A self-adaptive polishing system and method for a monolithic deflection reach of a reach stacker

Abstract

The application discloses a kind of self-adapting polishing system and method of single type deflection reach stacker girder, comprising: line sweep laser sensor, flexible tooling, controller, polishing robot end;Polishing method is: collecting girder laser scanning data and analysis, obtain girder pose data and adjust girder to standard pose according to girder pose data;Scan girder surface under standard pose, respectively obtain the deflection deformation of girder surface, the appearance of weld surface;And according to the appearance of weld surface, obtain weld width, height data and automatically adjust polishing processing parameters;Polishing trajectory is generated based on adjusted polishing processing parameters for controlling polishing robot end;The application is by integrating workpiece pose adjustment algorithm, polishing trajectory guiding algorithm and laser line sweep sensing technology, to solve adaptive polishing problem, improve artificial polishing effect, to realize the automation of adaptive polishing process with deflection deformation girder guiding and improve the environmental problem caused by polishing.

Description

An adaptive grinding system and method for a single-unit deflection front-mounted main beam Technical Field

[0001] This invention belongs to the field of adaptive intelligent grinding, specifically relating to an adaptive grinding system and method for a single-unit deflection front-mounted main beam. Background Technology

[0002] Cylindrical main beam structures are key structural components of lifting and port machinery, used to bear significant loads, and are also widely used in other engineering machinery. However, due to the complex production and operating environment, main beams often experience deflection and deformation during splicing and welding processes. In the weld area, height and position changes occur due to the welding process. Traditional manual grinding methods are still used in the grinding process, which suffers from uneven grinding, damage to the base material, and a tendency to create localized stress concentrations. This cannot meet the high-precision grinding requirements for main beams with deflection deformation, and makes it difficult to achieve ideal results in this area using traditional methods.

[0003] In recent years, automated grinding technology has been widely used in engineering machinery manufacturing. However, existing automated grinding technologies still have certain limitations in solving the problem of base material deflection and deformation, and in adaptive grinding of weld height and position.

[0004] Existing methods all employ dedicated grinding systems for specific products. These systems primarily rely on feature recognition to identify weld characteristics and locations during grinding. However, this approach is prone to matching failures for simple, long, straight welds and cannot meet the adaptive grinding requirements of large-span cylindrical beam welds with significant deflection. Therefore, existing methods and systems cannot be directly applied to grinding cylindrical main beam welds. While grinding systems can be adjusted according to the product, the adjusted systems still struggle to adapt to the complex deflection of the main beam and cannot automatically adjust the height and position of the weld area during grinding. This presents significant technical challenges in practical engineering applications. Furthermore, environmental issues are a pressing concern in the construction machinery manufacturing industry. Traditional grinding methods can generate substantial amounts of dust and waste, polluting the working environment and ecology, and even posing a threat to the health of operators. Summary of the Invention

[0005] Purpose of the invention: In order to overcome the shortcomings of the prior art, the present invention provides an adaptive grinding system and method for a single-unit deflection front-mounted main beam. By integrating workpiece posture adjustment algorithm, grinding trajectory guidance algorithm and laser line scanning sensing technology, the invention solves the problem of adaptive grinding, improves the effect of manual grinding, thereby realizing the automated guidance of the adaptive grinding process of the main beam with deflection deformation and improving the environmental protection problems caused by grinding.

[0006] Technical Solution: Firstly, this invention provides an adaptive grinding system for a single-unit deflection front-mounted main beam, comprising:

[0007] Line-scan laser sensor, flexible tooling, controller, and end effector of grinding robot;

[0008] The line-scanning laser sensor, flexible tooling, and grinding robot end effector are electrically connected and communicate with the controller. The controller is also electrically connected to the workstation to optimize data processing and calculation functions.

[0009] The line-scan laser sensor is used to collect laser scanning data of the main beam;

[0010] The flexible fixture is used to hoist and fix the main beam and adjust the main beam to a standard position according to the clockwise or counterclockwise position change trajectory.

[0011] The workstation receives the laser scanning data of the main beam forwarded by the controller. The workstation has pre-stored standard pose and calculation model to determine the pose data of the main beam and calculate the topographic scanning data of the main beam surface and weld surface, thereby obtaining the main beam pose data, the deflection deformation curve of the main beam surface, and the weld width and height of the weld surface, and forwards them to the controller. The main beam laser scanning data includes: main beam pose data, and topographic scanning data of the main beam surface and weld surface.

