A method for error compensation in efficient chamfering of H-shaped steel

Abstract

The present invention discloses an H-shaped steel efficient chamfering processing error compensation method, including obtaining upper and lower surface point cloud data of the H-shaped steel by using upper and lower three-dimensional laser scanners, obtaining a point cloud data set of the H-shaped steel by data preprocessing, registration and merging, obtaining a three-dimensional data model of the H-shaped steel by reverse processing, obtaining the chamfer size by a standard H-shaped steel chamfering model, and then optimizing the chamfering processing path to obtain a total deformation value, and obtaining a processing error compensation value by controlling the size of the deformation value and comparing it with the allowable processing error. The present invention optimizes the chamfering path during the processing process, reduces the deformation value during the processing of the H-shaped steel, can adjust the error compensation value during the processing process in real time, and improves the processing accuracy of the H-shaped steel.

Description

Technical Field

[0001] The present invention relates to the field of mechanical processing, and in particular to an error compensation method for high-efficiency chamfering processing of H-shaped steel. Background Art

[0002] In order to ensure the spraying quality of H-shaped steel and improve the quality and performance of the coating, the edges and corners of the H-shaped steel need to be chamfered in advance when spraying the H-shaped steel. The rounded corner structure helps to evenly cover the paint and reduce the loss of paint, thereby improving the adhesion of the coating. At the same time, the rounded corner design can also improve the aesthetics of the structure, reduce the risk of corrosion, and enhance the overall toughness of the structure, making it more resistant to external shock and vibration. The current processing equipment is prone to deformation of H-shaped steel during chamfering, resulting in poor processing results. At the same time, in the actual chamfering process of H-shaped steel, due to the accumulation of errors in the process system, errors will occur during the processing of H-shaped steel, affecting the dimensional accuracy of the chamfer, and unqualified chamfering will occur, requiring manual secondary processing, which increases the workload of personnel. Summary of the Invention

[0003] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide an efficient chamfering error compensation method for H-shaped steel. The method can effectively reduce the deformation generated during the chamfering process of H-shaped steel, thereby improving the processing accuracy of H-shaped steel and avoiding secondary processing of H-shaped steel.

[0004] A method for compensating errors in high-efficiency chamfering of H-shaped steel, characterized by comprising the following steps:

[0005] Step 1: Install the H-shaped steel to be chamfered on the H-shaped steel chamfering system, and install a first 3D laser scanner and a second 3D laser scanner on the upper and lower sides of the H-shaped steel respectively;

[0006] Step 2: respectively start the first 3D laser scanner and the second 3D laser scanner to scan the upper surface and the lower surface of the H-shaped steel to obtain point cloud data sets S1 and S2 of the upper surface and the lower surface of the H-shaped steel;

[0007] Step 3: The point cloud data sets S1 and S2 obtained in step 2 are subjected to data preprocessing, data registration, and data merging to obtain the point cloud data set S3 of the H-shaped steel. The point cloud data set S3 is reversely processed to obtain the actual three-dimensional data model of the H-shaped steel.

[0008] Step 4: Create a standardized H-shaped steel model in the 3D simulation software, set the chamfer size of the H-shaped steel, and obtain a standardized model of the H-shaped steel after chamfering;

[0009] Step 5: Import the actual 3D data model of the H-shaped steel obtained in step 3 into the H-shaped steel chamfering processing simulation software, compare it with the standardized model after the H-shaped steel is chamfered, obtain the actual chamfer size of the H-shaped steel, simulate and analyze the H-shaped steel chamfering processing path according to the actual chamfer size of the H-shaped steel, optimize the processing path through simulation analysis, and ensure that the total deformation value Δf generated during the H-shaped steel chamfering process is hmin smallest;

[0010] Step 6: Extract the total deformation value Δf generated during the H-shaped steel simulation chamfering process obtained in step 5 hmin , cutting feed ΔH and the cutting path during actual processing of H-shaped steel, the total deformation value Δf hmin Perform discretization processing to obtain the simulated deformation values ​​at m processing points f m ;

