. And the data acquisition system is guided to realize comprehensive and accurate image acquisition of the blade surface.

Description

Technical Field

[0001] The utility model relates to the technical field of image acquisition and processing, in particular to a surface image acquisition system based on 3D visual path planning. Background Art

[0002] Existing methods for capturing images of turbine blade surfaces primarily rely on predetermined paths and fixed angles, a method that suffers from numerous drawbacks. First, the predetermined path and fixed angle acquisition methods are inefficient and cannot flexibly accommodate the complex geometric structure of the blades, resulting in some areas being unable to be effectively covered and making it difficult to guarantee the comprehensiveness and accuracy of image acquisition. Second, the complex structure of the blade surface and the diversity of products further increase the difficulty and time cost of image acquisition, especially when faced with blades of different types and shapes. Traditional methods struggle to adapt to rapidly changing demands. This method is not only time-consuming and labor-intensive, but also prone to missing key details, impacting subsequent quality inspection and analysis.

[0003] The development of 3D vision technology, combined with intelligent path planning algorithms, has provided a new solution for blade surface image acquisition. By constructing a 3D model of the blade in real time and intelligently planning the acquisition path algorithm, the position and angle of the acquisition equipment can be dynamically adjusted, guiding the data acquisition system to achieve comprehensive and accurate image acquisition of the blade surface. This system can not only significantly improve acquisition efficiency and reduce unnecessary repetitions and pauses, but also improve image quality, ensuring that every detail is clearly captured. Intelligent path planning can also be adaptively adjusted according to the different characteristics of the blade, greatly improving the flexibility and adaptability of the system and meeting the image acquisition needs of various complex surface structures. Through this advanced technical means, turbine blade surface image acquisition will become more efficient, comprehensive, and accurate, providing reliable data support for subsequent analysis and maintenance. Summary of the Invention

[0004] To solve the above problems, the utility model provides a turbine blade surface image acquisition system based on 3D visual path planning for different types of turbine blades, which have different sizes, structures, surface features and other characteristics. The system uses 3D sensors and intelligent algorithms to plan the surface image acquisition path, guiding the data acquisition system to achieve automated and high-precision blade surface image acquisition, so as to solve the problems of low efficiency, incomplete acquisition, and low image quality in the existing technology.

[0005] The technical solution of the utility model is as follows:

[0006] A steam turbine blade surface image acquisition system based on 3D visual path planning includes an industrial robot, a product tooling platform, a surface data acquisition unit, and a geometric optical unit. The product tooling platform is located in the working direction of the industrial robot, the surface data acquisition unit is installed at the working end of the robot, and the geometric optical unit is installed below and in front of the surface data acquisition unit. The light source illumination range of the geometric optical unit covers the acquisition range of the surface data acquisition unit.

[0007] Several groups of fixtures are provided on the product tooling platform, which can clamp blades of different specifications at the same time, and there is a certain distance between each two groups of fixtures to ensure that there is sufficient distance between the clamped blades, the blades do not block each other, and do not affect the surface data acquisition unit to collect the surface image of each group of blades.

[0008] The industrial robot has a moving range covering the entire product tooling platform. When the industrial robot receives an instruction, it drives the surface data acquisition unit and the geometric optical unit to move to the specified position, and the surface data acquisition unit and the geometric optical unit start working.

[0009] The industrial robot determines a moving path according to a position transformation relationship between a robot end joint coordinate system and a camera coordinate system.

[0010] The surface data acquisition unit includes a 3D sensor and a 2D industrial camera. The 3D sensor and the 2D industrial camera are both installed at the end of the industrial robot, and the 3D sensor in the working state is located above the 2D industrial camera.

[0011] The surface data acquisition unit is equipped with a camera light source connector installed along the shooting direction of the 2D industrial camera.

[0012] The geometric optical unit includes at least a ring light source and a strip light source, which illuminate the blades on the product tooling platform under different angles and lighting conditions, highlighting the details and features of the blade surface and improving the contrast and clarity of the image; the ring light source and strip light source are both installed at the end of the industrial robot through the camera light source connector, the ring light source is installed at the front end of the 2D industrial camera, and the strip light source is installed at the front end of the ring light source.

[0013] Furthermore, in the operating state steam turbine blade surface image acquisition system, the height of the strip light source is located between the 3D sensor and the ring light source.

