Automatic processing device and method for gear seat welding notch

Abstract

The present application relates to an automatic processing device and method for a gear seat welding notch, which includes a workbench, a cutting robot, a robot control system, a reciprocating platform, and a rotary support frame. The reciprocating platform is mounted above the workbench, the cutting robot is mounted on the reciprocating platform and its position is controlled by the reciprocating platform, the rotary support frame is mounted on the workbench, a gear seat fixing fixture that can rotate freely around its own axis is mounted on the rotary support frame, the gear seat to be processed is mounted on the gear seat fixing fixture, a servo motor that drives the gear seat fixing fixture to rotate is provided on the rotary support frame, an image acquisition device is installed on the cutting robot, and lighting lamps are provided on both sides of the rotary support frame. Automatic identification and cutting of gear seat welding notches are achieved, thereby improving cutting accuracy.

Description

Technical Field

[0001] The present application relates to the technical field of coal mining device manufacturing, and in particular to an automatic processing device and method for a gear seat welding notch. Background Art

[0002] A shearer drum unit is a type of coal shearer that uses a drum to break coal. It consists of a motor, traction unit, and cutting unit (including the coal-cutting drum). It rides on a working face conveyor or runs on the floor. The drum, equipped with spiral blades and picks, breaks the coal and loads it onto the conveyor, where it is used to cut, break, and crush coal at the working face.

[0003] Currently, before welding the tooth seats on the shearer drum, the tooth seat welding notch must be machined. There are many different types of tooth seat welding notches. The earliest method used was to manually draw lines and cut the tooth seat welding notch with a manual flame (such as acetylene gas, natural gas, etc.). This method has low precision, low efficiency, and good economics. Later, a method using special templates to process the tooth seat welding notch was gradually developed instead of manual line drawing and manual flame cutting. This method has improved efficiency, but the accuracy is still not high. In recent years, with the rise of intelligent manufacturing, there is a demand for automation in the processing of shearer drum tooth seats. Summary of the Invention

[0004] In order to realize automatic identification and automatic cutting of the gear seat welding notch and improve cutting accuracy, the present application provides a gear seat welding notch automatic processing device and processing method.

[0005] The present application provides a device and method for automatically processing a welding notch of a gear seat, which adopts the following technical solutions:

[0006] A device and method for automatically processing a gear seat welding notch, comprising a workbench, a cutting robot, a robot control system, a reciprocating table and a rotary support frame, wherein the reciprocating table is mounted above the workbench, the cutting robot is mounted on the reciprocating table and the position of the cutting robot is controlled by the reciprocating table, the rotary support frame is mounted on the workbench, a gear seat fixing fixture that can rotate freely around its own axis is mounted on the rotary support frame, the gear seat to be processed is mounted on the gear seat fixing fixture, a servo motor that drives the gear seat fixing fixture to rotate is provided on the rotary support frame, an image acquisition device is installed on the cutting robot, and lighting lamps are provided on both sides of the rotary support frame.

[0007] By adopting the above technical solution, the gear seat is installed on the gear seat fixing fixture, the gear seat is rotated by linking the gear seat fixing fixture with a servo motor, the gear seat to be processed position is adjusted, the cutting robot is controlled to move by the reciprocating moving table, the image acquisition device collects the processing position of the gear seat, the lighting lamp supplements the light source of the image acquisition device to improve the image acquisition effect, and the cutting robot is controlled by the robot control system to cut the gear seat, so as to realize automatic recognition and automatic cutting of the gear seat welding notch and improve the cutting accuracy.

[0008] Optionally, the image acquisition device uses a camera.

[0009] By adopting the above technical solution, the image of the tooth seat position and cutting status can be easily captured through the camera.

[0010] Optionally, the robot control system is provided with a plurality of communication modules, and the cutting robot, the reciprocating moving platform and the servo motor are respectively communicatively connected to the robot control system via a communication module.

[0011] By adopting the above technical solution, the robot control system can remotely control the cutting robot, reciprocating moving table and servo motor to work through the communication module, thereby realizing automation.

[0012] An analysis method using an analyzer comprises the following steps:

[0013] S1: Input the control program into the robot control system by importing the program;

[0014] S2: Setting a characteristic mark next to each welding notch of the gear seat to be processed, wherein each characteristic mark is different from another and corresponds one to one to the welding notch of the gear seat to be processed;

[0015] S3: The robot control system controls the gear holder fixing fixture to rotate through the servo motor, and rotates the gear holder to be processed to the preset processing position of the gear holder welding notch;

[0016] S4: The robot control system controls the movement of the cutting robot through the reciprocating moving table. The image acquisition device collects pictures or videos containing feature identifiers. The controller receives the pictures or videos and extracts the feature identifiers from them. The feature identifiers are then compared with the system knowledge base stored in the controller, and the corresponding control program is sent to the cutting robot.

