A method for intelligently identifying and cutting seamless products using a vision-guided water jet

Abstract

The present invention discloses a device and method for intelligently identifying and cutting seamless products with a vision-guided water jet, comprising a water jet cutting machine and a visual inspection module, wherein a workbench is provided at the lower end of the water jet cutting machine, the middle of the workbench is recessed to form a working groove, a wash basin bracket is installed in the working groove, a rock plate bracket is installed at the upper right end of the workbench, and the visual inspection module is installed directly above the wash basin bracket. The present invention solves the problems of traditional ceramic sanitary ware seamless splicing products, such as complex traditional process operation, strong coupling, very inaccurate contour recognition, imprecise calibration, long time consumption, high labor cost, and great influence by environmental factors.

Description

Technical Field

[0001] The invention belongs to the technical field of sanitary ware processing, and in particular relates to a device and a method for intelligently identifying and cutting seamless products with a vision-guided water jet. Background Art

[0002] At present, the seamless splicing products in the ceramic sanitary ware industry are developing on a large scale, but their production efficiency is still very slow. Seamless splicing products are made by cutting the upper rock plate and the under-counter basin separately by a water jet cutting machine, and then processing and splicing the two. There are currently two main water jet cutting processes for such products on the market: manual measurement and water jet distance measurement.

[0003] The manual measurement method refers to manually measuring the contour data of the undercounter basin using measuring tools such as a tape measure, and roughly drawing the cutting line CAD graphics based on the data. On the one hand, manual measurement leads to a large gap between the actual cutting route of the product plate and the ideal size, poor product edge fitting effect, and unclear position correspondence between the substrate to be cut and the water jet cutting machine, making it impossible to achieve true "precise seamless splicing"; on the other hand, manual production efficiency is low, it takes an hour to produce just one product, and the average daily output is very small, which consumes a lot of manpower and material resources and increases the economic loss of the enterprise.

[0004] The water jet distance measurement method is based on the distance measurement function of the water jet. Within the preset range, the height of the under-counter basin is densely measured to obtain a 3D point cloud formed by the height data. After selecting the starting point for cutting, the water jet continues to cut along the contour line to finally obtain a high-precision finished product. Although this method is theoretically feasible, it will encounter many problems in engineering use: (1) Long measurement time: The dense distance measurement method causes the measurement time to be even longer than manual measurement; (2) Low measurement accuracy: On the glaze and inclined surface of the under-counter basin, the accuracy of the distance meter is difficult to meet the requirements; (3) Poor anti-interference ability: Environmental factors such as water flow, water accumulation, and water mist of the water jet cutting machine will cause significant interference to the measurement accuracy. Summary of the invention

[0005] The purpose of the present invention is to provide a device and method for intelligently identifying and cutting seamless products with a visually guided water jet, aiming to solve the problems existing in the above-mentioned background technology. To achieve the above-mentioned purpose, the technical solution adopted by the present invention is:

[0006] A device for intelligently identifying and cutting seamless products with a vision-guided water jet comprises a water jet cutting machine and a visual inspection module. A workbench is provided at the lower end of the water jet cutting machine. The middle of the workbench is recessed to form a working groove. A wash basin bracket is installed in the working groove. A rock slab bracket is installed at the upper right end of the workbench. The visual inspection module is installed directly above the wash basin bracket.

[0007] Preferably, the water jet cutting machine comprises a water jet support, a water jet beam and a water jet head, the water jet support is mounted at the left and right ends of the water jet beam, the water jet head is mounted on the water jet beam, the water jet head moves left and right along the water jet beam, water jet guide rails are provided at the left and right ends of the workbench, the water jet support is mounted on the water jet guide rail, and the water jet support moves back and forth along the water jet guide rail.

[0008] Preferably, level rods are installed at the upper ends of the left and right sides of the wash basin bracket, a level cross bar is connected to the two level rods, and a level is installed on the level cross bar.

[0009] Preferably, the wash basin bracket comprises a bracket column and a bracket cross bar, the bracket column is provided with a cross bar frame block, the bracket cross bar is installed on the upper end of the cross bar frame block, and the level support rod is installed on the upper end of the bracket cross bar.

[0010] Preferably, a guide groove is provided on the support column, the cross bar frame block can be movably installed in the guide groove, the cross bar frame block can adjust the height along the guide groove, and the cross bar frame block and the guide groove are fixed by screws.

[0011] Preferably, auxiliary fixing members are provided at the left and right ends of the bracket crossbar. The auxiliary fixing members are provided with fixing screw holes. The fixing screws are installed through the fixing screw holes. The fixing screws will press against the left and right ends of the wash basin to fix it.

[0012] Preferably, a rock slab limiter is provided at the upper end of the rock slab support.

