An intelligent winding machine device based on a CCD camera and its working method

Abstract

The present invention discloses an intelligent rolling machine device based on a CCD camera and its working method. The device includes a curling mechanism, a CCD camera, an image processing unit, and a rotating support device; the rotating support device is used to fixedly support the conical workpiece to be processed and can rotate coaxially and synchronously with the rotation of the conical workpiece. The curling mechanism is arranged on one side of the rotating support device, and the curling mechanism is used to curl the edge of the conical workpiece during the rotation of the conical workpiece; the CCD camera is fixed directly above the rotating support device, and the CCD camera is used to take pictures of the conical workpiece; the image processing unit is connected to the CCD camera, and the image processing unit is used to calculate the diameter of the edge of the conical workpiece by using the photos taken by the CCD camera. The present invention can realize the automatic or semi-automatic processing of capping and curling, greatly improving the curling efficiency and accuracy.

Description

Technical Field

[0001] The present invention belongs to the field of automation equipment, and particularly relates to an intelligent rolling machine device based on a CCD camera and its working method. Background Art

[0002] For the processing of large-scale tanks, splicing technology is mostly used for welding and grinding. To a certain extent, the quality of the formed tank body depends on the splicing accuracy. Therefore, when the tank body is capped and welded, the matching accuracy between the cap and the cylinder body is crucial. To obtain a cap with the target size, a curling process is required, but currently, factories mostly rely on manual labor. In the existing curling technology, manual measurement of the edge circumference is required multiple times, and there are large errors in this process, and it is difficult to ensure the smoothness of the edge contour. Summary of the Invention

[0003] Aiming at the deficiencies existing in the curling of existing conical workpieces, the purpose of the present invention is to provide an intelligent rolling machine device based on a CCD camera and its working method. The present invention can realize the automatic or semi-automatic processing of cap curling, greatly improving the curling efficiency and accuracy.

[0004] The technical solution adopted by the present invention is as follows:

[0005] An intelligent rolling machine device based on a CCD camera includes a curling mechanism, a CCD camera, an image processing unit, and a rotating support device; the rotating support device is used to fixedly support the conical workpiece to be processed and can rotate coaxially and synchronously with the rotation of the conical workpiece. The curling mechanism is arranged on one side of the rotating support device, and the curling mechanism is used to curl the edge of the conical workpiece during the rotation of the conical workpiece; the CCD camera is fixed directly above the rotating support device, and the CCD camera is used to take pictures of the conical workpiece; the image processing unit is connected to the CCD camera, and the image processing unit is used to calculate the diameter of the edge of the conical workpiece by using the photos taken by the CCD camera.

[0006] Preferably, the curling mechanism includes a driving wheel and a curling structure. The curling structure includes a balance wheel, a grinding wheel, and a grinding wheel adjustment mechanism. The grinding wheel is arranged above the driving wheel; after the conical workpiece is arranged on the rotating support device, the driving wheel is located below the edge of the conical workpiece and can contact the conical workpiece. The driving wheel is used to support and drive the conical workpiece to rotate around the rotating shaft of the rotating support device. The grinding wheel is located above the edge of the conical workpiece and can contact the conical workpiece. The grinding wheel and the driving wheel are arranged offset in the radial direction of the conical workpiece. The grinding wheel is used to press down the edge of the conical workpiece and generate a bending moment between the contact point of the edge of the conical workpiece and the driving wheel, so as to realize the curling of the conical workpiece.

[0007] The grinding wheel adjusting mechanism is connected to the grinding wheel, and the grinding wheel adjusting mechanism is used to adjust the feed amount when the grinding wheel presses down the edge of the conical workpiece.

[0008] Balance wheels are provided on both sides of the grinding wheel. After the conical workpiece is set on the rotary support device, the balance wheels are in contact with the conical workpiece, and are used to keep the conical workpiece stable during the curling process.

[0009] Preferably, both the grinding wheel and the balance wheels are in the form of driven wheels.

[0010] Preferably, the curling structure is arranged on a curling structure adjusting mechanism, and the curling structure adjusting mechanism can adjust the curling structure to move axially along the adjusting wheel disc to adjust the feed amount when the grinding wheel presses down the edge of the conical workpiece.

[0011] Preferably, the intelligent curling machine device based on a CCD camera of the present invention further includes a workbench. The rotary support device is installed on the workbench. The rotary support device adopts a rotary shaft, and the rotary shaft is rotatably connected to the workbench. The conical workpiece can be installed at the top of the rotary shaft.

