Virtual assembly method for hydraulic gate

Abstract

The invention belongs to the technical field of mechanical virtual assembly, and particularly relates to a hydraulic gate virtual assembly method which comprises the steps that an arrangement scheme of visual measurement marks is formulated and implemented; all parts of the gate product are shot in all directions through visual equipment; analyzing actual measurement coordinate data of each measurement point in the picture under the three-dimensional coordinate system by using coordinate analysis software; the actual measurement coordinate data under the three-dimensional coordinate system are imported into three-dimensional software in batches, and a gate component assembly point cloud model is generated; establishing a gate component assembly theoretical model by utilizing three-dimensional software; and performing assembly comparison on the gate component assembly point cloud model and the gate component assembly theoretical model in three-dimensional software to obtain corresponding dimensional deviation and component matching deviation to serve as a basis for formulating a gate product repair scheme. The method has the characteristics of convenience, high efficiency and high measurement precision, and can quickly and visually reflect the dimensional deviation of the gate component through comparison of a physical model and a theoretical model.

Description

Technical Field

[0001] The present invention belongs to the technical field of mechanical virtual assembly, and in particular relates to a hydraulic gate virtual assembly method. Background Art

[0002] With the continuous increase in the construction scale and installed capacity of hydropower stations, the external dimensions, pressure head and other parameters of hydropower station gates have also increased. The manufacturing accuracy of hydraulic gates is directly related to the water retaining performance of the gates. Due to the limitations of hoisting and transportation conditions, the gates are composed of multiple blocks of gate leaves, arc gate arms, arc gate hinges, etc. How to complete the pre-assembly and high-precision inspection of the gates in the factory to ensure the accuracy of the arc gate installation on site has always been the focus and difficulty of arc gate manufacturing.

[0003] Traditional arc doors are assembled vertically or horizontally in the factory to check the matching size between each block and the matching relationship between each component. Although this method can effectively measure the key dimensions of the arc door, as the size and weight of the arc door continue to increase, higher requirements are placed on the lifting capacity of the lifting equipment and the assembly site. The traditional factory pre-assembly operation has a long work cycle, requires high experience for pre-assembly personnel and inspection personnel, and the production management cost remains high. Summary of the invention

[0004] The present invention aims to solve the technical problem and provides a hydraulic gate virtual assembly method, which is convenient, efficient and has high measurement accuracy. It can quickly compare the physical model with the theoretical model and intuitively reflect the size deviation of the gate component.

[0005] The technical solutions adopted to achieve the above purpose are as follows: A hydraulic gate virtual assembly method comprises the following steps: S1. For the gate products that have been welded, formulate and implement the layout plan of visual measurement marks according to their structural characteristics; the visual measurement marks include coding rulers, marking points and measuring points; S2, according to the layout of visual measurement marks, use visual equipment to take all-round photos of the components of the gate product; S3, importing the captured image into coordinate analysis software, using the coordinate analysis software to analyze the actual measurement coordinate data of each measurement point in the image, transferring the actual measurement coordinate data into a three-dimensional coordinate system, and determining a model comparison benchmark; S4, batch importing the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model; S5, based on the design drawings of the gate products, use Inventor 3D software to establish the gate component assembly theoretical model and determine the model comparison benchmark; S6. In Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which will serve as the basis for formulating the gate product repair plan.

[0006] Preferably, the structural features of the gate product include the outer contour, symmetry plane, center line and measurement axis hole of the gate product. The structural features of the gate product include the outer contour and product characteristic hole of the gate product. For the outer contour, a contour line is preset based on the contour edge of the gate product, and measurement points are posted on the contour line at intervals; for the product characteristic hole, a number of measurement points are posted on the inner side wall of the product characteristic hole at intervals in the circumferential direction.

[0007] Preferably, in step S1, the distance between adjacent marking points is less than or equal to 500 mm.

[0008] Preferably, in step S1, the coding ruler is arranged around the gate product according to the positions of the marking points and the measuring points.