[0011] Step 7: Install a tool processing cutting force detection device in the H-shaped steel chamfering system, and chamfer according to the cutting feed ΔH obtained in step 6 and the cutting path during the actual processing of the H-shaped steel. The real-time cutting force P during the chamfering process is detected by the cutting force detection device, and the real-time deformation value generated during the chamfering process of the H-shaped steel is calculated based on the real-time cutting force P. f t , the specific calculation formula is as follows:

[0012]

[0013] Where, f t is the real-time deformation value of the H-shaped steel chamfer, P is the real-time cutting force, L is the cutting distance, E is the elastic modulus of the steel, which is E=2.06e5MPa, and I is the cross-sectional inertia moment of the H-shaped steel, which can be found in the mechanical design manual;

[0014] Step 8: The real-time deformation value of H-shaped steel f t and the deformation value at the corresponding processing point f m Perform subtraction processing to obtain machining error e t :

[0015]

[0016] Where: e t is the real-time processing error, f t is the real-time deformation value, f m is the simulation deformation value;

[0017] Step 9: Set the allowable processing error value Δε in the H-beam chamfering control system. e t Compare with the allowable processing error value Δε, if e t ≤Δε, then e t As the machining error compensation value of the next point, if e t >Δε, the set allowable machining error value Δε will be used as the machining error compensation value for the next point.

[0018] The beneficial effects of the present invention are as follows: the method adopts a point cloud data processing method to obtain the processing size of the H-shaped steel and compares it with the standard size of the H-shaped steel to obtain the size of the chamfer of the H-shaped steel, and simulates and optimizes the processing path through a simulation method to obtain the minimum deformation value during the processing of the H-shaped steel, and then compares it with the actual processing process, so as to adjust the error compensation value during the processing in real time, reduce the deformation during the processing of the H-shaped steel, improve the processing accuracy, and thus meet the efficient processing requirements of the H-shaped steel. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a flow chart of an H-shaped steel high-efficiency chamfering error compensation method of the present invention;

[0020] Figure 2 This is a schematic structural diagram of an H-shaped steel high-efficiency chamfering processing system of the present invention;

[0021] Figure 3 Schematic diagram of chamfer height measurement according to the present invention. DETAILED DESCRIPTION

[0022] The method of the present invention will be further described below with reference to the accompanying drawings.

[0023] As shown in the accompanying drawings, a method for compensating errors in high-efficiency chamfering of H-shaped steel according to the present invention comprises the following steps:

[0024] Step 1: Install the H-shaped steel to be chamfered on the H-shaped steel chamfering system 3, and install the first 3D laser scanner 1 and the second 3D laser scanner 2 on the upper and lower sides of the H-shaped steel respectively;

[0025] Step 2: Start the first 3D laser scanner 1 and the second 3D laser scanner 2 to scan the upper and lower surfaces of the H-shaped steel to obtain the point cloud data set S1 of the upper and lower surfaces of the H-shaped steel.

[0026] and S2;

[0027] Step 3: The point cloud data sets S1 and S2 obtained in step 2 are subjected to data preprocessing, data registration, and data merging to obtain the point cloud data set S3 of the H-shaped steel. The point cloud data set S3 is reversely processed to obtain the 3D data model of the H-shaped steel. The specific steps are as follows:

[0028] The first step is to use the kd-tree method to construct the spatial index structure of the point cloud data sets S1 and S2, and for any point P in the spatial index structure i Perform nearest neighbor search and construct any point P i Neighborhood point set , k is the k points in the nearest neighbor search distance;

[0029] Step 2: Construct the neighborhood point set N(P i ) is the weighted covariance matrix C i , through the covariance matrix C i Perform eigenvalue decomposition to obtain three eigenvalues ​​λ1, λ2, and λ3, as well as the corresponding eigenvectors e1, e2, and e3. Compare the eigenvalues ​​λ1, λ2, and λ3, and select the eigenvector corresponding to the minimum value among λ1, λ2, and λ3 as the normal vector of the point:

[0030] (1)

[0031] (2)

[0032] (3)