[0012] Preferably, the intelligent curling machine device based on a CCD camera of the present invention further includes a fixing frame. The CCD camera is installed on the fixing frame. The fixing frame adopts a telescopic rod, and the fixing frame can adjust the height of the CCD camera.

[0013] Preferably, the image processing unit includes a controller and a host computer. The CCD camera and the curling mechanism are both connected to the controller, and the controller is connected to the host computer.

[0014] The working method of the intelligent curling machine device based on a CCD camera as described above in the present invention includes the following processes:

[0015] Set the conical workpiece on the rotary support device, and use the curling mechanism to drive the conical workpiece to rotate around the rotating shaft of the rotary support device and curl the edge of the conical workpiece during the rotation of the conical workpiece.

[0016] During the process of curling the edge of the conical workpiece by using the curling mechanism, use the CCD camera to collect images of the conical workpiece. The collected images include the image features of the curled edge of the conical workpiece.

[0017] The image processing unit processes the images collected by the CCD camera to obtain the diameter of the edge of the conical workpiece.

[0018] According to the diameter of the edge of the conical workpiece, use the curling mechanism to curl the edge of the conical workpiece until the diameter of the edge of the conical workpiece reaches a preset value, and the curling ends.

[0019] Preferably, when the image processing unit processes the image collected by the CCD camera, the contour information of the conical workpiece is obtained, the contour of the conical workpiece is ellipse-fitted according to the contour information of the conical workpiece to obtain an ellipse equation, and the contour dimensions of the conical workpiece are calculated through the ellipse equation.

[0020] Preferably, when the image processing unit processes the image collected by the CCD camera, the image is first binarized, and then the image edge contour information is extracted by using an image processing optimization algorithm to obtain the contour information of the conical workpiece;

[0021] When the contour of the conical workpiece is ellipse-fitted according to the contour information of the conical workpiece, the ellipse in all the contour information of the conical workpiece is fitted by using an ellipse fitting algorithm, and then the ellipse equation fitted to the unique edge contour of the conical workpiece is screened out by using a limiting condition.

[0022] The present invention has the following beneficial effects:

[0023] In the intelligent rolling machine device based on a CCD camera of the present invention, the rotating support device can fixedly support the conical workpiece to be processed and can rotate coaxially and synchronously with the rotation of the conical workpiece, meeting the basic requirements for the processing of the conical workpiece. By setting a curling mechanism, the conical workpiece can be driven to rotate around the rotating shaft of the rotating support device and the edge of the conical workpiece can be curled during the rotation of the conical workpiece; the CCD camera is fixed directly above the rotating support device, and during the curling process of the conical workpiece, the image of the conical workpiece can be collected in real time, and the collected image contains the image features of the curled edge of the conical workpiece; through the image processing unit, the image containing the image features of the curled edge of the conical workpiece collected by the CCD camera can be processed to calculate the diameter of the edge of the conical workpiece. By using this non-contact photographing measurement, the efficiency of size measurement during the curling process can be greatly improved and the accuracy is relatively high. Therefore, the intelligent rolling machine device based on a CCD camera of the present invention can obtain the edge dimensions of the conical workpiece in real time during the curling process of the conical workpiece. When the curling mechanism is an automated or semi-automated mechanism, the present invention can realize the automated or semi-automated curling of the conical workpiece, which can greatly improve the work efficiency. Description of the Drawings

[0024] Fig. 1(a) is a side view of the intelligent rolling machine device based on a CCD camera of the present invention; Fig. 1(b) is a top view of the intelligent rolling machine device based on a CCD camera of the present invention.

[0025] Figure 2 is a flowchart of the intelligent rolling machine device based on a CCD camera of the present invention for measuring the size of a conical workpiece in an embodiment of the present invention.

[0026] In the figure: 1 base, 2 workbench, 3 drive motor, 4 adjustment wheel disc, 5 drive wheel, 6 adjustment handle, 7 conical workpiece, 8 CCD camera, 9 fixing bracket, 10 controller, 11 host computer, 12 digital display screen, 13 balance wheel, 14 grinding wheel. Detailed implementation mode