[0009] Preferably, in step S1, the measuring point is a square sticker, and a circular fluorescent coating is arranged at the center of the square sticker.

[0010] Preferably, in step S1, the marking point is a square sticker, and different fluorescent points are arranged and combined based on grid division in the square sticker to number the marking point.

[0011] Preferably, in step S1, the coding ruler is a long strip of sticker or ruler rod, with measuring points posted on both ends and marking points posted in the middle.

[0012] Preferably, in step S3, the model comparison reference is a reference plane and / or reference line fitted based on actual measured coordinate data of the measurement points.

[0013] Preferably, in step S3, invalid points and interference points appearing in the image parsing process are based on the MPS industrial photogrammetry system.

[0014] Preferably, in step S3, the position of the origin of the three-dimensional coordinate system is customized based on the structural characteristics of the gate product.

[0015] Beneficial effects of the present invention: The present invention proposes a method for virtual assembly of hydraulic gates. By formulating and implementing the layout plan of visual measurement marks, visual equipment is used to collect visual measurement marks, and coordinate analysis software and three-dimensional software are combined to realize data collection and processing of visual measurement marks and assembly point cloud models of gate components. In this process, according to the coordinate information of the visual measurement marks in the three-dimensional coordinate system, the actual size data of the gate product and the actual assembly relationship of the components are accurately captured. On this basis, the theoretical assembly model of the gate components is established according to the product information of the design drawings to realize the accurate input of the theoretical size data of the gate product and the theoretical assembly relationship of the components. Finally, the three-dimensional software is used to perform assembly comparison based on the same model comparison benchmark to obtain the corresponding size deviation and component matching deviation as the basis for formulating the gate product repair plan. In summary, the technical solution has the characteristics of convenience, high efficiency and high measurement accuracy. It can transform the traditional heavy physical pre-assembly of products into virtual assembly of point cloud models and theoretical models, which is of great significance to shortening the production cycle of gate products in the factory and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a preferred implementation flow chart of this technical solution; Figure 2 A schematic diagram of an example of a layout scheme for visual measurement identification; Figure 3 for Figure 2 A-direction view; Figure 4 for Figure 2 B-direction view; Figure 5 This is a schematic diagram of the internal operation of the MPS industrial photogrammetry system; Figure 6 This is a schematic diagram of a picture after grayscale processing in the coordinate analysis software; Figure 7 Schematic diagram of an example of comparison between the point cloud model and the theoretical model.

[0017] In the figure: 1. Reference plane; 2. Reference line; 3. Measuring point; 4. Marking point. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solution and advantages of the invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings in the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments.

[0019] Therefore, the following detailed description of the invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Example 1 This embodiment discloses a hydraulic gate virtual assembly method, as a basic implementation scheme of this technical solution, such as Figure 1 As shown, the following steps are included: S1. For the gate products that have been welded, formulate and implement the layout plan of visual measurement marks according to their structural characteristics; among them, the visual measurement marks include coding rulers, marking points and measuring points. In the actual implementation process, the components of the gate products include gate leaf blocks, arc gate arms and arc gate hinges, etc. It is necessary to post marking points and measuring points for each component separately, and arrange the coding ruler according to the positions of the marking points and measuring points, combined with the subsequent required shooting angles.

[0021] S2, according to the layout of visual measurement marks, use visual equipment to take all-round photos of the various parts of the gate product. That is, when using visual equipment to take pictures of the various parts of the gate product, it is necessary to shoot from multiple angles to ensure that all measurement points and marking points on the parts are captured. During the shooting process, the laid-out code ruler does not need to be moved, and the ruler serves as a reference and scale. When shooting marking points and measuring points, just take the nearest code ruler into the photo.