[0012] The controller forwards the laser scanning data of the main beam, receives the main beam pose data, the deflection deformation curve of the main beam surface, and the weld width and height of the weld surface; generates clockwise or counterclockwise pose transformation trajectories based on the main beam pose data to adjust the main beam to the standard pose; and updates the grinding processing parameters and generates a grinding trajectory according to the deflection deformation curve, weld width and height.

[0013] The end effector of the grinding robot is used to adaptively adjust the coordinates during the grinding process according to the grinding trajectory.

[0014] In a further embodiment, the line-scan laser sensor is mounted in front of the grinding spindle at the end of the grinding robot.

[0015] In a second aspect, the present invention provides an adaptive grinding method for a single-unit deflection front-mounted main beam, comprising:

[0016] Collect and analyze the laser scanning data of the main beam to obtain the main beam's pose data;

[0017] Adjust the main girder to the standard position based on the main girder's position data;

[0018] The surface of the main beam is scanned in the standard pose to obtain the deflection deformation of the main beam surface and the morphology of the weld surface; and the weld width and height data are obtained based on the morphology of the weld surface.

[0019] The grinding parameters are automatically adjusted based on the deflection deformation, weld width, and height data of the main beam surface.

[0020] A grinding trajectory is generated based on the adjusted grinding parameters to control the end effector of the grinding robot, wherein the grinding speed is preset in the trajectory parameters.

[0021] In a further embodiment, laser scanning data of the main beam is acquired and analyzed to obtain the main beam pose data, including:

[0022] The laser scanning data of the main beam is collected and the coordinates are transformed to obtain the coordinate values ​​of each data point.

[0023] The coordinates of each data point are imported into the container in the scanning order and stored and then subjected to Hough transformation to obtain the edge straight line data of the main beam.

[0024] Determine the main beam's pose data based on the edge straight line data of the main beam;

[0025] The scanning sequence is from the outside of one end of the main beam inwards.

[0026] And sampling is performed using a single laser with a sampling rate of 400 data points, a field of view of 40 mm, and a scanning interval of 0.1 mm.

[0027] In a further embodiment, adjusting the main beam to a standard pose based on the main beam pose data includes:

[0028] Calculate the angle between the edge of the main beam's pose and the standard pose based on the main beam's pose data, and determine the direction of the main beam's pose.

[0029] Based on the angle between the main beam pose and the standard pose, the direction of the main beam pose generates a clockwise or counterclockwise pose transformation trajectory.

[0030] Based on the clockwise or counterclockwise motion trajectory change control, the flexible tooling drives the main beam to move clockwise or counterclockwise.

[0031] The expression for the clockwise pose transformation of the main beam's pose edge is:

[0032]

[0033] The expression for the counterclockwise pose transformation of the main beam's pose edge is:

[0034]

[0035] In the formula, (x′, y′, z′) is the transformed pose, (x, y, z) is the transformed pose, and α is the angle between the main beam pose and the standard pose;

[0036] The expression for the motion quantity of flexible tooling is:

[0037] Δx = x′ - x.

[0038] In a further embodiment, the surface of the main beam is scanned in a standard pose to obtain the deflection deformation of the main beam surface and the morphology of the weld surface, including:

[0039] Laser scanning data of the weldless area and the welded area on the surface of the main beam were acquired separately.

[0040] The laser scanning data of the weldless location is calculated using a deflection deformation measurement model to determine the deflection deformation curve of the main beam; and the X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature are calculated using the laser scanning data of the weld location to describe the morphology of the weld surface.

[0041] In a further embodiment, the deflection curve of the main beam is determined by calculating laser scanning data at the weldless location using a deflection deformation measurement model, including:

[0042] Laser scanning data from the weldless location is imported into a one-dimensional Gaussian filtering algorithm to obtain the center point of the line-scan laser data; based on the center point of the line-scan laser data, the centerline of the main beam surface is determined.

[0043] Select discrete points uniformly distributed along the centerline of the main beam surface as surface fitting points; and substitute the discrete centerline coordinates into the least squares method to fit the deflection deformation curve.

[0044] The fitted deflection curves are stored as a coordinate sequence in the controller, which is used to control the coordinates during the robot's end-effector grinding operation.