[0017] S5: The cutting robot starts to ignite and cuts according to the notch curve set by the control program. After the cutting is completed, the cutting robot turns off the fire, and the reciprocating moving table controls the cutting robot to move back to a safe position;

[0018] S6: The robot control system controls the gear holder fixing fixture to rotate through the servo motor, rotates the gear holder to be processed to a preset processing position of the next gear holder welding notch, and then executes steps S4 and S5;

[0019] S7: Repeat step S6 until all the tooth seat welding notches are processed.

[0020] By adopting the above technical solution, each tooth seat welding gap can be automatically identified, and the corresponding cutting processing program can be selected according to the different models of the tooth seat welding gap, thereby improving the processing efficiency and realizing automatic cutting.

[0021] Optionally, the feature identifier uses numbers and / or letters.

[0022] By adopting the above technical solution, the image acquisition device can be facilitated to acquire images through numbers and / or letters.

[0023] Optionally, the controller controls the cutting speed of the tooth seat welding notch.

[0024] By adopting the above technical solution, images of the cutting conditions are collected, and the cutting speed of the tooth seat welding notch is conveniently adjusted through the controller according to the cutting conditions.

[0025] Optionally, an image acquisition device is used to capture images of the gear seat welding notch being processed. The blades on the gear seat or the steel plates of the end disc constitute the plate. Image analysis and comparison are used to determine whether the current flame is in place by the appearance of flame at the bottom of the plate. If it is not cut through, the controller controls the cutting gun to slow down and continue cutting until it is cut through. If it is determined that it has been cut through, the controller controls the cutting gun to maintain the current speed.

[0026] By adopting the above technical solution, image analysis technology is used to achieve intelligent speed regulation during the gear seat welding notch cutting operation, which avoids the low efficiency caused by long cutting time and the problem of irregular incision caused by insufficient cutting time.

[0027] Optionally, the process of image analysis and comparison is as follows: divide the image into several sub-images of the same size, with a total number of A; compare each sub-image with the image features of the flame and identify and determine, and mark the sub-image containing the image features of the flame as flame; count the number B of sub-images marked as flames, identify whether each subset has the characteristics of the flame, if it is recognized as such, add the count to B, calculate the proportion of sub-images containing the image features of the flame in all sub-images R=B×100% / A, when the proportion exceeds the set threshold, it is determined that the plate should be cut at this moment, maintain the current cutting speed to continue cutting the gap, and then continue to execute the identification in a loop to determine whether to issue a speed change instruction.

[0028] By adopting the above technical solution, by comparing the quantity ratio between the flame sub-image and the total sub-image, an image recognition effect is obtained, the cutting speed of the cutting robot on the tooth seat is controlled, and automatic control is achieved.

[0029] Optionally, the average flame component ratio of the three images is used as input.

[0030] By adopting the above technical solution, since a single image may have problems such as out-of-focus and other low image quality issues, three images are collected for identification and calculation of R. After calculating the average value, it is determined whether it exceeds the set value to improve the calculation accuracy.

[0031] In summary, this application includes at least one of the following beneficial technical effects:

[0032] 1. Install the gear holder on the gear holder fixture, rotate the gear holder through the servo motor linkage gear holder fixture, adjust the gear holder to be processed, control the cutting robot to move through the reciprocating table, collect the image acquisition device to collect the gear holder processing position, and use the lighting lamp to supplement the image acquisition device to improve the image acquisition effect. The robot control system controls the cutting robot to cut the gear holder, realize automatic recognition and cutting of the gear holder welding notch, and improve cutting accuracy.

[0033] 2. It can automatically identify each gear seat welding gap and select the corresponding cutting process according to the different types of gear seat welding gaps, thereby improving processing efficiency and realizing automatic cutting;

[0034] 3. Image analysis technology is used to achieve intelligent speed regulation during the gear seat welding notch cutting operation, avoiding the low efficiency caused by long cutting time and the problem of irregular incision caused by insufficient cutting time. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 The present invention is a schematic diagram of the overall structure of an automatic processing device for a gear seat welding notch.

[0036] Figure 2 The present invention is a flow chart of a method for processing a gear seat welding notch.

[0037] Explanation of the accompanying symbols: 1. Workbench; 2. Cutting robot; 21. Image acquisition device; 22. Cutting gun; 3. Reciprocating moving table; 4. Rotary support frame; 41. Servo motor; 42. Gear seat fixing tool; 5. Lighting lamp. DETAILED DESCRIPTION

[0038] The present application is further described in detail below in conjunction with all the accompanying drawings.

[0039] The embodiments of the present application disclose an automatic processing device and method for a gear seat welding notch.