[0022] S3, import the captured image into the coordinate analysis software, use the coordinate analysis software to analyze the actual measurement coordinate data of each measurement point in the image, transfer the actual measurement coordinate data into the three-dimensional coordinate system, and determine the model comparison benchmark. In this process, the measurement point in the image is used to solve the actual measurement coordinate data of the point; since the structural features of each component are composed of multiple images, the marking point is used to accurately transmit the coordinates of the measurement point, and the role of the code ruler is a scale. The coordinate relationship between other points in the photo that are not on the code ruler (including measurement points and marking points) is solved through the actual distance of the standard code ruler in the photo.

[0023] S4, batch import the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model.

[0024] S5, according to the design drawings of the gate products, use Inventor 3D software to establish the gate component assembly theoretical model and determine the model comparison benchmark. This step involves the process of modeling based on the design drawing information (including key features of the matching between components, interface dimensions, and outline dimensions, etc.).

[0025] S6. In Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which will serve as the basis for formulating the gate product repair plan.

[0026] Example 2 This embodiment discloses a hydraulic gate virtual assembly method, which, as a preferred implementation scheme of the technical solution, comprises the following steps: S1, such as Figure 2-Figure 4 As shown in the figure, for the gate products after welding, a layout plan of visual measurement identification is formulated and implemented according to its structural characteristics. Among them, the visual measurement identification includes coding ruler, marking point and measuring point.

[0027] The structural features of the gate product include the outer contour of the gate product and the product characteristic holes. For the outer contour, a contour line is preset based on the contour edge of the gate product, and measurement points are posted at intervals on the contour line. Furthermore, under normal circumstances, the contour edge of the gate product can be used as a contour line. When the contour edge of the gate product is not convenient for posting measurement points, the contour line is set 50 mm inward from the contour edge of the gate product. For the product characteristic holes, a number of measurement points are posted at intervals on the inner side wall of the product characteristic hole. In addition, it also includes the plane features of the gate product. The plane features of the gate product can be reflected based on the corresponding outer contour features. Therefore, there is no need to arrange measurement points specifically for the plane features of the gate product.

[0028] The arrangement of the marking points depends on the position and angle of the visual capture. Generally, 3 to 4 marking points are guaranteed in a single photo to ensure the accuracy of the coordinate transmission of each subsequent measurement point. In actual operation, the number of marking points in a single photo can be guaranteed by adjusting the distance between the camera lens of the visual device and the photographed area, as well as the spacing between the marking points. For example, if the shooting distance in step S2 is preset to 3 to 5 meters, the spacing between adjacent marking points here is not greater than 500 mm.

[0029] The coding ruler is arranged around the gate product according to the positions of the marking points and measuring points.

[0030] S2, according to the layout of visual measurement marks, use visual equipment to take all-round photos of the various components of the gate product. In this process, the code ruler mainly provides a reference and scale in the shooting and subsequent measurement. When shooting the marking points and measurement points around the code ruler, just shoot the nearest code ruler into the photo, and the code ruler does not need to be moved during the entire all-round shooting process.

[0031] S3, such as Figure 5As shown, the captured image is imported into the coordinate analysis software, the actual measurement coordinate data of each measurement point in the image is analyzed by the coordinate analysis software, the actual measurement coordinate data is transferred into the three-dimensional coordinate system, and the model comparison benchmark is determined.

[0032] S4, batch import the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model.

[0033] S5, based on the design drawings of the gate products, use Inventor 3D software to establish the gate component assembly theoretical model and determine the model comparison benchmark.

[0034] S6. In Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which will serve as the basis for formulating the gate product repair plan.

[0035] Example 3 This embodiment discloses a hydraulic gate virtual assembly method, which, as a preferred implementation scheme of the technical solution, comprises the following steps: S1, for the gate products after welding, formulate and implement the layout plan of visual measurement identification according to its structural characteristics. The visual measurement identification includes coding ruler, marking point and measuring point.

[0036] The measuring point is a square sticker with a circular fluorescent coating in the center. In actual operation, the size of the measuring point can be set as needed, such as the side length of the measuring point can be set to 13mm, and the diameter of the circular fluorescent coating in the center can be set to 6mm.