[0013] Preferably, the visual inspection module includes an industrial camera, a camera column, a camera support rod and a camera mounting rod, the camera support rod is installed on the camera column, the camera mounting rod is installed on the camera support rod, the industrial camera is installed on the camera mounting rod, the camera support rod can adjust the height of the industrial camera along the camera column, and the camera mounting rod can adjust the position of the industrial camera along the camera support rod.

[0014] A method for visually guiding water jet intelligent identification and cutting of seamless products, the method is applicable to a device for visually guiding water jet intelligent identification and cutting of seamless products, and the steps are:

[0015] S1: placing and fixing the wash basin to be cut on the wash basin bracket;

[0016] S2: installing the level meter on the upper end of the wash basin bracket, lighting the wash basin with the level meter to form a laser curve, and marking a plurality of calibration points on the wash basin with the laser curve;

[0017] S3: The visual inspection module collects and processes the image of the wash basin, obtains the image coordinates of the calibration points based on the calibration points, performs coordinate conversion to obtain the workpiece coordinates, and obtains the laser curve image coordinates;

[0018] S4: Use the workpiece coordinates as drawing points to automatically draw and generate a CAD file with the wash basin number, production date, cutting line of the faucet installation hole of the rock plate, and cutting line of the wash basin;

[0019] S5: The water jet cutting machine reads the CAD file and cuts the wash basin according to the wash basin cutting line;

[0020] S6: The water jet cutting machine reads the CAD file and cuts the rock slab according to the wash basin cutting line.

[0021] Preferably, the visual inspection module collects the wash basin image, and processes the wash basin image into workpiece coordinates through a visual program, including:

[0022] S31: using an industrial camera to collect an image of the wash basin, and recording the image coordinates of each calibration point;

[0023] S32: Based on the calibration points, linear mapping is performed on the calibration point image coordinates to obtain the workpiece coordinates on the water jet cutting machine.

[0024] S33: The software processes the wash basin image to obtain the laser curve image coordinates of the laser curve in the image.

[0025] Beneficial effects of the present invention:

[0026] 1. The present invention combines the water jet cutting process with visual technology, uses a level to accurately obtain the contour of the workpiece to be cut, and provides precise positioning features for the visual inspection module, achieving perfect recognition of the product contour within half a second;

[0027] 2. The present invention uses coordinate transformation to map the coordinates of the calibration points of the wash basin image to the workpiece coordinates, so as to achieve accurate correspondence between the cutting position calibrated by the level meter and the workpiece coordinates;

[0028] 3. Use industrial camera "image acquisition + image recognition" to achieve fast measurement, which saves time, greatly improves production efficiency, and has high product cutting accuracy;

[0029] 4. The present invention can be applied to seamless splicing products of different sizes and appearances, with high flexibility, simple operation and low manual learning cost;

[0030] 5. The present invention will not be affected by water splashes, dust, etc. when implemented, thereby improving cutting stability and accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1An overall schematic diagram of a device for intelligently identifying and cutting seamless products with a vision-guided water jet provided by an embodiment of the present invention;

[0032] Figure 2 A schematic diagram of a wash basin bracket structure of a device for intelligently identifying and cutting seamless products with a vision-guided water jet provided in an embodiment of the present invention;

[0033] Figure 3 A schematic diagram of a workflow of a method for intelligently identifying and cutting seamless products with a vision-guided water jet provided by an embodiment of the present invention;

[0034] Among them, the reference numerals in the figure are:

[0035] 1. Workbench; 11. Work slot; 12. Water jet guide rail; 2. Visual inspection module; 21. Industrial camera; 22. Camera column; 23. Camera support rod; 24. Camera mounting rod; 3. Water jet cutting machine; 31. Water jet support column; 32. Water jet beam; 33. Water jet head; 4. Wash basin bracket; 41. Bracket column; 42. Bracket cross bar; 43. Cross bar frame block; 44. Guide groove; 45. Auxiliary fixings; 5. Rock plate bracket; 51. Rock plate limiter; 61. Level support rod; 62. Level cross bar; 63. Level; 7. Wash basin. DETAILED DESCRIPTION

[0036] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0037] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may also be a centered element. When an element is considered to be "connected" to another element, it may be directly connected to the other element or there may be a centered element at the same time. On the contrary, when an element is referred to as being "directly on" another element, there is no intermediate element. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only and are not intended to be the only implementation method. The terms "upper end", "lower end", "left side", "right side", "front end", "rear end" and similar expressions used herein are positional relationships with reference to the accompanying drawings.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0039] The technical solution of this patent is further described in detail below in conjunction with specific implementation methods.

