A roller profile detection method

Abstract

The present invention provides a roller profile detection method, comprising the following steps: Step 1, preparation: conveying the roller to the detection workbench; Step 2, roller profile detection: using a detection mechanism to detect the profile of the roller in multiple positions, and obtaining the length, diameter and shaping amount values ​​of the roller in multiple positions; Step 3, roller profile judgment: comparing the length, diameter and shaping amount values ​​of the roller in multiple positions with the length, diameter and shaping amount design values ​​of the roller, judging whether the length, diameter and shaping amount values ​​of the roller meet the design requirements and judging whether the roller profile has an ellipse. The present invention realizes all-round detection of the roller by detecting different positions of the roller, and improves the detection accuracy by averaging multiple detection results; and can simultaneously detect the diameter, length and shaping amount of the roller.

Description

Technical Field

[0001] The present invention relates to the technical field of roller profile detection, and in particular to a roller profile detection method. Background Art

[0002] Rollers are key core components in the main bearings of tunnel boring machines that bear loads and resist impacts. The slight differences in the roller profile dimensions have a great impact on the working performance of the main bearings. If the roller profile dimension differences are too large, it will lead to local load concentration in the load-bearing area of ​​the main bearing roller group, aggravating the friction and wear of the rollers and raceways, causing vibration and noise, and easily causing early failure of the main bearings of the tunnel boring machine.

[0003] In order to ensure the normal operation of the main bearing of the tunnel boring machine and avoid economic losses caused by subsequent production, rollers with unqualified sizes should be removed in time.

[0004] At present, the profile detection of rollers is generally carried out by manual detection and sorting machine detection. Among them, the manual detection method can no longer meet the needs of modern industry due to the low detection efficiency and high labor costs; and the sorting machine detection also has problems such as single sorting equipment and small sorting range. Summary of the invention

[0005] The purpose of the present invention is to provide a roller profile detection method to address the deficiencies in the prior art, so as to detect the geometric dimensions of the roller profile and whether there is an ellipse, thereby helping to select rollers with unqualified dimensions and ensure the normal operation of the main bearing of the tunnel boring machine.

[0006] To achieve the above object, the present invention provides a roller profile detection method, comprising the following steps:

[0007] Step 1: Preparation: transport the roller to the first detection position;

[0008] Step 2: Roller profile detection: Use a detection mechanism to detect the roller profile in multiple positions, and obtain the length, diameter and modification amount values ​​of the roller in multiple positions;

[0009] Step 3: Determine the roller profile: Compare the length, diameter and shaping amount values ​​of the roller in multiple positions with the design values ​​of the length, diameter and shaping amount of the roller to determine whether the length, diameter and shaping amount values ​​of the roller meet the design requirements and whether the roller profile is elliptical.

[0010] Preferably, in step one, a conveying mechanism is used to convey the roller to the inspection workbench; the conveying mechanism is configured as a belt conveying structure, and a plurality of trapezoidal protrusions are evenly distributed on the upper surface of the belt in the belt conveying structure, and the roller is clamped and conveyed by two adjacent trapezoidal protrusions.

[0011] Preferably, the conversion of the roller into multiple positions in step 2 is performed by clamping and rotating the roller using a rotary clamping mechanism; the rotary clamping mechanism is configured as a rotary cylinder.

[0012] Preferably, in step 2, the relationship between the multiple positions of the roller is set so that the latter position is rotated 120° relative to the former position.

[0013] Preferably, the detection mechanism in step 2 is configured as an industrial camera.