[0045] In a further embodiment, the laser scanning data at the weld-free location is imported into a one-dimensional Gaussian filtering algorithm to obtain the expression for the center point of the line-scan laser data:

[0046]

[0047]

[0048] In the formula, X is the point coordinate matrix of the laser line scan, and G is the normalized one-dimensional Gaussian kernel;

[0049] The process of substituting the discrete center point coordinates into the least squares method to fit the deflection deformation curve is as follows:

[0050] The preset curve equation is in the form of z = a²x 2+a1x+a, where a0, a1, a2 are unknown. Substituting (y1, z1) into the equation, we get:

[0051]

[0052] Similarly (x) i y i ), i = 1, 2…n, we can obtain:

[0053]

[0054] Combined into a matrix form: Ax = T, where:

[0055]

[0056] Then we can find that x is:

[0057] x=(A T A) -1 A T T

[0058] In the formula, x0…x n , where is the X-axis coordinate of a discrete point on the weld centerline, t1…y n , where z′1…z′ are the Y-axis coordinates of discrete points on the weld centerline. n The coordinates of the discrete points on the center line of the main beam surface are the Z-axis coordinates, and A and T are the intermediate matrices used for calculation.

[0059] Let x′ = x, y′ = y, the fitted deflection curve in terms of coordinate sequence is expressed as:

[0060] {(x0, y′1, z′1)…(x n y′ n , z′ n )}.

[0061] In a further embodiment, the X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature are calculated using laser scanning data of the weld location. This is used to describe the morphology of the weld surface, including:

[0062] The center point of the weld feature is obtained by passing the laser scanning data of the weld location through a one-dimensional Gaussian filter;

[0063] Determine the centerline of the weld based on the center point of the weld features;

[0064] The coordinates of discrete points evenly distributed along the centerline of the weld are selected as the weld morphology fitting points.

[0065] The fitted weld morphology curves are stored as a coordinate sequence in the controller to generate the weld grinding motion trajectory.

[0066] In a further embodiment, the trajectory parameters include a preset expression for the grinding speed:

[0067]

[0068] In the formula, f is the feed speed of the flexible grinding device during operation, in mm / s; h is a constant, which is the general height value of the actual weld; d is the hardness coefficient, with a value range of (0, 1]; and Δz is the weld height.

[0069] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0070] (1) This invention, through laser line scanning and adaptive guided grinding methods, can acquire precise data of the main beam surface in real time during the grinding process, maintaining an accuracy within 0.1mm, thus achieving high-precision grinding of weld position and weld height. This meets the precision requirements of high-end engineering machinery manufacturing processes;

[0071] (2) This invention can generate a high-precision adaptive grinding trajectory based on the deflection change of the cylindrical main beam base material; by adjusting the hardness coefficient of the adaptive grinding speed, the corresponding adaptive grinding speed can be obtained to meet the grinding requirements of main beams made of different materials; for the same weld material, the grinding speed can also be adaptively adjusted according to the weld height. It realizes adaptive grinding according to different deformation conditions, different base materials, and different weld heights, and has high versatility.

[0072] (3) This invention employs a highly efficient computational algorithm to calculate the scanned data, thus requiring relatively little computation. The computation time required during the grinding process is very short, with almost no delay. Laser line scanning technology boasts excellent scanning speed, enabling rapid and accurate acquisition of data from the main beam surface, resulting in a very fast scanning process and shortening the production cycle. The adaptive grinding speed is dynamically generated during the grinding process based on the actual scanned data and the morphology of the weld surface, saving time and allowing for real-time adjustment to adapt to the current situation.

[0073] (4) The adaptive guided grinding method of this invention has excellent shape adaptability and grinding speed adaptability. Through laser line scanning and pose adjustment algorithms, the end-effector position or end effector motion curve of the robot tool is generated to match the shape of the main beam, ensuring the adaptability of the grinding process. Regardless of the deflection deformation on the main beam surface, the shape accuracy is maintained, thus achieving high-quality grinding. The grinding speed is automatically adjusted according to the change in weld height, using different grinding speeds for welds of different heights. Through adaptive adjustment of the grinding trajectory and grinding speed, it is ensured that the grinding process adapts to the surface shape of the main beam and automatically adjusts the grinding speed according to the actual weld conditions, ensuring high precision and high quality. This high-quality grinding guarantees the surface quality and performance of the final engineering machinery product.

[0074] (5) This invention features low equipment cost, long tool life, and high portability. By employing an adaptive guided grinding method, this invention reduces the need for expensive custom equipment, thereby saving procurement costs. Reduced wear on the grinding tools extends their lifespan, lowering maintenance and replacement costs. The high portability of this invention makes it applicable to various main beams and workpieces, eliminating the need to customize new equipment for each project and reducing the cost of adapting to new tasks. Attached Figure Description

[0075] Figure 1 is a structural block diagram of the adaptive guided grinding system of the single-unit deflection front-mounted main beam of the present invention.