[0040] like Figures 1 to 3 As shown, an embodiment of the present invention provides a device for intelligently identifying and cutting seamless products with a vision-guided water jet, comprising a water jet cutting machine 3 and a visual inspection module 2. A workbench 1 is provided at the lower end of the water jet cutting machine 3. The middle part of the workbench 1 is recessed to form a working groove 11. A wash basin bracket 4 is installed in the working groove 11. A rock slab bracket 5 is installed at the upper right end of the workbench 1. The visual inspection module 2 is installed directly above the wash basin bracket 4.

[0041] In this embodiment, the water jet cutting machine 3 includes a water jet support 31, a water jet beam 32 and a water jet head 33. The water jet support 31 is installed at the left and right ends of the water jet beam 32, and the water jet head 33 is installed on the water jet beam 32. The water jet head 33 moves left and right along the water jet beam 32. Water jet guide rails 12 are provided at the left and right ends of the workbench 1. The water jet support 31 is installed on the water jet guide rail 12, and the water jet support 31 moves back and forth along the water jet guide rail 12.

[0042] In this embodiment, level rods 61 are installed at the upper ends of the left and right sides of the wash basin bracket 4 , and a level cross bar 62 is connected to the two level rods 61 , and a level 63 is installed on the level cross bar 62 .

[0043] In this embodiment, the wash basin bracket 4 includes a bracket column 41 and a bracket cross bar 42, the bracket column 41 is provided with a cross bar frame block 43, the bracket cross bar 42 is installed on the upper end of the cross bar frame block 43, and the level rod 61 is installed on the upper end of the bracket cross bar 42;

[0044] A guide groove 44 is provided on the support column 41 , and the crossbar frame block 43 can be movably installed in the guide groove 44 . The crossbar frame block 43 can adjust the height along the guide groove 44 , and the support crossbar 42 is fixed to the guide groove 44 by screws.

[0045] When in use, the height of the crossbar bracket block 43 can be adjusted according to the depth of the wash basin 7, thereby adjusting the height of the bracket crossbar 42.

[0046] In this embodiment, auxiliary fixing parts 45 are provided at the left and right ends of the bracket cross bar 42. The auxiliary fixing parts 45 are provided with fixing screw holes. The fixing screws are installed through the fixing screw holes. The fixing screws will press against the left and right ends of the wash basin 7 to fix the wash basin 7, so that the wash basin 7 is placed on the wash basin bracket 4 for processing and is more stable.

[0047] In this embodiment, a rock slab limiter 51 is provided at the upper end of the rock slab support 5, and a rock slab limiter groove is provided on the rock slab limiter 51. The rock slab can improve the cutting accuracy by clamping the corners into the rock slab limiter groove to a new limited position.

[0048] In this embodiment, the visual inspection module 2 includes an industrial camera 21, a camera column 22, a camera support rod 23 and a camera mounting rod 24. The camera support rod 23 is installed on the camera column 22, the camera mounting rod 24 is installed on the camera support rod 23, and the industrial camera 21 is installed on the camera mounting rod 24. The camera support rod 23 can adjust the height of the industrial camera 21 along the camera column 22, and the camera mounting rod 24 can adjust the position of the industrial camera 21 along the camera support rod 23.

[0049] A method for intelligently identifying and cutting seamless products by a vision-guided water jet, the method is applicable to a device for intelligently identifying and cutting seamless products by a vision-guided water jet, and the steps are:

[0050] S1: placing and fixing the wash basin 7 to be cut on the wash basin bracket 4;

[0051] S2: Install the level 63 on the upper end of the wash basin bracket 4, illuminate the wash basin 7 with the level 63 to form a laser curve, and mark multiple calibration points on the wash basin 7 through the laser curve;

[0052] S3: The visual inspection module 2 collects and processes the image of the wash basin, obtains the image coordinates of the calibration points based on the calibration points, performs coordinate conversion to obtain the workpiece coordinates, and obtains the laser curve image coordinates;

[0053] S31: using the industrial camera 21 to capture the wash basin image, and recording the calibration point image coordinates of each calibration point;

[0054] S32: Based on the calibration points, linear mapping is performed on the calibration point image coordinates to obtain the workpiece coordinates on the water jet cutting machine.

[0055] S33: The software processes the wash basin image to obtain the laser curve image coordinates of the laser curve in the image.

[0056] S4: Use the workpiece coordinates as drawing points to automatically draw and generate a CAD file with the wash basin number, production date, cutting line of the faucet installation hole of the rock plate, and cutting line of the wash basin;

[0057] S5: The water jet cutting machine 3 reads the CAD file and cuts the wash basin 7 according to the wash basin cutting line;

[0058] S6: The water jet cutting machine 3 reads the CAD file and cuts the rock slab according to the wash basin cutting line.