[0014] Preferably, the specific process of obtaining the length, diameter and shaping amount values ​​of the roller in multiple positions in step 2 is as follows:

[0015] 1) The detection mechanism detects the profile of the roller in multiple positions and forms a roller image;

[0016] 2) The roller image is sent to a computer for grayscale processing so that each pixel in the pixel matrix satisfies the following relationship: R=G=B, where R represents the value of the red variable, G represents the value of the green variable, and B represents the value of the blue variable;

[0017] 3) Performing a linear grayscale transformation on the roller image after noise reduction;

[0018] 4) Process the roller image into a binary image with only two values, and set the threshold to 130, that is, the pixel values ​​greater than 130 are set to 255, and the pixel values ​​less than or equal to 130 are set to 0;

[0019] 5) Use the Sobel operator to enhance the edge effect of the image and highlight the contour features of the image;

[0020] 6) Fit the minimum circumscribed rectangle of the roller edge in the image, specifically: set the width D′ and length L′ of the rectangle to the diameter D of the roller jk and length L jk , fitting the modification amount P(x jk );

[0021] 7) Find the average of the sizes fitted from k photos, where the length L n The average value is calculated using the following formula:

[0022]

[0023] Diameter D n The average value is calculated using the following formula:

[0024]

[0025] Modification amount P(x n ) is calculated using the following formula:

[0026]

[0027] Where: k represents the number of photos of the roller detection position, n=1…i, i is the number of detection mechanisms.

[0028] Preferably, the specific process of comparing the length, diameter and modification amount values ​​obtained in the roller profile detection with the design values ​​of the roller in step 3 is as follows:

[0029] 1) Calculate the deviation between the detected roller value and the roller design value:

[0030] The deviation between the detected roller diameter and the designed roller diameter is calculated by the following formula:

[0031] ΔD n =D n -D;

[0032] The deviation between the detected roller length and the designed roller length is calculated by the following formula:

[0033] ΔL n =L n -L;

[0034] The deviation between the roller modification amount obtained by testing and the design value of the roller modification amount is calculated by the following formula:

[0035] ΔP(x n )=P(x n )-P(x);

[0036] Where, ΔD n is the deviation between the detected roller diameter and the design value, ΔL n is the deviation between the detected roller length and the design value, ΔP(x n ) is the deviation between the detected roller modification amount and the design value, n = 1…i;

[0037] 2) Determine whether the roller profile meets the design requirements: such as ΔD n Meet the tolerance requirement ΔD n ∈[a,b], the roller diameter meets the design requirements; if ΔL n Meet the tolerance requirement ΔL n ∈[c,d], the roller length meets the design requirements; if ΔP(x n ) meets the tolerance requirement ΔP(x n )∈[e,f], the roller modification amount meets the design requirements.

[0038] Preferably, the specific process of judging whether the roller profile is elliptical in step 3 is as follows:

[0039] 1) When D max -D min ≤ΔD m When , there is no ellipse, which meets the design requirements. Here ΔD m The maximum difference in roller diameter design, D max is the maximum value of the roller diameter detected, D min is the minimum value of the roller diameter detected;

[0040] 2) If ΔD n , ΔL n and ΔP(x n ) all meet the design requirements, and D max -D min ≤ΔD m , then the roller size is qualified, otherwise, the roller size is unqualified.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] The present invention realizes all-round detection of the roller by detecting different positions of the roller, and improves the detection accuracy by averaging multiple detection results; and can detect the diameter, length and shaping amount of the roller at the same time; this method overcomes the shortcomings of manual detection and sorting machine detection, saves labor costs, avoids possible errors in manual detection, and can detect rollers of different sizes, and has the characteristics of a wide range of applications.

[0043] In addition to the above-described purposes, features and advantages, the present invention has other purposes, features and advantages. The present invention will be further described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The drawings constituting a part of this application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0045] Figure 1 is a schematic diagram of the connection between the roller and the conveying mechanism in an embodiment of the present invention;

[0046] Figure 2 yes Figure 1 A partial enlarged schematic diagram in the middle;

[0047] FIG3( a ) is a schematic diagram of the first measured position of the roller (wherein the shaded portion is the detection surface);

[0048] FIG3(b) is a schematic diagram of the second measured state of the roller (wherein the shaded portion is the detection surface, and to distinguish it from the first measured state, this figure is a schematic diagram of the state when the roller is not rotating, that is, a schematic diagram of the same state as FIG3(a));

[0049] Figure 3(c) is a schematic diagram of the third measured position of the roller (the shaded portion is the detection surface, and to distinguish it from the first measured position and the second measured position, this figure is a schematic diagram of the state when the roller is not rotating, that is, a schematic diagram of the same state as Figure 3(a)).