[0037] The marker point is a square sticker, and different fluorescent points are arranged and combined based on the grid division in the square sticker to number the marker point. In actual operation, the size of the marker point can be set as needed, such as the side length of the marker point can be set to 65mm, where the side length of the grid is set to 5mm.

[0038] The coding ruler is a long strip of sticker or ruler with a standard length of 1.2m. There are measuring points at both ends and marking points in the middle.

[0039] S2, according to the layout of visual measurement marks, use visual equipment to take all-round photos of the components of the gate product.

[0040] S3, importing the captured image into the coordinate analysis software, using the coordinate analysis software to analyze the actual measurement coordinate data of each measurement point in the image, transferring the actual measurement coordinate data into a three-dimensional coordinate system, and determining the model comparison benchmark.

[0041] S4, batch import the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model.

[0042] S5, based on the design drawings of the gate products, use Inventor 3D software to establish the gate component assembly theoretical model and determine the model comparison benchmark.

[0043] S6. In Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which will serve as the basis for formulating the gate product repair plan.

[0044] Example 4 This embodiment discloses a hydraulic gate virtual assembly method, which, as a preferred implementation scheme of the technical solution, comprises the following steps: S1. For the gate products that have been welded, formulate and implement the layout plan of visual measurement marks according to their structural characteristics; among which: The visual measurement mark includes a coding ruler, a marking point and a measuring point. The measuring point is a square sticker with a circular fluorescent coating in the center. The marking point is a square sticker with different fluorescent points arranged and combined based on the grid division to number the marking points. The coding ruler is a long strip of sticker or ruler with measuring points posted at both ends and a marking point posted in the middle.

[0045] The structural features of the gate product include the outer contour of the gate product and the product characteristic hole. For the outer contour, a contour line is preset based on the contour edge of the gate product, and measurement points are posted at intervals on the contour line. For the product characteristic hole, a number of measurement points are posted at intervals on the inner side wall of the product characteristic hole.

[0046] When pasting marking points, the distance between adjacent marking points shall be less than or equal to 500mm.

[0047] When laying out the coding ruler, the coding ruler is laid out around the gate product according to the positions of the marking points and the measuring points.

[0048] S2, according to the layout of the visual measurement mark, determine the shooting distance (such as 4m), use a fixed-focus high-pixel camera to take all-round photos of the various components of the gate product, and ensure that 3 to 4 marking points are included in each single picture taken. In this process, since one photo cannot capture the overall shape of the flattened gate, the image data is collected by taking multiple photos from multiple angles, that is, all-round shooting. S3, such as Figure 5As shown, the photographed image is imported into the coordinate analysis software, and the coordinate analysis software is used to analyze the actual measurement coordinate data of each measurement point in the image, and the actual measurement coordinate data is transferred into the three-dimensional coordinate system, and the model comparison benchmark is determined. In this process, for the analysis of multiple photos, the ratio of the actual photo and the gate product is obtained through the coding ruler, and the coordinates of each measurement point in the photo are calculated based on the ratio. The role of the marker point is to transmit the coordinate data of the measurement point, forming a data closed loop of all measurement points of the workpiece.

[0049] In this step, in order to facilitate the subsequent comparison of the gate component assembly point cloud model and the gate component assembly theoretical model under the same benchmark conditions, it is necessary to customize the position of the origin of the three-dimensional coordinate system based on the structural characteristics of the gate product, and fit and solve the gate product plane features and / or plane centerline features based on the actual measured coordinate data in the three-dimensional coordinate system. The gate product plane features and plane centerline features are used as the benchmark for subsequent equipment comparison (the gate product plane features are the reference planes, and the plane centerline is the reference line).

[0050] The position of the origin of the three-dimensional coordinate system is specifically defined by defining the origin of the three-dimensional coordinate system at the position of the symmetry plane (gate product plane feature) of the corresponding hydraulic gate product component or at other representative feature planes, lines or points. After the position of the three-dimensional coordinate system is determined, the actual measured coordinate data can be transferred into the three-dimensional coordinate system.