[0059] Working method:

[0060] In this embodiment, first, by installing and lighting the level 63, the level 63 will produce a laser curve on the wash basin 7, and the calibration point is marked on the wash basin 7 in accordance with the position of the laser curve. The industrial camera 21 captures the wash basin image of the wash basin and the laser curve, and transmits the wash basin image to the visual program. The visual program processes the calibration points in the wash basin image through S3~S4 and outputs a CAD file with the cutting line of the wash basin 7. The water jet cutting machine 3 uses this CAD file with the cutting line of the wash basin to cut the wash basin 7 on the wash basin bracket 4 and the rock slab on the rock slab bracket 5 respectively. When processing wash basins and rock slabs of the same size and model in the future, there is no need to repeat the steps of S1~S4, and the CAD file can be directly used in combination with the laser curve for processing.

[0061] In this embodiment, the detection and recognition algorithm of the visual program can accurately identify the product outline and calculate the workpiece coordinates through the calibration points, thereby outputting a CAD file with the cutting line of the wash basin 7, and automatically positioning it to the target height by the coordinate system conversion calculation. Finally, the water jet cutting machine 3 performs chamfering of the base material and the rock plate according to the outline, realizing high-precision seamless splicing of the base material and the plate of the new seamless splicing product. The processing technology is simple, the coupling is low, the fitting accuracy is high, the calibration is accurate, the processing efficiency is high, and it is not affected by the low accuracy of the rangefinder of the water jet cutting machine 3.

[0062] The above implementation modes are only used to illustrate the present invention, but not to limit the present invention. Ordinary technicians in the relevant technical field can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, all equivalent technical solutions also belong to the scope of the present invention. The patent protection scope of the present invention should be defined by the claims.

Claims

1. A method for intelligently identifying and cutting seamless products using a vision-guided water jet, characterized in that: The device for intelligently identifying and cutting seamless products with a vision-guided water jet comprises a water jet cutting machine and a visual inspection module. A workbench is provided at the lower end of the water jet cutting machine. The middle of the workbench is recessed to form a working groove. A wash basin bracket is installed in the working groove. A rock plate bracket is installed at the upper right end of the workbench. The visual inspection module is installed directly above the wash basin bracket. The water jet cutting machine comprises a water jet support, a water jet beam and a water jet head, wherein the water jet support is mounted at the left and right ends of the water jet beam, the water jet head is mounted on the water jet beam, and the water jet head moves left and right along the water jet beam, and water jet guide rails are arranged at the left and right ends of the workbench, the water jet support is mounted on the water jet guide rails, and the water jet support moves forward and backward along the water jet guide rails; Level rods are installed at the upper ends of the left and right sides of the wash basin bracket, and a level cross bar is installed between the two level rods, and a level is installed on the level cross bar; The wash basin bracket comprises a bracket column and a bracket cross bar, the bracket column is provided with a cross bar frame block, the bracket cross bar is installed at the upper end of the cross bar frame block, and the level rod is installed at the upper end of the bracket cross bar; Auxiliary fixing pieces are disposed opposite to each other at the left and right ends of the bracket crossbar; A rock plate limiting piece is provided at the upper end of the rock plate bracket; The visual inspection module includes an industrial camera, a camera column, a camera support rod and a camera mounting rod, wherein the camera support rod is mounted on the camera column, the camera mounting rod is mounted on the camera support rod, and the industrial camera is mounted on the camera mounting rod; The method comprises the following steps: S1: placing and fixing the wash basin to be cut on the wash basin bracket; S2: installing the level meter on the upper end of the wash basin bracket, lighting the wash basin with the level meter to form a laser curve, and marking a plurality of calibration points on the wash basin with the laser curve; S3: The visual inspection module collects and processes the image of the wash basin, obtains the image coordinates of the calibration points based on the calibration points, performs coordinate conversion to obtain the workpiece coordinates, and obtains the laser curve image coordinates; S4: Use the workpiece coordinates as drawing points to automatically draw and generate a CAD file with the wash basin number, production date, cutting line of the faucet installation hole of the rock plate, and cutting line of the wash basin; S5: The water jet cutting machine reads the CAD file and cuts the wash basin according to the wash basin cutting line; S6: The water jet cutting machine reads the CAD file and cuts the rock slab according to the wash basin cutting line.

2. The method for intelligently identifying and cutting seamless products by using a vision-guided water jet according to claim 1, characterized in that: The visual inspection module collects the wash basin image, and processes the wash basin image into workpiece coordinates through a visual program, including: S31: using an industrial camera to collect an image of the wash basin, and recording the image coordinates of each calibration point; S32: Based on the calibration points, linear mapping is performed on the calibration point image coordinates to obtain the workpiece coordinates on the water jet cutting machine. S33: The software processes the wash basin image to obtain the laser curve image coordinates of the laser curve in the image.

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