[0050] in:

[0051] 1. Roller, 2. Conveying mechanism, 3. Detection mechanism, 4. Computer. DETAILED DESCRIPTION

[0052] In order to make the above-mentioned purposes, features and advantages of the present invention more clear and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings. It should be noted that the drawings of the present invention are all simplified and use non-precise proportions, which are only used to conveniently and clearly assist in explaining the implementation of the present invention; the "number" mentioned in the present invention is not limited to the specific number in the examples in the accompanying drawings; the directions or positional relationships indicated by "front", "middle", "back", "left", "right", "up", "down", "top", "bottom", "middle", etc. mentioned in the present invention are based on the directions or positional relationships shown in the drawings of the present invention, and do not indicate or imply that the devices or components referred to must have a specific direction, nor can they be understood as limitations on the present invention.

[0053] This embodiment:

[0054] The present invention provides a roller profile detection method, which specifically comprises the following steps:

[0055] Step 1: Preparation: convey the roller to the first detection position through the conveying mechanism, and place the roller at the first detection position in the first detected position;

[0056] Step 2: Roller profile detection: Use a detection mechanism to detect multiple positions of the roller, and obtain the length, diameter and modification amount data of the roller respectively;

[0057] Step 3: Roller profile determination: Compare the length, diameter and shaping amount values ​​obtained from the roller profile detection with the design values ​​of the roller to determine whether the length, diameter and shaping amount values ​​of the roller meet the design requirements and whether the roller profile is elliptical.

[0058] See also Figure 1 and Figure 2As shown, the first detection position is set so that the central axis of the roller 1 is consistent with the conveying direction of the conveying mechanism 2; the conveying mechanism 2 is set as a belt conveying structure, and the upper surface of the belt in the conveying mechanism 2 is provided with a plurality of trapezoidal protrusions arranged in sequence, and the roller 1 is placed between two adjacent trapezoidal protrusions and clamped by the two adjacent trapezoidal protrusions to achieve effective fixation of the roller, thereby preventing the roller from affecting the detection accuracy due to the incorrect placement of the roller during the detection process.

[0059] See also Figure 1 3(a), 3(b) and 3(c), taking the case where there are three detection mechanisms 3 and three roller detection positions as an example, the detection mechanism 3 is provided with a first detection mechanism, a second detection mechanism and a third detection mechanism which are sequentially arranged along the running direction of the conveying mechanism, and the first detection mechanism is located above the first detection position, and is used to detect the end face of the first detected position a of the roller to form a roller image, and transmit the roller image to the computer 4 for processing to obtain the length L1, diameter D1 and shaping amount P(x1) values ​​of the roller;

[0060] The roller detected by the first detection mechanism is transported to the bottom of the second detection mechanism by the conveying mechanism, and the roller is rotated 120° along its central axis by the clamping mechanism so that the end face of the second detected position b of the roller is placed directly below the second detection mechanism. The second detection mechanism detects the end face of the b section to form a roller image, and transmits the roller image to the computer 4 for processing, and obtains the length L2, diameter D2 and modification amount P(x2) values ​​of the roller;

[0061] After being inspected by the second inspection mechanism, the roller is transported to the bottom of the third inspection mechanism through the conveying mechanism, and the roller is rotated 120° along its central axis by the clamping mechanism so that the end face of the third measured position c of the roller is placed directly below the third inspection mechanism. The third inspection mechanism inspects the end face of the c section to form a roller image, and transmits the roller image to the computer 4 for processing, and obtains the length L3, diameter D3 and shaping amount P (x3) values ​​of the roller.