[0027] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0028] Referring to FIGS. 1(a) and 1(b), the intelligent curling machine device based on a CCD camera according to the present invention includes a base 1, a workbench 2, a driving motor 3, an adjusting wheel disc 4, a driving wheel 5, an adjusting handle 6, a CCD camera 8, a fixing bracket 9, a controller 10, a host computer 11, a digital display screen 12, a balance wheel 13, and a grinding wheel 14. The general idea of the present invention is that the balance wheel 13 is used to ensure the smooth axial rotation of the conical workpiece 7, and the driving motor 3 drives the driving wheel 5 to rotate at a constant speed, thereby driving the conical workpiece 7 to rotate; at the same time, during the curling process, the feed amount of the adjusting handle 6 at one end of the grinding wheel 14 is controlled to apply a bending moment to the edge of the conical workpiece 7 to achieve the curling function; in order to obtain the appropriate size of the conical workpiece, the CCD camera 8 is used to take pictures from above, and the diameter size of the conical workpiece is obtained through image processing and displayed on the digital display screen. When the conical workpiece 7 is placed in the processing position, the driving wheel 5 is located below the conical workpiece 7, and the axial angle of the driving wheel 5 with the horizontal plane is determined by the shape specification of the conical workpiece 7. The axial direction of the driving wheel 5 is parallel to the generatrix of the surface of the conical workpiece 7; the power of the driving wheel 5 is provided by the driving motor 3 through the motor shaft, and at the same time, the driving wheel 5 also serves as a support. The conical workpiece 7 is horizontally placed during processing and is driven by friction by the driving wheel 5 to rotate uniformly around the axis. The curling shape of the conical workpiece is circular. The adjusting wheel disc 4 can drive the curling structure to make a reciprocating motion along the axial direction of the adjusting wheel disc 4, aiming to meet the curling requirements of conical workpieces of different specifications. When the conical workpiece 7 is placed in the processing position, the grinding wheel 14 is located above the conical workpiece 7, and the grinding wheel 14 is in contact with the upper surface of the edge of the conical workpiece 7. The axial angle of the grinding wheel 14 with the horizontal plane is determined by the shape specification of the conical workpiece. The axial direction of the grinding wheel 14 is parallel to the generatrix of the surface of the conical workpiece 7, and the axial direction of the grinding wheel 14 is parallel to the circumferential direction of the driving wheel 5; the grinding wheel 14 is a driven wheel without power drive. The adjusting handle 6 can drive the grinding wheel 14 to make a reciprocating motion along the axial direction of the adjusting handle, aiming to adjust the bending moment during the curling of the conical workpiece 7; the adjusting handle 6 has a self-locking function. The conical workpiece 7 is a thin-walled machining part; the edge is circular. The technical solution of the present invention is particularly suitable for curling large-diameter covers (such as conical workpieces with a diameter of 1000 - 3000 mm). The CCD camera 8 is installed on the fixing bracket 9, and the CCD camera 8 vertically takes pictures directly above the conical workpiece 7. The optical axis of the CCD camera 8 is coaxial with the axis of the conical workpiece 7. The fixing position between the fixing bracket 9 and the base 1 can be adjusted; the function of the fixing bracket 9 is to keep the shooting angle of the CCD camera 8 unchanged; the fixing bracket 9 can adjust the height of the camera. The balance wheel 13 is arranged obliquely according to the shape of the conical workpiece like the driving wheel 5 and the grinding wheel 14; the balance wheels 13 are symmetrically distributed on both sides of the grinding wheel 14 and are in contact with the conical workpiece 7, and are used to keep the workpiece stable during the curling process; each balance wheel 13 can be adjusted around the axis and has a locking function. The CCD camera 8 can collect the image features of the curling edge of the conical workpiece 7, and the contour information can be obtained through the image processing program, so as to perform elliptical fitting on the contour, and finally obtain the contour size through the elliptical equation.The conical workpiece 7 rotates continuously and uniformly driven by the driving wheel 5, and the controller 10 controls the start and stop of the driving motor 3. The controller 10, the CCD camera 8 and the driving motor 3 are electrically connected. The host computer 11, the controller 10 and the digital display screen 12 are electrically connected. The host computer uses an industrial computer, the controller selects an STM32 microcontroller, the CCD camera selects a CCD industrial camera, the driving motor selects a stepping motor, and the digital display screen selects an LED digital display screen. The above components are all common and have no particularity. When in use, just select a suitable model according to actual requirements.

[0029] Based on the above intelligent rolling machine equipment based on a CCD camera, its curling process mainly includes the following steps:

[0030] Step 1. Rotation of the conical workpiece 7: Fix the conical workpiece 7 at the rotating shaft on the workbench, set the motor speed in the host computer 11, and the rotating shaft can be set to be telescopic up and down, so as to adapt to the processing requirements of conical workpieces 7 with different tapers; then the host computer 11 controls the driving motor 3 to drive the driving wheel 5 to rotate uniformly through the controller 10, thereby driving the conical workpiece 7 to rotate uniformly.