[0076] Figure 2 is a flowchart of the adaptive guided grinding method for the single-unit deflection front-mounted main beam of the present invention;

[0077] Figure 3 is a schematic diagram of the main beam position adjustment of the present invention;

[0078] Figure 4 is a schematic diagram of the process of obtaining the weld center point cloud of the present invention;

[0079] Figure 5 is a diagram illustrating an embodiment of the grinding trajectory generation method of the present invention;

[0080] Figure 6 is a cross-sectional view of the main beam of the present invention.

[0081] Reference numerals: Main beam 1, Line scan laser sensor 2, First flexible fixture 31, Second flexible fixture 32, Workstation 4. Detailed Implementation

[0082] To better understand the technical content of the present invention, the technical solution of the present invention will be further introduced and explained below with reference to specific embodiments, but is not limited thereto.

[0083] The adaptive guided grinding system of the single-unit deflection front-end lifting main beam 11 is further illustrated in Figure 1, including: line-scan laser sensor 2, flexible tooling, controller, and grinding robot end effector;

[0084] The line-scanning laser sensor 2, the flexible tooling, and the end effector of the grinding robot are electrically connected and communicate with the controller. The controller is also electrically connected to the workstation 4 to optimize data processing and calculation functions.

[0085] Line scan laser sensor 2 is used to collect laser scan data of main beam 1; line scan laser sensor 2 is installed in front of the grinding spindle at the end of the grinding robot.

[0086] The flexible fixture is used to hoist and fix the main beam 1 and adjust the main beam 1 to the standard position according to the clockwise or counterclockwise position change trajectory; the flexible fixture includes: a first flexible fixture 31 and a second flexible fixture 32, which are respectively set at both ends of the main beam 1, and hoist and fix the main beam 1 from both ends of the main beam 1.

[0087] Workstation 4 receives the laser scanning data of the main beam 1 forwarded by the controller. Workstation 4 has pre-stored standard pose and calculation model to determine the pose data of the main beam 1, calculate the topographic scanning data of the surface of the main beam 1 and the weld surface, thereby obtaining the pose data of the main beam 1, the deflection curve of the surface of the main beam 1, and the weld width and height of the weld surface, and forwards them to the controller. Among them, the laser scanning data of the main beam 1 includes: the pose data of the main beam 1, the topographic scanning data of the surface of the main beam 1 and the weld surface. As shown in Figure 6, the main beam is welded from two identical profiles, and the weld is located at the center of the cross section of the main beam.

[0088] The controller forwards the laser scanning data of the main beam 1, receives the pose data of the main beam 1, the deflection deformation curve of the surface of the main beam 1, and the weld width and height of the weld surface; it generates clockwise or counterclockwise pose transformation trajectories based on the pose data of the main beam 1 to adjust the main beam 1 to the standard pose; and it updates the grinding processing parameters and generates the grinding trajectory according to the deflection deformation curve, weld width and height.

[0089] The end effector of the grinding robot is used to adaptively adjust its coordinates during the grinding process based on the grinding trajectory.

[0090] In this embodiment, the pose of the main beam 1 is acquired by a line-scan laser sensor 2, flexible tooling, controller, and the end effector of the grinding robot, and adjusted to the standard grinding pose. The upper surface of the main beam 1 is scanned, and the line-scan data is fitted to determine the deflection deformation of the main beam 1 surface. Based on this, the robot end effector position or end effector motion curve is generated. Based on the weld surface morphology, the processing parameters of the grinding tool are automatically adjusted to achieve adaptive grinding of weld height and weld position, realizing adaptive guided grinding, ensuring the accuracy and high quality of the grinding process, and filling a gap in industry applications.

[0091] The method of the present invention is further illustrated with reference to Figures 2 to 5, including:

[0092] S1. Collect and analyze the laser scanning data of the main beam 1 to obtain the pose data of the main beam 1;

[0093] S2. Adjust the main beam 1 to the standard position based on the main beam 1 position data;

[0094] S3. Scan the surface of the main beam 1 in the standard pose to obtain the deflection deformation of the main beam 1 surface and the morphology of the weld surface; and obtain the weld width and height data based on the morphology of the weld surface.