[0062] Preferably, the steps of processing the roller image are as follows:

[0063] 1) The roller image is sent to a computer for grayscale processing so that each pixel in the pixel matrix satisfies the following relationship: R (value of the red variable) = G (value of the green variable) = B (value of the blue variable);

[0064] 2) Performing a linear grayscale transformation on the roller image after noise reduction;

[0065] 3) Process the roller image into a binary image with only two values, and set the threshold to 130 (i.e., pixel values ​​greater than 130 are set to 255, and pixel values ​​less than or equal to 130 are set to 0);

[0066] 4) Use the Sobel operator to enhance the edge effect of the image and highlight the contour features of the image;

[0067] 5) Fit the minimum circumscribed rectangle of the roller edge in the image, specifically: set the width D′ and length L′ of the rectangle to the diameter D of the roller jk and length L jk , fitting the roller modification amount P(x jk );

[0068] 6) Find the average of the sizes fitted from k photos, where the length L n The average value is calculated using the following formula:

[0069]

[0070] Diameter D n The average value is calculated using the following formula:

[0071]

[0072] Modification amount P(x n ) is calculated using the following formula:

[0073]

[0074] The method for calculating the average values ​​of the length L2, diameter D2 and shaping amount P(x2) detected by the second detection mechanism and the length L3, diameter D3 and shaping amount P(x3) detected by the third detection mechanism is the same as the method for calculating the average values ​​of the length L1, diameter D1 and shaping amount P(x1) detected by the first detection mechanism.

[0075] Preferably, the specific process of comparing the length, diameter and modification amount values ​​obtained in the roller profile detection with the design values ​​of the roller is as follows:

[0076] 1) Calculate the deviation between the detected roller value and the roller design value:

[0077] The deviation between the detected roller diameter and the designed roller diameter is calculated by the following formula:

[0078] ΔD n =D n -D(n=1,2,3) (4);

[0079] The deviation between the detected roller length and the designed roller length is calculated by the following formula:

[0080] ΔL n =L n-L(n=1,2,3) (5);

[0081] The deviation between the roller modification amount obtained by testing and the design value of the roller modification amount is calculated by the following formula:

[0082] ΔP(x n )=P(x n )-P(x)(n=1,2,3) (6).

[0083] Where, ΔD n is the deviation between the detected roller diameter and the design value, ΔL n is the deviation between the detected roller length and the design value, ΔP(x n ) is the deviation between the detected roller modification amount and the design value;

[0084] 2) Determine whether the roller profile meets the design requirements: such as ΔD n Meet the tolerance requirement ΔD n ∈[a,b], the roller diameter meets the design requirements; if ΔL n Meet the tolerance requirement ΔL n ∈[c,d], the roller length meets the design requirements; if ΔP(x n ) meets the tolerance requirement ΔP(x n )∈[e,f], the roller modification amount meets the design requirements.

[0085] Preferably, the specific process of determining whether the roller has an ellipse is as follows:

[0086] 1) When D max -D min ≤ΔD m When , there is no ellipse, which meets the design requirements. Here ΔD m The maximum difference in roller diameter design, D max is the maximum value of the roller diameter detected, D min is the minimum value of the roller diameter detected;

[0087] 2) If ΔD n , ΔL n and ΔP(x n ) all meet the design requirements, and D max -D min ≤ΔD m , then the roller size is qualified, otherwise, the roller size is unqualified.

