Reaction kettle end socket moving measurement and trepanning integrated robot and operation method

Abstract

The invention relates to a reaction kettle end socket moving measurement and trepanning integrated robot and an operation method. The robot comprises a control module, a moving platform, a multi-axis mechanical arm, a measurement module and a trepanning module, wherein the moving platform, the multi-axis mechanical arm, the measurement module and the trepanning module are connected with the control module. One end of the multi-axis mechanical arm is mounted on the moving platform, and the measuring module and the tapping module are integrally arranged at the other end of the multi-axis mechanical arm; the moving platform is used for driving the robot to move, the multi-axis mechanical arm adjusts the positions and postures of the measuring module and the tapping module according to instructions of the control module, the measuring module is used for conducting point cloud scanning on the end socket, the tapping module is used for tapping and beveling of the end socket, and the control module is used for receiving data collected by the measuring module. And the control module is used for controlling the action of the robot, the measuring path of the measuring module and the tapping posture of the tapping module. Compared with the prior art, the device has the advantages of being high in positioning precision and trepanning efficiency, wide in application range and the like.

Description

Technical Field

[0001] The invention relates to the technical field of engineering machinery automation and high-precision machining, and in particular to a robot and an operating method for integrating movement measurement and hole opening of a reactor head. Background Art

[0002] With the increasing requirements for the accuracy of containers used in chemical experiments and industrial production equipment, higher requirements are also placed on the processing accuracy of reactor heads.

[0003] In the existing production and processing process, due to the large size of the head (the maximum diameter can reach 3.5 meters), the placement deviation during manual lifting is large, there are processing errors, and each cutting and opening requires multiple workers to manually measure, locate, draw lines and determine the center point. This method is not only time-consuming and inefficient, but also has a large error risk and cannot meet the high-precision processing requirements. Especially when facing large heads, the stability and consistency of manual operation are difficult to guarantee, which has become a bottleneck in the cutting and opening process.

[0004] At present, the mobile measurement and opening method used for large components such as aerospace and wind turbine blades is a multi-scale combination method of global measurement positioning and local measurement positioning. For example, the invention with the publication number CN109990701A discloses a large-scale complex curved surface three-dimensional morphology robot mobile measurement system and method, the system includes structured light three-dimensional scanning equipment, industrial robots, autonomous mobile platforms, stereoscopic vision measurement equipment and ground positioning targets; the method uses the above system to measure and includes the following steps: calibrating the coordinates of the positioning target in the global coordinate system; calibrating the robot hand-eye relationship; planning the automatic measurement path; obtaining the point cloud data of each station; obtaining the point cloud posture of each station; aligning the point cloud data of multiple stations. However, the above multi-scale, combined measurement method is precise, but it is obviously a considerable burden for the processing of ordinary large components. Considering the measurement difficulty and cost, the above positioning method is obviously not suitable for the processing of ordinary large components.

[0005] At present, the chemical reactor head processing scene always has problems such as high labor intensity, single work process, low efficiency of workers' hole drilling, and risks of accidents in some specific plant areas. Therefore, the first task is to overcome the problems of manual calibration measurement, marking positioning, adjustment at different measurement positions, and high labor intensity of repeated measurements in the reactor head project. Summary of the invention

[0006] The purpose of the present invention is to overcome the defects of the above-mentioned prior art that manual measurement of holes is required and the gantry fixed hole cannot solve the in-situ measurement, and to provide a reactor head mobile measurement and hole opening integrated robot and operation method that includes measurement positioning and cutting hole opening mobile operations.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] This solution provides an integrated robot for moving, measuring and drilling a reactor head, including a control module and a mobile platform connected to the control module, a multi-axis robotic arm, a measuring module and a drilling module; one end of the multi-axis robotic arm is mounted on the mobile platform, and the measuring module and the drilling module are integrated at the other end of the multi-axis robotic arm;

[0009] The mobile platform is used to drive the robot to move, the multi-axis robotic arm adjusts the position and posture of the measuring module and the hole-opening module according to the instructions of the control module, the measuring module is used to perform point cloud scanning on the head, the hole-opening module is used to open holes and bevel the head, the control module is used to receive data collected by the measuring module and determine the hole-opening position of the head, and the control module is used to control the movement of the robot, the measurement path of the measuring module and the hole-opening posture of the hole-opening module.