[0040] Reference Figure 1 and Figure 2 , a gear seat welding notch automatic processing device, includes a workbench 1, a cutting robot 2, a robot control system, a reciprocating moving table 3 and a rotary support frame 4, the reciprocating moving table 3 is installed on the workbench 1, the cutting robot 2 is installed on the reciprocating moving table 3, the cutting robot 2 is controlled by the reciprocating moving table 3 to move along the length direction of the reciprocating moving table 3, the rotary support frame 4 is installed on the workbench 1, the rotary support frame 4 is equipped with a gear seat fixing workpiece, and the rotary support frame 4 is provided with a servo motor 41 for driving the gear seat fixing tooling 42 to rotate, and the gear seat fixing tooling 42 is freely rotated around its own axis by the servo motor 41, the gear seat is installed on the gear seat fixing tooling 42, and the gear seat is cut by the cutting robot 2.

[0041] The cutting robot 2 is equipped with an image acquisition device 21. The image acquisition device 21 uses a camera to acquire images of the tooth seat position and cutting status, and sends the acquired images to the robot control system to control the cutting robot 2 to perform cutting processing.

[0042] Lighting lamps 5 are installed on both sides of the rotary support frame 4 to supplement the light source of the image acquisition device 21 and improve the image acquisition effect.

[0043] The robot control system is provided with multiple communication modules. The cutting robot 2, the reciprocating platform 3 and the servo motor 41 are respectively connected to the robot control system via a communication module to realize remote control of the cutting robot 2, the reciprocating platform 3 and the servo motor 41.

[0044] A method for processing a tooth seat welding notch, comprising the following steps: S1: inputting a control program into a robot control system by importing a program; S2: setting a characteristic mark next to each tooth seat welding notch to be processed, wherein each characteristic mark is different from each other and corresponds one-to-one to the welding notch of the tooth seat to be processed; S3: the robot control system controls the tooth seat fixing tool 42 to rotate through a servo motor 41, and rotates the tooth seat to be processed to a preset processing position of the tooth seat welding notch; S4: the robot control system controls the cutting robot 2 to move through a reciprocating moving table 3, and the image acquisition device 21 collects pictures or videos containing characteristic marks, and a controller is used to receive the pictures or videos. The frequency is obtained and feature identifiers are extracted from it, and then the feature identifiers are compared with the system knowledge base stored in the controller, and the corresponding control program is sent to the cutting robot 2; S5: the cutting robot 2 is ignited and cuts according to the notch curve set by the control program. After the cutting is completed, the cutting robot 2 is turned off, and the reciprocating table 3 controls the cutting robot 2 to move back to a safe position; S6: the robot control system controls the gear seat fixing tool 42 to rotate through the servo motor 41, and rotates the gear seat to be processed to the preset processing position of the next gear seat welding notch, and then executes steps S4 and S5; S7: repeat step S6 until all gear seat welding notches are processed.

[0045] The characteristic identifier uses numbers and / or letters to facilitate the image acquisition and recognition by the image acquisition device 21.

[0046] An image acquisition device 21 is used to capture images of the gear seat welding notch during processing. The blades or end plates on the gear seat constitute the plate. Image analysis and comparison are used to determine whether the current flame is in place by marking the appearance of flames at the bottom of the plate. The controller controls the cutting speed of the gear seat welding notch. If the not cut through, the controller controls the cutting gun 22 to slow down and continue cutting until the notch is cut through. If it is determined that the notch has been cut through, the controller controls the cutting gun 22 to maintain the current speed and adjust the speed during the gear seat welding notch cutting operation, thereby avoiding low efficiency due to long cutting time and irregular incisions due to insufficient cutting time.

[0047] The process of image analysis and comparison is as follows: divide the image into several sub-images of the same size, with a total number of A; compare each sub-image with the image features of the flame and identify and determine, and mark the sub-image containing the flame image features as flame; count the number of sub-images marked as flames B, identify whether each subset has the characteristics of flames, if it is recognized, add the count to B, calculate the proportion of sub-images containing flame image features in all sub-images R=B×100% / A, when the proportion exceeds the set threshold, it is judged that the plate is cut at this moment, maintain the current cutting speed to continue cutting the gap, and then continue to execute the identification in a loop to determine whether to issue a speed change instruction.

[0048] In order to avoid the problem of low image quality such as out-of-focus in one image, which may affect the judgment of connection, the average value of the flame component ratio of the three images is used as the input. R is calculated by collecting three images. After calculating the average value, it is judged whether it exceeds the set value to improve the calculation accuracy.