[0088] The above description is only a preferred embodiment of the present invention and is 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 roller profile detection method, characterized in that: The following steps are involved: Step 1: Preparation: transport the roller to the first detection position; Step 2: Roller profile detection: Use a detection mechanism to detect the roller profile in multiple positions, and obtain the length, diameter and modification value of the roller in multiple positions; the specific process is as follows: 1) The detection mechanism detects the profile of the roller in multiple positions and forms a roller image; 2) The roller image is sent to a computer for grayscale processing so that each pixel in the pixel matrix satisfies the following relationship: R=G=B, where R represents the value of the red variable, G represents the value of the green variable, and B represents the value of the blue variable; 3) Performing a linear grayscale transformation on the roller image after noise reduction; 4) Process the roller image into a binary image with only two values, and set the threshold to 130, that is, the pixel values ​​greater than 130 are set to 255, and the pixel values ​​less than or equal to 130 are set to 0; 5) Use the Sobel operator to enhance the edge effect of the image and highlight the contour features of the image; 6) Fit the minimum circumscribed rectangle of the roller edge in the image, specifically: set the width D′ and length L′ of the rectangle to the diameter D of the roller jk and length L jk , fitting the modification amount P(x jk ); 7) Find the average of the sizes fitted from k photos, where the length L n The average value is calculated using the following formula: Diameter D n The average value is calculated using the following formula: Modification amount P(x n ) is calculated using the following formula: Where: k represents the number of photos of the roller detection position, n = 1...i, i is the number of detection mechanisms; Step 3: Determine the roller profile: Compare the length, diameter and shaping amount values ​​of the roller in multiple positions with the design values ​​of the length, diameter and shaping amount of the roller to determine whether the length, diameter and shaping amount values ​​of the roller meet the design requirements and whether the roller profile is elliptical.

2. The roller profile detection method according to claim 1, characterized in that: In the step 1, a conveying mechanism is used to convey the roller to the inspection workbench; The conveying mechanism is configured as a belt conveying structure, and a plurality of trapezoidal protrusions are evenly distributed on the upper surface of the belt in the belt conveying structure, and the roller is clamped and conveyed by two adjacent trapezoidal protrusions.

3. The roller profile detection method according to claim 1, characterized in that: The conversion of the roller's multiple positions in step 2 is performed by clamping and rotating the roller using a rotary clamping mechanism; The rotary clamping mechanism is configured as a rotary cylinder.

4. The roller profile detection method according to claim 3, characterized in that: In the step 2, the relationship between the multiple positions of the roller is set so that the latter position is rotated 120° relative to the former position.

5. The roller profile detection method according to claim 4, characterized in that: In the step 2, the detection mechanism is set as an industrial camera.

6. The roller profile detection method according to claim 1, characterized in that: The specific process of comparing the length, diameter and modification amount values ​​obtained in the roller profile detection with the design values ​​of the roller in step 3 is as follows: 1) Calculate the deviation between the detected roller value and the roller design value: The deviation between the detected roller diameter and the designed roller diameter is calculated by the following formula: ΔD n =D n -D; The deviation between the detected roller length and the designed roller length is calculated by the following formula: ΔL n =L n -L; The deviation between the roller modification amount obtained by testing and the design value of the roller modification amount is calculated by the following formula: ΔP(x n )=P(x n )-P(x); Where, ΔD n is the deviation between the detected roller diameter and the design value, ΔL n is the deviation between the detected roller length and the design value, ΔP(x n ) is the deviation between the detected roller modification amount and the design value, n = 1…i, i is the number of detection mechanisms; 2) Determine whether the roller profile meets the design requirements: such as ΔD n Meet the tolerance requirement ΔD n ∈[a,b], the roller diameter meets the design requirements; if ΔL n Meet the tolerance requirement ΔL n ∈[c,d], the roller length meets the design requirements; if ΔP(x n ) meets the tolerance requirement ΔP(x n )∈[e,f], the roller modification amount meets the design requirements.

7. The roller profile detection method according to claim 6, characterized in that: The specific process of judging whether the roller profile is an ellipse in step 3 is as follows: 1) When D max -D min ≤ΔD m When , there is no ellipse, which meets the design requirements. Here ΔD m The maximum difference in roller diameter design, D max is the maximum value of the roller diameter detected, D min is the minimum value of the detected roller diameter; 2) If ΔD n , ΔL n and ΔP(x n ) all meet the design requirements, and D max -D min ≤ΔD m , then the roller size is qualified, otherwise, the roller size is unqualified.

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