[0033] Where C i is the covariance matrix of the i-th point; γ i is the weighting coefficient; d i is the distance from each neighborhood point to , μ i is the average distance of all neighboring points to, p i ' is the center of the neighborhood point set, T is the transposed matrix symbol, i, j = 1, 2…k;

[0034] Step 3: Take the point p determined in step 2 i The normal vector of point cloud data set S1 and S2 is used as the layering direction to perform layering processing;

[0035] Step 4: Repeat step 3 and perform n-times layering on the point cloud data sets S1 and S2 to obtain a new point cloud data set S1. ’ and S2 ’ ;

[0036] Step 5: Use the point cloud filtering algorithm to obtain the new point cloud data set S1 after n layers ’and S2 ’ Perform filtering and noise reduction processing to eliminate errors generated during data acquisition;

[0037] Step 6: The new point cloud data set S1 ’ and S2 ’ The ICP algorithm is used for precise registration and data merging to obtain the overall three-dimensional point cloud data S3 of the H-shaped steel;

[0038] Step 7: Perform reverse processing based on the overall 3D point cloud data S3 of the H-shaped steel to convert the overall 3D point cloud data S3 of the H-shaped steel into an actual 3D model of the H-shaped steel;

[0039] Step 4: Create a standardized H-shaped steel model in the 3D simulation software, set the chamfer size of the H-shaped steel, and obtain a standardized model of the H-shaped steel after chamfering;

[0040] Step 5: Import the actual 3D model of the H-shaped steel obtained in step 3 into the H-shaped steel chamfering processing simulation software, compare it with the standardized model after the H-shaped steel is chamfered, obtain the actual chamfer size of the H-shaped steel, simulate and analyze the H-shaped steel chamfering processing path according to the actual chamfer size of the H-shaped steel, optimize the processing path through simulation analysis, and ensure that the deformation value Δf generated during the H-shaped steel chamfering process is hmin At least, the specific path optimization process is as follows:

[0041] The first step is to import the actual three-dimensional model of the H-shaped steel obtained in step 3 into the H-shaped steel chamfering processing simulation software, compare it with the standardized model of the H-shaped steel after chamfering, obtain the actual chamfer size of the H-shaped steel, and obtain the parametric equation f (x, y, z) of the chamfered surface of the H-shaped steel through the simulation software;

[0042] Step 2: Select a point G at any position on the chamfered surface of the H-shaped steel and calculate the Gaussian curvature K of point G. G and the mean curvature Q G , according to the Gaussian curvature K of point G G and the mean curvature Q G Calculate the complexity C of the chamfer area of ​​the H-beam G , the calculation method is as follows:

[0043] (4)

[0044] Where: C G is the complexity of the chamfer area, K G is the Gaussian curvature, , Q G is the mean curvature, , and is the weight coefficient used to adjust the contribution of Gaussian curvature and mean curvature to complexity, A is the area around point G, dA is the basic unit of surface integral, A G is the area corresponding to A on the Gaussian map, d(A) is the diameter of the area around point G, is the gradient of the surface, is the sum of the derivatives of the parametric equation f(x, y, z) of the chamfered surface of the H-shaped steel after taking the derivatives of the parameters x, y, and z respectively;

[0045] Step 3: According to the complexity C G Calculate the number of cutting layers for the chamfer of H-shaped steel:

[0046] (5)

[0047] Where N G is the number of cutting layers of the chamfer of the H-shaped steel, C G is the complexity of the chamfer area, H G is the chamfer height, which is the height from the sharp corner of the H-shaped steel to the vertex of the curved surface, and is measured by simulation software;

[0048] Step 4: Cutting the number of layers N G Calculate the cutting feed rate ΔH when chamfering H-shaped steel;

[0049] Step 5: Simulate and analyze the H-shaped steel chamfering processing path through the cutting feed ΔH during the chamfering of the H-shaped steel, and obtain the deformation value generated during each layer processing. After the simulation is completed, the deformation value of each layer is accumulated to obtain the total deformation value Δf when the H-shaped steel is chamfered h :

[0050] (6)

[0051] Where Δf h is the total deformation value when the H-shaped steel is chamfered, Δf1 is the first layer deformation value when the H-shaped steel is chamfered, and Δf2 is the second layer deformation value when the H-shaped steel is chamfered. The Nth when chamfering H-shaped steel G Layer deformation value;