[0031] Step 2. Curling process: Apply pressure to the conical workpiece 7 by controlling and adjusting the feed of the handle 6. At the same time, the bottom driving wheel 5 undertakes the supporting work. Use the misalignment between the driving wheel 5 and the grinding wheel 14 to generate a bending moment at the edge of the conical workpiece 7, and complete the curling process along with the rotation. Specifically, the controller 10 controls the driving motor 3 to drive the conical workpiece 7 to rotate, and continuously adjusts the handle 6 to change the feed amount during the curling process, and cooperates with the driving wheel 5 to provide the curling bending moment.

[0032] Step 3. Dimension measurement: The CCD camera 8 can collect the image features of the curled edge of the conical workpiece 7 from above. The contour information can be obtained through the image processing program, so as to perform ellipse fitting on the contour. Finally, the contour dimensions are obtained through the ellipse equation (considering the actual situation that the conical workpiece will have an angular offset from the camera shooting plane, so ellipse fitting is performed); after judging whether the dimensions meet the requirements, determine whether the conical workpiece is qualified or repeat Step 2.

[0033] See Figure 2 , Step 3 includes the following steps:

[0034] Step 3.1. Image acquisition: The parameters of the CCD camera 8 are preset in advance. Before acquisition, the host computer 11 makes the driving motor 3 stop rotating through the controller 10. The host computer 10 controls the CCD camera 8 to take pictures and store them.

[0035] Step 3.2. Image processing: Perform binary processing on the image, and then use the image processing optimization algorithm to extract the image edge contour information.

[0036] Step 3.3, contour fitting: Use the ellipse fitting algorithm to fit the ellipses in all the contour information, and then use the limiting conditions to screen out the ellipse fitted from the unique edge contour of the conical workpiece, that is, exclude other interference items in the image information.

[0037] Step 3.4, dimension calculation: After extracting the target fitted ellipse, obtain the center of the fitted ellipse, the major and minor axes of the ellipse, and the numerical values of the parameters in the general parameter equation of the ellipse, so as to obtain the number of pixels q of the major axis of the ellipse. i 。

[0038] Specifically, the general parameter equation of the ellipse is as follows

[0039] Ax 2 +Bxy + Cy 2 +Dx + Ey + F = 0

[0040] Among them, A, B, C, D, E, and F respectively represent the parameters to be solved in the general equation expression of the ellipse.

[0041] Before the curling process starts, it is necessary to perform the processing of Step 3.3 on the unprocessed conical workpiece 7 once, and measure the actual diameter manually multiple times; it is obtained that the average actual diameter size d is proportional to the number of pixels q of the major axis of the ellipse obtained after extracting the contour:

[0042]

[0043] Furthermore, the actual diameter size d required after curling can be obtained i = kq i 。

[0044] Furthermore, the dimension data d i is displayed on the digital display screen.

[0045] In addition, the adjustment wheel can be adjusted to adapt to conical workpieces of different specifications, and the position of the fixing frame can also be changed according to the actual situation. In the existing curling technology, it is necessary to measure the edge circumference manually multiple times during the entire curling process to grasp the gap from the target diameter size, with a large error and low efficiency. After adopting the present invention, compared with the original manual method, the curling efficiency can be greatly improved, and automation is achieved; using a CCD camera for image processing can improve the measurement accuracy during the curling process; reduce the labor intensity of workers, and improve the work efficiency and curling quality.