[0095] S4. Automatically adjust grinding parameters based on the deflection deformation, weld width, and height data of the main beam 1 surface;

[0096] S5. Generate a grinding trajectory based on the adjusted grinding processing parameters, wherein the grinding speed is preset in the trajectory parameters.

[0097] The laser scanning data of main beam 1 was acquired and analyzed to obtain the pose data of main beam 1, including:

[0098] Collect laser scanning data of main beam 1 and perform coordinate transformation to obtain the coordinate values ​​of each data point;

[0099] The coordinates of each data point are imported into the container in the scanning order and stored and then Hough transformation is performed to obtain the edge straight line data of the main beam 1.

[0100] Determine the pose data of main beam 1 based on the edge straight line data of main beam 1;

[0101] The scanning sequence is from the outside of one end of the main beam 1 inwards;

[0102] And sampling is performed using a single laser with a sampling rate of 400 data points, a field of view of 40 mm, and a scanning interval of 0.1 mm;

[0103] In this embodiment, the field of view is 40mm, and a single laser sampler collects 400 data points. The scanning proceeds from the outside of one end of the main beam 1 inwards, with a scanning interval of 0.1mm. The obtained points are stored sequentially in a 400x400 container according to the data type point(x,y,z). The first point in each row with non-zero y and z coordinates is stored in a sequential container Arr[] based on the x value, while the coordinates of the remaining points are set to zero.

[0104] Adjust the main girder 1 to the standard position based on the main girder 1 position data, including:

[0105] Calculate the angle between the edge of the main beam 1 pose and the standard pose based on the pose data of the main beam 1, and determine the direction of the main beam 1 pose;

[0106] Based on the angle between the pose of main beam 1 and the standard pose, the direction of the pose of main beam 1 generates a clockwise or counterclockwise pose transformation trajectory.

[0107] Based on the clockwise or counterclockwise motion trajectory control, the flexible tooling drives the main beam 1 to move clockwise or counterclockwise. In this embodiment, the coordinates of points in the container are subjected to Hough transformation, and the detected straight line is the edge of the main beam 1. The deviation direction of the main beam 1's pose is obtained by comparing the y-coordinates of the first and last points in the container, and the angle α between the actual pose and the standard pose is calculated. The vertical direction is the standard pose.

[0108] The expression for the clockwise pose transformation of the main beam 1 pose edge is:

[0109]

[0110] The expression for the counterclockwise pose transformation of the main beam 1 pose edge is:

[0111]

[0112] In the formula, (x′, y′, z′) is the transformed pose, (x, y, z) is the transformed pose, and α is the angle between the pose of main beam 1 and the standard pose;

[0113] In this embodiment, based on the orientation of the main beam 1, the required adjustment amount is transmitted to the first flexible fixture 31 and the second flexible fixture 32 shown in Figure 1, adjusting the orientation of the main beam 1 from both ends to the standard orientation as shown in Figure 3; the expression for the adjustment amount of the flexible fixture is:

[0114] Δx=x′-x

[0115] Under standard pose, the surface of main beam 1 is scanned to obtain the deflection deformation of the main beam 1 surface and the morphology of the weld surface, including:

[0116] Laser scanning data of the weldless area and the welded area on the surface of the main beam 1 were acquired respectively.

[0117] The deflection deformation curve of the main beam 1 is determined by calculating the laser scanning data of the weldless position using the deflection deformation measurement model; and the X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature are calculated by using the laser scanning data of the weld position to describe the morphology of the weld surface.

[0118] The deflection curve of the main beam 1 is determined by calculating laser scanning data at the weldless location using a deflection deformation measurement model, including:

[0119] The laser scanning data of the weldless location is imported into a one-dimensional Gaussian filtering algorithm to obtain the center point of the line scan laser data; based on the center point of the line scan laser data, the center line of the surface of the main beam 1 is determined.

[0120] Select discrete points uniformly distributed along the centerline of the main beam 1 as surface fitting points; and substitute the discrete centerline coordinates into the least squares method to fit the deflection deformation curve.

[0121] The fitted deflection deformation curve is stored as a coordinate sequence in the controller, which is used to control the coordinates during the robot's end effector grinding operation. In this embodiment, seven points near the center point are used for fitting.