[0014] Furthermore, in order to adapt to the acquisition environment and requirements of the turbine blade surface image acquisition system, the annular light source can adjust the brightness, color temperature, illumination direction and angle, and the strip light source can also adjust the brightness, illumination direction and angle.

[0015] During operation, the system's 3D sensor acquires three-dimensional point cloud data from the turbine blade surface to construct a high-precision 3D model. This step includes data preprocessing, such as denoising and filtering, to ensure model accuracy. Building a high-precision 3D surface model provides the foundation for subsequent path planning. Automatic path planning, based on the high-precision 3D model, then guides the 2D industrial camera in the data acquisition unit to capture images of the blade surface. Finally, feature analysis is performed on the acquired blade surface image data to generate conclusions.

[0016] The technical solution of the utility model has the following beneficial effects:

[0017] (1) Improve detection accuracy. This utility model uses 3D vision technology to obtain high-resolution three-dimensional point cloud data of the blade surface. The intelligent planning path guides the high-precision 2D vision system to collect surface images, which can capture subtle defects on the blade surface, such as tiny cracks, inclusions, fisheyes, etc. This high-precision detection greatly improves the reliability and accuracy of the detection results.

[0018] (2) Enhanced detection efficiency. Through an intelligent path planning algorithm, the utility model can automatically generate the optimal image acquisition path to cover the entire blade surface. Compared with traditional manual inspection and two-dimensional imaging systems, automatic path planning significantly reduces image acquisition time and improves detection efficiency. At the same time, the system can continuously and seamlessly acquire images, avoiding pauses and repetitions in manual operations.

[0019] (3) Reduce human error. Traditional blade surface inspection relies on the operator's experience and subjective judgment, which can easily lead to inconsistent inspection results. This system uses automated 3D visual modeling and intelligent path planning to guide high-precision 2D surface image acquisition, effectively reducing human error, achieving standardization and consistency in the inspection process, and ensuring the objectivity and stability of the inspection results.

[0020] (4) Improve data management and analysis capabilities. All relevant data of the utility model can be directly stored in the database, which is convenient for subsequent management and analysis. Combined with data analysis tools, the historical data of the blades can be tracked and compared to help predict the service life and maintenance cycle of the blades, thereby optimizing the maintenance strategy.

[0021] (5) Support for multiple blade types. The utility model has a high degree of flexibility and adaptability, and can adapt to turbine blades of different types and sizes, achieving accurate detection of different blades, and expanding the application range and practicality of the system.

[0022] (6) Strong integration and easy maintenance. The utility model can be seamlessly integrated with the existing steam turbine production line and maintenance system, which is easy to implement and promote. The system design focuses on modularity and maintainability, which facilitates subsequent upgrades and maintenance and reduces the operating costs of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a structural diagram of the present utility model.

[0024] Among them, the accompanying drawings are marked as: 1. industrial robot, 2. 3D sensor, 3. 2D industrial camera, 4. ring light source, 5. camera light source connector, 6. strip light source, 7. turbine blade, 8. product tooling platform. DETAILED DESCRIPTION

[0025] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings.

[0026] Example 1

[0027] A steam turbine blade surface image acquisition system based on 3D visual path planning includes an industrial robot 1, a product tooling platform 8, a surface data acquisition unit and a geometric optical unit. The product tooling platform 8 is located in the working direction of the industrial robot 1, the surface data acquisition unit is installed at the working end of the robot, and the geometric optical unit is installed below and in front of the surface data acquisition unit. The light source illumination range of the geometric optical unit covers the acquisition range of the surface data acquisition unit.

[0028] The product tooling platform 8 is provided with several groups of clamps, which can simultaneously clamp turbine blades 7 of different specifications, and there is a certain distance between each two groups of clamps to ensure that there is sufficient distance between the clamped blades, the blades do not block each other, and do not affect the surface data acquisition unit to collect the surface image of each group of blades.

[0029] The industrial robot 1 has a moving range covering the entire product tooling platform 8. When the industrial robot 1 receives an instruction, it drives the surface data acquisition unit and the geometric optical unit to move to the specified position, and the surface data acquisition unit and the geometric optical unit start working.

[0030] The industrial robot 1 determines a moving path according to a position transformation relationship between the robot end joint coordinate system and the camera coordinate system.

[0031] The surface data acquisition unit includes a 3D sensor 2 and a 2D industrial camera 3 . Both the 3D sensor 2 and the 2D industrial camera 3 are installed at the end of the industrial robot 1 , and the 3D sensor 2 in the working state is located above the 2D industrial camera 3 .