[0046] In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment contains only an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An intelligent coiling machine device based on a CCD camera, characterized in that, It includes a hemming mechanism, a CCD camera (8), an image processing unit, and a rotating support device; the rotating support device is used to fixedly support the conical workpiece (7) to be processed and can rotate coaxially and synchronously with the rotation of the conical workpiece (7). The hemming mechanism is arranged on one side of the rotating support device and is used to hem the edge of the conical workpiece (7) during the rotation of the conical workpiece (7); the CCD camera (8) is fixed directly above the rotating support device and is used to take pictures of the conical workpiece (7). The image collected by the CCD camera (8) contains the image features of the hemmed edge of the conical workpiece (7); the image processing unit is connected to the CCD camera (8) and is used to calculate the diameter of the edge of the conical workpiece (7) by using the photo taken by the CCD camera (8). When the image processing unit processes the image collected by the CCD camera (8), the contour information of the conical workpiece (7) is obtained. According to the contour information of the conical workpiece (7), the contour of the conical workpiece (7) is ellipse-fitted to obtain an ellipse equation, and the contour dimensions of the conical workpiece (7) are calculated through the ellipse equation; when the contour of the conical workpiece (7) is ellipse-fitted according to the contour information of the conical workpiece (7), the ellipse in all the contour information of the conical workpiece (7) is fitted by using the ellipse fitting algorithm, and then the ellipse equation fitted by the unique conical workpiece edge contour is selected by using the limiting conditions; The hemming mechanism includes a driving wheel (5) and a hemming structure. The hemming structure includes a balance wheel (13), a grinding wheel (14), and a grinding wheel adjusting mechanism. The grinding wheel (14) is arranged above the driving wheel (5); after the conical workpiece (7) is arranged on the rotating support device, the driving wheel (5) is located below the edge of the conical workpiece (7) and can be in contact with the conical workpiece (7). The driving wheel (5) is used to support and drive the conical workpiece (7) to rotate around the rotating shaft of the rotating support device. The grinding wheel (14) is located above the edge of the conical workpiece (7) and can be in contact with the conical workpiece (7). The grinding wheel (14) and the driving wheel (5) are arranged in a radial offset on the conical workpiece (7). The grinding wheel (14) is used to press down the edge of the conical workpiece (7) and generate a bending moment between the contact point of the edge of the conical workpiece (7) and the driving wheel (5) to realize the hemming of the conical workpiece (7); The grinding wheel adjusting mechanism is connected to the grinding wheel (14) and is used to adjust the feed amount when the grinding wheel (14) presses down the edge of the conical workpiece (7); The balance wheels (13) are arranged on both sides of the grinding wheel (14). After the conical workpiece (7) is arranged on the rotating support device, the balance wheels (13) are in contact with the conical workpiece (7) and are used to keep the conical workpiece (7) stable during the hemming process.

2. The intelligent coiling device based on a CCD camera according to claim 1, characterized in that, Both the grinding wheel (14) and the balance wheel (13) are arranged in the form of driven wheels.

3. An intelligent coiling machine device based on a CCD camera according to claim 1, characterized in that, The hemming structure is arranged on a hemming structure adjustment mechanism, and the hemming structure adjustment mechanism can adjust the movement of the hemming structure along the axial direction of the adjustment turntable (4) to adjust the feed amount when the grinding wheel (14) presses down the edge of the conical workpiece (7).

4. An intelligent coiling machine device based on a CCD camera according to claim 1, characterized in that, It further includes a workbench (2). The rotary support device is installed on the workbench (2). The rotary support device adopts a rotary shaft, and the rotary shaft is rotatably connected to the workbench (2). The conical workpiece (7) can be installed at the top end of the rotary shaft.

5. An intelligent coiling machine device based on a CCD camera according to claim 1, characterized in that, It further includes a fixing frame (9). The CCD camera (8) is installed on the fixing frame (9). The fixing frame (9) adopts a telescopic rod, and the fixing frame (9) can adjust the height of the CCD camera (8).

6. The intelligent coiling machine device based on a CCD camera according to claim 1, characterized in that, The image processing unit includes a controller (10) and a host computer (11). The CCD camera (8) and the hemming mechanism are both connected to the controller (10), and the controller (10) is connected to the host computer (11).

7. The working method of the intelligent winding machine device based on a CCD camera according to any one of claims 1-6, characterized in that, It includes the following process: Set the conical workpiece (7) on the rotary support device, and use the hemming mechanism to drive the conical workpiece (7) to rotate around the rotating shaft of the rotary support device and hem the edge of the conical workpiece (7) during the rotation of the conical workpiece (7). During the process of hemming the edge of the conical workpiece (7) by the hemming mechanism, use the CCD camera (8) to collect images of the conical workpiece (7). The collected images contain the image features of the hemmed edge of the conical workpiece (7). The image processing unit processes the images collected by the CCD camera (8) to obtain the diameter of the edge of the conical workpiece (7). According to the diameter of the edge of the conical workpiece (7), use the hemming mechanism to hem the edge of the conical workpiece (7) until the diameter of the edge of the conical workpiece (7) reaches a preset value, and the hemming ends. When the image processing unit processes the images collected by the CCD camera (8), it obtains the contour information of the conical workpiece (7). According to the contour information of the conical workpiece (7), the contour of the conical workpiece (7) is ellipse-fitted to obtain an ellipse equation, and the contour dimensions of the conical workpiece (7) are calculated through the ellipse equation. When the image processing unit processes the images collected by the CCD camera (8), it first performs binary processing on the images, and then uses an image processing optimization algorithm to extract the edge contour information of the images to obtain the contour information of the conical workpiece (7). When performing ellipse fitting on the contour of the conical workpiece (7) according to the contour information of the conical workpiece (7), use the ellipse fitting algorithm to fit the ellipse in all the contour information of the conical workpiece (7), and then use the limiting conditions to screen out the ellipse equation fitted by the unique edge contour of the conical workpiece.

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