[0122] The laser scanning data from the weldless location is imported into a one-dimensional Gaussian filtering algorithm to obtain the expression for the center point of the line-scan laser data:

[0123]

[0124]

[0125] In the formula, X is the point coordinate matrix of the laser line scan, and G is the normalized one-dimensional Gaussian kernel;

[0126] The process of substituting the discrete center point coordinates into the least squares method to fit the deflection deformation curve is as follows:

[0127] The preset curve equation is in the form of z = a²x 2 +a1x+a, where a0, a1, a2 are unknown. Substituting (y1, z1) into the equation, we get:

[0128]

[0129] Similarly (x) i y i ), i = 1, 2…n, we can obtain:

[0130]

[0131] Combined into a matrix form: Ax = T, where:

[0132]

[0133] Then we can find that x is:

[0134] x=(A T A) -1 A T T

[0135] In the formula, x0…x n , where y1…t is the X-axis coordinate of a discrete point on the weld centerline. n , where z′1…z′ are the Y-axis coordinates of discrete points on the weld centerline. n The coordinates of the discrete points on the center line of the main beam surface are the Z-axis coordinates, and A and T are the intermediate matrices used for calculation.

[0136] Let x′ = x, y′ = y, the fitted deflection curve in terms of coordinate sequence is expressed as:

[0137] {(x0, y′1, z′1)…(x n y′ n , z′ n )}.

[0138] The X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature are calculated using laser scanning data of the weld location. These parameters are used to describe the morphology of the weld surface, including:

[0139] The center point of the weld feature is obtained by passing the laser scanning data of the weld location through a one-dimensional Gaussian filter;

[0140] Determine the centerline of the weld based on the center point of the weld features;

[0141] The coordinates of discrete points evenly distributed along the centerline of the weld are selected as the weld morphology fitting points.

[0142] The fitted weld morphology curve is stored as a coordinate sequence in the controller to generate the weld grinding motion trajectory. In this embodiment, as shown in Figure 4, during grinding, the line-scanning laser sensor 2 is installed in front of the grinding spindle, scanning the weld along the x-axis of the main beam 1 to obtain the y-coordinate of the center point of the weld feature and the weld height Δz, as shown in Figure 4. The y-coordinate of the weld center point is used to replace y′ in step S3, guiding the robot end effector to move according to the fitted curve in S3, or according to the hash points {(x0, y′1, z′1)…(x n y′ n , z′ n The point coordinates of the movement are used to achieve an adaptive trajectory on the centerline of the weld.

[0143] The preset expression for the grinding speed in the trajectory parameters is:

[0144]

[0145] In the formula, f is the feed speed of the flexible grinding device during operation, in mm / s; h is a constant, which is the general height value of the actual weld; d is the hardness coefficient, with a value range of (0, 1]; and Δz is the weld height.

[0146] By controlling the trajectory and speed of the grinding tool according to grinding parameters, an adaptive grinding trajectory along the workpiece deformation curve and an adaptive grinding speed based on the weld height are achieved. Figure 5 shows a schematic diagram of the final grinding trajectory. Furthermore, in practical use, this invention, through laser line scanning and adaptive guided grinding methods, can acquire precise data of the main beam 1 surface in real time during the grinding process, maintaining an accuracy within 0.1mm, thus achieving high-precision grinding of the weld position and height. This meets the precision requirements of high-end engineering machinery manufacturing processes.

[0147] During processing, this invention can generate a high-precision adaptive grinding trajectory based on the deflection changes of the cylindrical main beam 1 base material. By adjusting the hardness coefficient of the adaptive grinding speed, a corresponding adaptive grinding speed can be obtained to meet the grinding requirements of main beams 1 made of different materials. For the same weld material, the grinding speed can also be adaptively adjusted according to the weld height. This achieves adaptive grinding based on different deformation conditions, different base materials, and different weld heights, demonstrating high versatility.

[0148] Secondly, this invention employs a highly efficient computational algorithm to calculate the scanned data, resulting in a relatively small computational load. During the grinding process, the required computation time is extremely short, with virtually no delay. Laser line scanning technology boasts excellent scanning speed, enabling rapid and accurate acquisition of data from the surface of the main beam 1. Therefore, the entire scanning process is very fast, shortening the production cycle. The adaptive grinding speed is dynamically generated during the grinding process based on the actual scanned data and the morphology of the weld surface, saving time and allowing for real-time adjustment to adapt to the current situation.