[0052] Step 6: Adjust the weight coefficient of step 2 and Repeat steps 2 to 5 to obtain multiple total deformation values ​​Δf h , compare the total deformation values ​​Δf obtained h The size of Δf h Minimum value Δf hmin is the total deformation value generated when the H-shaped steel is chamfered, and the total deformation value Δf hminThe corresponding cutting feed ΔH is the actual cutting feed during machining, Δf hmin The corresponding cutting path is the cutting path during the actual processing of H-shaped steel;

[0053] Step 6: Extract the total deformation value Δf generated during the H-shaped steel simulation chamfering process obtained in step 5 hmin , cutting feed ΔH and the cutting path during actual processing of H-shaped steel, the total deformation value Δf hmin Perform discretization processing to obtain the simulated deformation values ​​at m processing points f m ;

[0054] Step 7: Install a tool processing cutting force detection device in the H-shaped steel chamfering system, and chamfer according to the cutting feed ΔH obtained in step 6 and the cutting path during the actual processing of the H-shaped steel. The real-time cutting force P during the chamfering process is detected by the cutting force detection device, and the real-time deformation value generated during the chamfering process of the H-shaped steel is calculated based on the real-time cutting force P. f t , the specific calculation formula is as follows:

[0055] (7)

[0056] Where, f t is the real-time deformation value of the H-shaped steel chamfer, P is the real-time cutting force, L is the cutting distance, E is the elastic modulus of the steel, which is E=2.06e5MPa, and I is the cross-sectional inertia moment of the H-shaped steel, which can be found in the mechanical design manual;

[0057] Step 8: The real-time deformation value of H-shaped steel f t and the deformation value at the corresponding processing point f m Perform subtraction processing to obtain machining error e t :

[0058] (8)

[0059] Where: e t is the real-time processing error, f t is the real-time deformation value, f m is the simulation deformation value;

[0060] Step 9: Set the allowable processing error value Δε in the H-beam chamfering control system. e tCompare with the allowable processing error value Δε, if e t ≤Δε, then e t As the machining error compensation value of the next point, if e t >Δε, the set allowable machining error value Δε will be used as the machining error compensation value for the next point.

[0061] The above-described embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A method for compensating errors in high-efficiency chamfering of H-shaped steel, characterized in that The following steps are involved: Step 1: Install the H-shaped steel to be chamfered on the H-shaped steel chamfering system, and install a first 3D laser scanner and a second 3D laser scanner on the upper side and the lower side of the H-shaped steel respectively; Step 2: respectively start the first 3D laser scanner and the second 3D laser scanner to scan the upper surface and the lower surface of the H-shaped steel to obtain point cloud data sets S1 and S2 of the upper surface and the lower surface of the H-shaped steel; Step 3: The point cloud data sets S1 and S2 obtained in step 2 are subjected to data preprocessing, data registration and data merging to obtain the point cloud data set S3 of the H-shaped steel, and the point cloud data set S3 is reversely processed to obtain the actual three-dimensional data model of the H-shaped steel; Step 4: Establish a standardized H-shaped steel model in the three-dimensional simulation software, set the chamfer size of the H-shaped steel, and obtain a standardized model of the H-shaped steel after chamfering; Step 5: Import the actual 3D data model of the H-shaped steel obtained in step 3 into the H-shaped steel chamfering processing simulation software, compare it with the standardized model after the H-shaped steel is chamfered, obtain the actual chamfer size of the H-shaped steel, simulate and analyze the H-shaped steel chamfering processing path according to the actual chamfer size of the H-shaped steel, optimize the processing path through simulation analysis, and ensure that the total deformation value Δf generated during the chamfering process of the H-shaped steel is hmin Minimum; Step 6: Extract the total deformation value Δf generated during the H-beam simulation chamfering process obtained in step 5 hmin , cutting feed rate ΔH and the cutting path during the actual processing of H-shaped steel, the total deformation value Δf hmin Discretization is performed to obtain the simulated deformation values ​​at m processing points f m ; Step 7: Install a tool processing cutting force detection device in the H-beam chamfering system, perform chamfering according to the cutting feed ΔH obtained in step 6 and the cutting path during the actual processing of the H-beam, detect the real-time cutting force P during the chamfering process through the cutting force detection device, and calculate the real-time deformation value generated during the chamfering process of the H-beam from the real-time cutting force P f t , the specific calculation formula is as follows: In the formula, f t is the real-time deformation value of the chamfer of the H-shaped steel, P is the real-time cutting force, L is the cutting distance, E is the elastic modulus of the steel, E=2.06e5MPa, I is the section inertia moment of the H-shaped steel, which is obtained according to the mechanical design manual; Step 8: The real-time deformation value of H-shaped steel f t And the deformation value at the corresponding processing point f m Perform subtraction processing to obtain the processing error ε t : Where: ε t is the real-time processing error, f t is the real-time deformation value, f m is the simulation deformation value; Step 9: Set the allowable processing error value Δε in the H-beam chamfering control system. ε t Compared with the allowable processing error value Δε, if ε t ≤Δε, then ε t As the machining error compensation value of the next point, if ε t >Δε, the set allowable machining error value Δε will be used as the machining error compensation value of the next point.