[0032] The surface data acquisition unit is equipped with a camera light source connector 5 installed along the shooting direction of the 2D industrial camera 3 .

[0033] The geometric optical unit includes at least a ring light source 4 and a strip light source 6, which illuminate the blades on the product tooling platform 8 under different angles and lighting conditions, highlighting the details and features of the blade surface and improving the contrast and clarity of the image; the ring light source 4 and the strip light source 6 are both installed at the end of the industrial robot 1 through the camera light source connector 5, the ring light source 4 is installed at the front end of the 2D industrial camera 3, and the strip light source 6 is installed at the front end of the ring light source 4.

[0034] Furthermore, in the operating state steam turbine blade surface image acquisition system, the height of the strip light source 6 is located between the 3D sensor 2 and the annular light source 4.

[0035] Furthermore, to adapt to the acquisition environment and requirements of the turbine blade surface image acquisition system, the annular light source 4 can adjust the brightness, color temperature, irradiation direction and angle, and the strip light source 6 can also adjust the brightness, irradiation direction and angle.

[0036] During operation, the system:

[0037] The industrial robot 1 used is a 6-axis industrial robot with a working range radius of 900 mm and a load of 0.9 kg.

[0038] The 3D sensor 2 used is a binocular face scanning grating 3D camera with the characteristics of small and medium field of view, high precision, and high beat rate. Its working indicators include: working distance 700mm~1300mm, effective field of view 400mm*400mm~1100mm*1100mm, so it is compatible with product specifications of approximately 400mm*400~1000mm*1000mm.

[0039] The 2D industrial camera 3 used has a resolution of 5120*5120 and a pixel size of 2.5um.

[0040] The focal length of the industrial lens used is 35mm.

[0041] During operation, the system's 3D sensor 2 acquires three-dimensional point cloud data from the turbine blade surface to construct a high-precision 3D model. This step includes data preprocessing, such as denoising and filtering, to ensure model accuracy. Building a high-precision 3D surface model provides the foundation for subsequent path planning. Automatic path planning, based on the high-precision 3D model, then guides the 2D industrial camera 3 in the data acquisition unit to capture blade surface images. Finally, feature analysis is performed on the acquired blade surface image data to generate analytical conclusions.

Claims

1. A steam turbine blade surface image acquisition system based on 3D visual path planning, characterized by: The invention comprises an industrial robot (1), a product tooling platform (8), a surface data acquisition unit and a geometric optical unit, wherein the product tooling platform (8) is located in the working direction of the industrial robot (1), the surface data acquisition unit is installed at the working end of the robot, and the geometric optical unit is installed below and in front of the surface data acquisition unit, and the light source illumination range of the geometric optical unit covers the collection range of the surface data acquisition unit.

2. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 1, characterized in that: The product tooling platform (8) is provided with several groups of clamps for simultaneously clamping blades of different specifications, and a distance is left between each two groups of clamps to ensure that the clamped blades are within the collection range of the surface data collection unit.

3. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 1, characterized in that: The movement range of the industrial robot (1) covers the entire product tooling platform (8); the industrial robot (1) determines the movement path according to the position transformation relationship between the robot end joint coordinate system and the camera coordinate system.

4. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 1, characterized in that: The surface data acquisition unit comprises a 3D sensor (2) and a 2D industrial camera (3), both of which are installed at the end of the industrial robot (1), and the 3D sensor (2) in the operating state is located above the 2D industrial camera (3).

5. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 4, characterized in that: The surface data acquisition unit is provided with a camera light source connecting piece (5) installed along the shooting direction of the 2D industrial camera (3).

6. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 5, characterized in that: The geometric optical unit comprises at least a ring light source (4) and a strip light source (6); the ring light source (4) and the strip light source (6) are both mounted on the end of the industrial robot (1) via a camera light source connector (5), the ring light source (4) is mounted on the front end of the 2D industrial camera (3), and the strip light source (6) is mounted on the front end of the ring light source (4).

7. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 6, characterized in that: In a steam turbine blade surface image acquisition system in an operating state, the strip light source (6) is located at a height between the 3D sensor (2) and the annular light source (4).

8. The steam turbine blade surface image acquisition system based on 3D visual path planning according to claim 6, characterized in that: The brightness, color temperature, irradiation direction and angle of the annular light source (4) are adjustable, and the brightness, irradiation direction and angle of the strip light source (6) are adjustable.

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