[0149] Therefore, the adaptive guided grinding method of this invention has excellent shape adaptability and grinding speed adaptability. Through laser line scanning and pose adjustment algorithms, the end effector position or end effector motion curve of the robot tool is generated to match the shape of the main beam 1, ensuring the adaptability of the grinding process. Regardless of the deflection deformation on the surface of the main beam 1, the shape accuracy is maintained, thus achieving high-quality grinding. The grinding speed is automatically adjusted according to the change in weld height, using different grinding speeds for welds of different heights. Through adaptive adjustment of the grinding trajectory and grinding speed, it is ensured that the grinding process adapts to the surface shape of the main beam 1 and automatically adjusts the grinding speed according to the actual weld conditions, ensuring high precision and high quality. This high-quality grinding guarantees the surface quality and performance of the final engineering machinery product.

[0150] Furthermore, this invention features low equipment cost, long tool life, and high portability. By employing an adaptive guided grinding method, this invention reduces the need for expensive custom equipment, thereby saving procurement costs. Reduced wear on the grinding tools extends their lifespan, lowering maintenance and replacement costs. The high portability of this invention makes it applicable to various main beams and workpieces, eliminating the need to customize new equipment for each project and reducing the cost of adapting to new tasks.

[0151] In summary, this invention integrates workpiece pose adjustment algorithm, grinding trajectory guidance algorithm and laser line scanning sensing technology, and has multiple advantages such as high precision, high versatility, high quality, low cost and high efficiency.

[0152] Embodiments of this application may be provided as methods, systems, or computer program products. Therefore, this application may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0153] Embodiments of this application may be provided as methods, systems, or computer program products. Therefore, this application may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0154] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in one or more flowchart illustrations and / or one or more block diagrams.

[0155] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means that implement the functions specified in one or more flowcharts and / or one or more block diagrams.

[0156] These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, such that the instructions, which execute on the computer or other programmable apparatus, provide steps for implementing the functions specified in one or more flowcharts and / or one or more block diagrams.

[0157] The above description is only a preferred embodiment of the present invention. Without departing from the technical principle of the present invention, several improvements and modifications can be made, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An adaptive grinding system for a single-unit deflection front-mounted main beam, characterized in that, include: The system comprises a line-scan laser sensor, a flexible fixture, a controller, and a grinding robot end effector. The line-scan laser sensor, flexible fixture, and grinding robot end effector are electrically connected and communicate with the controller, which is also electrically connected to a workstation for optimizing data processing and calculation functions. The line-scan laser sensor is used to collect laser scanning data of the main beam. The flexible fixture is used to hoist and fix the main beam and adjust it to a standard pose according to a clockwise or counterclockwise pose change trajectory. The workstation receives the laser scanning data of the main beam forwarded by the controller. The workstation has pre-stored a standard pose and a calculation model to determine the main beam pose data and calculate the morphological scanning data of the main beam surface and weld surface, thereby obtaining the main beam's shape. The system receives pose data, deflection deformation curves of the main beam surface, and weld width and height, and forwards them to the controller. The main beam laser scanning data includes: main beam pose data, and topographic scanning data of the main beam surface and weld surface. The controller forwards the main beam laser scanning data, receives the main beam pose data, deflection deformation curves of the main beam surface, and weld width and height. Based on the main beam pose data, it generates clockwise or counterclockwise pose transformation trajectories to adjust the main beam to a standard pose. It also updates grinding parameters and generates a grinding trajectory based on the deflection deformation curves, weld width, and height. The grinding robot end effector adaptively adjusts its coordinates during grinding operations according to the grinding trajectory.

2. The adaptive grinding system for a single-unit deflection front-mounted main beam according to claim 1, characterized in that, The line-scan laser sensor is installed in front of the grinding spindle at the end of the grinding robot.

3. An adaptive grinding method for a single-unit deflection front-mounted main beam, characterized in that, Based on the system of claim 1, the method includes: acquiring and parsing laser scanning data of the main beam to obtain the main beam pose data; adjusting the main beam to a standard pose according to the main beam pose data; scanning the surface of the main beam in the standard pose to obtain the deflection deformation of the main beam surface and the morphology of the weld surface; obtaining the weld width and height data according to the morphology of the weld surface; automatically adjusting the grinding processing parameters according to the deflection deformation of the main beam surface, the weld width, and the height data; and generating a grinding trajectory based on the adjusted grinding processing parameters to control the end effector of the grinding robot, wherein the grinding speed is preset in the trajectory parameters.

4. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 3, characterized in that, The process involves acquiring and analyzing laser scanning data of the main beam to obtain its pose data. This includes: acquiring laser scanning data of the main beam and performing coordinate transformation to obtain the coordinate values ​​of each data point; importing the coordinates of each data point into a container for storage according to the scanning order and performing Hough transformation to obtain the edge line data of the main beam; determining the pose data of the main beam based on the edge line data; wherein the scanning order is from the outside of one end of the main beam inward; and sampling is performed using a single laser with a sampling amount of 400 data points, a field of view width of 40 mm, and a scanning interval of 0.1 mm.

5. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 3, characterized in that, Adjusting the main girder to a standard pose based on its pose data includes: calculating the angle between the main girder's pose edge and the standard pose, and determining the direction of the main girder's pose; generating a clockwise or counterclockwise pose transformation trajectory based on the angle between the main girder's pose and the standard pose; and controlling the flexible fixture to move the main girder clockwise or counterclockwise based on the clockwise or counterclockwise motion transformation trajectory. The expression for the clockwise pose transformation of the main girder's pose edge is: The expression for the counterclockwise pose transformation of the main beam's pose edge is: In the formula, (x′, y′, z′) is the transformed pose, (x, y, z) is the transformed pose, and α is the angle between the main beam pose and the standard pose; the expression for the motion of the flexible tooling is: Δx=x′-x.

6. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 3, characterized in that, The main beam surface is scanned in a standard pose to obtain the deflection deformation of the main beam surface and the morphology of the weld surface. This includes: acquiring laser scanning data of the weldless position and the weld position of the main beam surface; calculating the laser scanning data of the weldless position using a deflection deformation measurement model to determine the deflection deformation curve of the main beam; and calculating the X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature using the laser scanning data of the weld position to describe the morphology of the weld surface.

7. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 6, characterized in that, The deflection deformation curve of the main beam is determined by calculating the laser scanning data of the weldless location using a deflection deformation measurement model. This includes: importing the laser scanning data of the weldless location into a one-dimensional Gaussian filtering algorithm to obtain the center point of the line-scan laser data; determining the center line of the main beam surface based on the center point of the line-scan laser data; selecting the coordinates of discrete points uniformly distributed on the center line of the main beam surface as surface fitting points; and substituting the coordinates of the discrete points on the center line into the least squares method to fit the deflection deformation curve. The fitted deflection deformation curve is stored as a coordinate sequence in the controller for controlling the coordinates during the robot's end effector grinding operation.

8. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 7, characterized in that, The laser scanning data from the weldless location is imported into a one-dimensional Gaussian filtering algorithm to obtain the expression for the center point of the line-scan laser data: In the formula, X is the point coordinate matrix of the laser line scan, and G is the normalized one-dimensional Gaussian kernel; the process of substituting the discrete point coordinates on the center line into the least squares method to fit the deflection deformation curve is as follows: the preset curve equation is in the form of z = a²x 2 +a1x+a, where a0, a1, a2 are unknown. Substituting (y1, z1) into the equation, we get: Similarly (x) i y i ), i = 1, 2…n, we can obtain: Combined into a matrix form: Ax = T, where: Then we can find that x is: x = (A) T A) -1 A T In formula T, x0···x n , where y1...y2 is the X-axis coordinate of a discrete point on the weld centerline. n , where z′1…z′ are the Y-axis coordinates of discrete points on the weld centerline. n Let A and T be the discrete Z-axis coordinates of the points on the centerline of the main beam surface, and let A and T be the intermediate matrices used for calculation. Let x′ = x and y′ = y. The fitted deflection curve is expressed as a coordinate sequence as: {(x0, y′1, z′1)…(x n y′ n , z′ n )}.

9. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 6, characterized in that, The X-axis and Y-axis coordinates of the center point of the weld feature and the weld height of the center point of the straight weld feature are calculated using laser scanning data of the weld location to describe the morphology of the weld surface. This includes: obtaining the center point of the weld feature by passing the laser scanning data of the weld location through one-dimensional Gaussian filtering; determining the center line of the weld based on the center point of the weld feature; selecting discrete point coordinates uniformly distributed on the center line of the weld as weld morphology fitting points; wherein, the fitted weld morphology curve is stored in the controller as a coordinate sequence to generate the weld grinding motion trajectory.

10. The adaptive grinding method for a single-unit deflection front-mounted main beam according to claim 3, characterized in that, The preset expression for the grinding speed in the trajectory parameters is: In the formula, f is the feed speed of the flexible grinding device during operation, in mm / s; h is a constant, which is the general height value of the actual weld; d is the hardness coefficient, with a value range of (0, 1]; and Δz is the weld height.

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