2. The method for compensating an error in high-efficiency chamfering of H-shaped steel according to claim 1, characterized in that: Step 5: The specific path optimization process is as follows: The first step is to import the actual three-dimensional model of the H-shaped steel obtained in step 3 into the H-shaped steel chamfering processing simulation software, compare it with the standardized model after the H-shaped steel is chamfered, obtain the actual chamfer size of the H-shaped steel, and obtain the parameter equation f (x, y, z) at the chamfered surface of the H-shaped steel through the simulation software; Step 2: Select a point G at any position on the chamfered surface of the H-shaped steel and calculate the Gaussian curvature K of point G. G and the mean curvature Q G , according to the Gaussian curvature K of point G G and the mean curvature Q G Calculate the complexity C of the chamfer area of ​​the H-beam G , the calculation method is as follows: Where: C G is the complexity of the chamfer area, K G is the Gaussian curvature, , Q G is the mean curvature, , and is the weight coefficient used to adjust the contribution of Gaussian curvature and mean curvature to complexity, A is the area around point G, dA is the basic unit of surface integral, and A G is the area corresponding to A on the Gaussian map, d(A) is the diameter of the area around point G, is the gradient of the surface, is the sum of the derivatives of the parameter equation f (x, y, z) of the chamfered surface of the H-shaped steel after taking the derivatives of the parameters x, y, z respectively; Step 3: According to the complexity C G Calculate the number of cutting layers for the chamfer of the H-shaped steel: Where N G is the number of cutting layers of the chamfer of the H-shaped steel, C G is the complexity of the chamfer area, H G is the chamfer height, which is the height of the H-shaped steel corner from the vertex of the curved surface, and is measured by simulation software; Step 4: Cutting the number of layers N G Calculate the cutting feed ΔH when chamfering H-beam; Step 5: Simulate and analyze the chamfering process path of H-shaped steel by the cutting feed rate ΔH during chamfering of H-shaped steel, and obtain the deformation value generated during processing of each layer. After the simulation is completed, the deformation value of each layer is accumulated to obtain the total deformation value Δf when the H-shaped steel is chamfered h : Where Δf h is the total deformation value when the H-shaped steel is chamfered, Δf1 is the first layer deformation value when the H-shaped steel is chamfered, and Δf2 is the second layer deformation value when the H-shaped steel is chamfered. The Nth angle when chamfering H-shaped steel G Layer deformation value; Step 6: Adjust the weight coefficient of step 2 and Repeat steps 2 to 5 to obtain multiple total deformation values ​​Δf h , compare the total deformation values ​​Δf h The size of Δf h Minimum value Δf hmin is the total deformation value generated when the H-shaped steel is chamfered, and the total deformation value Δf hmin The corresponding cutting feed ΔH is the actual cutting feed during machining, Δf hmin The corresponding cutting path is the cutting path during the actual processing of H-beam.

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