[0051] In addition, the plane features and plane centerline features of the gate product are fitted based on the actual measured coordinate data in the three-dimensional coordinate system. The fitting and solving principle is: through the actual measured coordinate data of the measuring points on the contour lines on both sides, two contour lines are fitted, and the area between the two contour lines is the plane feature of the gate product; take the midpoint of the line connecting the two contour lines, and establish the plane centerline feature through the midpoint. For a single product feature hole, based on the actual measured coordinate data of all the measuring points inside it, the centerline of the shaft hole can be fitted.

[0052] However, in actual operation, Figure 4 As shown, the MPS industrial photogrammetry system will process the image in grayscale. After grayscale processing, the contrast of each measurement point and mark point in the photo will be greatly increased. Due to the influence of the shooting environment and other reflective objects, some points that are misjudged by the MPS industrial photogrammetry system may appear, namely invalid points and interference points. If the invalid points and interference points are not removed, when the MPS industrial photogrammetry system is used to fit a plane or a line based on the measurement points and the mark points, the fitting result will deviate from the actual result. Therefore, this step also includes the invalid points and interference points that appear in the image parsing process based on the MPS industrial photogrammetry system, specifically by manual deletion.

[0053] S4, batch import the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model.

[0054] S5. According to the design drawings of the gate products, the gate component assembly theoretical model is established using Inventor 3D software, and the plane features and / or corresponding plane centerline features of the gate component assembly theoretical model are correspondingly determined as a reference for assembly comparison.

[0055] S6, such as Figure 7 As shown, in the Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which serves as the basis for formulating the gate product repair plan.

Claims

1. A method for virtual assembly of hydraulic gates, characterized in that: The following steps are involved: S1. For the gate products that have been welded, formulate and implement the layout plan of visual measurement marks according to their structural characteristics; the visual measurement marks include coding rulers, marking points and measuring points; S2, according to the layout of visual measurement marks, use visual equipment to take all-round photos of the components of the gate product; S3, importing the captured image into coordinate analysis software, using the coordinate analysis software to analyze the actual measurement coordinate data of each measurement point in the image, transferring the actual measurement coordinate data into a three-dimensional coordinate system, and determining a model comparison benchmark; S4, batch importing the actual measured coordinate data in the three-dimensional coordinate system into the Inventor three-dimensional software to generate a gate component assembly point cloud model; S5, based on the design drawings of the gate products, use Inventor 3D software to establish the gate component assembly theoretical model and determine the model comparison benchmark; S6. In Inventor 3D software, the gate component assembly point cloud model and the gate component assembly theoretical model are assembled and compared based on the same model comparison benchmark to obtain the dimensional deviation and component matching deviation between the actual gate product and the gate product design, which will serve as the basis for formulating the gate product repair plan.

2. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In the step S1, the structural features of the gate product include the outer contour of the gate product and the product characteristic holes; For the outer contour, a contour line is preset based on the contour edge of the gate product, and measuring points are posted at intervals on the contour line; For the product characteristic hole, a number of measurement points are posted at intervals on the inner side wall of the product characteristic hole.

3. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S1, the distance between adjacent marking points is less than or equal to 500 mm.

4. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In the step S1, the coding ruler is arranged around the gate product according to the positions of the marking points and the measuring points.

5. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S1, the measuring point is a square sticker, and a circular fluorescent coating is set in the center of the square sticker.

6. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S1, the marking point is a square sticker, and different fluorescent points are arranged and combined based on grid division in the square sticker to number the marking point.

7. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S1, the coding ruler is a long strip of sticker or ruler, with measuring points posted on both ends and marking points posted in the middle.

8. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S3, the model comparison reference is a reference plane and / or reference line fitted based on the actual measured coordinate data of the measurement points.

9. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In the step S3, invalid points and interference points appearing in the image parsing process of the MPS industrial photogrammetry system are detected.

10. A method for virtual assembly of hydraulic gates as claimed in claim 1, characterized in that: In step S3, the position of the origin of the three-dimensional coordinate system is customized based on the structural characteristics of the gate product.

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