[0049] The implementation principle of the embodiment of the present application is as follows: the gear seat is installed on the gear seat fixing tool 42, the gear seat position is adjusted by the servo motor 41, and the gear seat is rotated to the preset processing position of the gear seat welding notch, the reciprocating moving table 3 adjusts the position of the cutting robot 2, and the image acquisition device 21 collects the picture or video of the feature identification, the controller receives the picture or video and extracts the feature identification from it, and then compares the feature identification with the system knowledge base stored in the controller, and sends the corresponding control program to the cutting robot 2. The cutting robot 2 controls the cutting gun 22 to cut according to the established program. During the cutting process, the image analysis and comparison is used to judge whether the current flame is processed in place by the appearance of flame at the bottom of the plate. The speed is adjusted during the gear seat welding notch cutting operation. After the cutting is completed, the reciprocating moving table 3 controls the cutting robot 2 to move back to a safe position, and the servo motor 41 controls the gear seat fixing tool 42 to rotate, and rotates the gear seat to be processed to the preset processing position of the next gear seat welding notch, and repeats the cutting process until all gear seat welding notches are processed.

[0050] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A method for processing a gear seat welding notch, characterized in that: Processing is performed based on an automatic processing device for a tooth seat welding notch, the automatic processing device for a tooth seat welding notch comprises a workbench (1), a cutting robot (2), a robot control system, a reciprocating platform (3) and a rotary support frame (4), wherein the reciprocating platform (3) is mounted above the workbench (1), the cutting robot (2) is mounted on the reciprocating platform (3) and the position of the cutting robot (2) is controlled by the reciprocating platform (3), the rotary support frame (4) is mounted on the workbench (1), a tooth seat fixing fixture (42) capable of rotating freely around its own axis is mounted on the rotary support frame (4), a tooth seat to be processed is mounted on the tooth seat fixing fixture (42), a servo motor (41) for driving the tooth seat fixing fixture (42) to rotate is provided on the rotary support frame (4), an image acquisition device (21) is mounted on the cutting robot (2), and lighting lamps (5) are provided on both sides of the rotary support frame (4); The steps include: S1: Input the control program into the robot control system by importing the program; S2: Setting a characteristic mark next to each welding notch of the gear seat to be processed, wherein each characteristic mark is different from another and corresponds one to one to the welding notch of the gear seat to be processed; S3: The robot control system controls the gear holder fixing fixture (42) to rotate via the servo motor (41), and rotates the gear holder to be processed to a preset processing position of the gear holder welding notch; S4: The robot control system controls the cutting robot (2) to move via the reciprocating moving platform (3), and the image acquisition device (21) acquires a picture or video containing a feature identifier. The controller receives the picture or video and extracts the feature identifier from the picture or video. The feature identifier is then compared with a system knowledge base stored in the controller, and a corresponding control program is sent to the cutting robot (2). S5: The cutting robot (2) is ignited and cuts according to the notch curve set by the control program. After the cutting is completed, the cutting robot (2) is turned off, and the reciprocating moving platform (3) controls the cutting robot (2) to move back to a safe position; S6: The robot control system controls the gear holder fixing fixture (42) to rotate via the servo motor (41), rotates the gear holder to be processed to a preset processing position of the next gear holder welding notch, and then executes steps S4 and S5; S7: Repeat step S6 until all the tooth seat welding notches are processed; The controller controls the cutting speed of the tooth seat welding notch; an image acquisition device (21) is used to capture an image of the tooth seat welding notch during processing, and the blades or end plates on the tooth seat constitute a plate. The image analysis and comparison is performed to determine whether the current flame is processed in place by taking the appearance of a flame at the bottom of the plate as a sign. If no cutting is performed, the controller controls the cutting gun (22) to slow down and continue cutting until the cutting is performed in place; if it is determined that the cutting is performed, the controller controls the cutting gun (22) to maintain the current speed; the image analysis and comparison process is as follows: the image is divided into a plurality of equal-sized The total number of sub-images is A; each sub-image is compared with the image features of the flame and identified and judged, and the sub-image containing the flame image features is marked as flame; the number of sub-images marked as flames is counted B, and each subset is identified as a flame feature. If it is recognized as a flame, the count is accumulated to B, and the proportion of sub-images containing flame image features in all sub-images is calculated as R=B×100% / A. When the proportion exceeds the set threshold, it is determined that the plate material should be cut at this moment, and the current cutting speed is maintained to continue cutting the gap. Then the identification is continued in a loop to determine whether a speed change instruction is issued.

2. A method for processing a gear seat welding notch according to claim 1, characterized in that: Characteristic identifiers use numbers and / or letters.

3. A method for processing a gear seat welding notch according to claim 1, characterized in that: The image acquisition device (21) adopts a camera.

4. The method for processing a gear seat welding notch according to claim 1, characterized in that: The robot control system is provided with a plurality of communication modules, and the cutting robot (2), the reciprocating moving platform (3) and the servo motor (41) are respectively connected to the robot control system through a communication module.

5. The method for processing a gear seat welding notch according to claim 1, characterized in that: The average value of the flame component ratios in the three images is used as input.

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