[0010] Furthermore, the measuring module includes a laser ranging sensor and a 3D structured light camera. The 3D structured light camera is used to collect the three-dimensional shape of the head, generate corresponding point cloud information, and transmit the point cloud information to the control module; the laser ranging sensor is used to position the measuring module and the opening module.

[0011] Furthermore, the opening module includes a plasma cutter and a movable guide rail, the movable guide rail is installed at the end of the multi-axis robotic arm, the plasma cutter is movably installed on the movable guide rail, and the movable guide rail is used to adjust the position of the plasma cutter; the plasma cutter is also connected to a servo motor, and the servo motor is used to adjust the inclination angle of the plasma cutter.

[0012] Furthermore, a spring roller is installed on one side of the plasma cutting machine, and when the plasma cutting machine is operating, the spring roller contacts the surface of the head.

[0013] Furthermore, the mobile platform is provided with an inertial measurement unit, a visual camera and a laser radar for environmental perception and dynamic obstacle avoidance of the mobile platform; wheels are provided at the lower end of the mobile platform, and locking pieces are provided on the wheels for fixing the movement of the wheels.

[0014] This solution also provides an operation method of a reactor head mobile measurement and hole opening integrated robot, comprising the following steps:

[0015] Obtain the diameter of the end cap and the arm span of the multi-axis robot arm, and compare the arm span of the multi-axis robot arm with the diameter of the end cap to determine the measurement method and the hole opening method of the hole opening position on the end cap;

[0016] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot arm is less than or equal to the first threshold, the position of the opening on the end cap is determined by a fixed point measurement method through a measurement module, and key feature points are calibrated;

[0017] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot arm is greater than the first threshold, the position of the hole on the end cap is determined by using a multiple station transfer measurement method in cooperation with the mobile platform through the measurement module, and the key feature points are calibrated;

[0018] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot arm is less than or equal to the second threshold, the hole opening module adopts a fixed point hole opening method to perform hole opening and groove beveling operations at the calibrated key feature point position;

[0019] If the ratio of the diameter of the head to the arm span of the multi-axis robot arm is greater than the second threshold, the drilling module cooperates with the mobile platform to adopt the transfer drilling method to perform drilling and beveling operations at the calibrated key feature point position.

[0020] Furthermore, the measurement module includes a 3D structured light camera, and the 3D structured light camera is used to collect the three-dimensional shape of the head and generate corresponding point cloud information. The fixed point measurement method includes the following steps:

[0021] The structural contour of the end cap is obtained by a 3D structured light camera; the structural contour of the end cap is divided into three sector-shaped areas with the center of the circle, and the center angle of each sector-shaped area is 120°; starting from the center of the structural contour of the end cap, the multi-axis robotic arm is moved in the three sector-shaped areas in turn;

[0022] Scan each sector area with a 3D structured light camera, and splice the scanned data in each sector area in real time; generate a complete point cloud model of the head based on the scanned data of the three sector areas;

[0023] The complete point cloud model data of the head is transmitted to the control module. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed of the head are determined, and the key feature points are calibrated.

[0024] Furthermore, the multiple station transfer measurement method comprises the following steps:

[0025] The structural contour of the head is obtained through the measurement module; the structural contour of the head is divided into three sector-shaped areas with the center angle of each sector-shaped area being 120°; three corresponding calibration plates are set outside the three sector-shaped areas of the head, and the external calibration plates are calibrated for internal and external parameters to obtain corresponding calibration parameters;

[0026] The measuring module is driven to move by the mobile platform, and the three calibration plates are scanned with the measuring module to determine the relative position of the measuring module and the end cap, and the point cloud scanning of the first sector area is performed; the measuring module is driven to move by the mobile platform, and the scanning action in the first sector area is repeated to obtain the point cloud scanning of the second and third sector areas;

[0027] The point cloud scanning data of the three fan-shaped areas are fused to obtain a complete point cloud model of the head. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed in the head are determined, and the key feature points are calibrated.

[0028] Furthermore, the hole opening module includes a plasma cutting machine, and the fixed point hole opening method includes the following steps:

[0029] Obtain the measurement results of the measurement module and the design drawings of the head, and calculate the coordinates, depth and groove angle of each opening on the head;

[0030] According to the hole opening information, the control module plans the moving path of the multi-axis robot arm, and the multi-axis robot arm drives the ion cutting machine to move;

[0031] Move the mobile platform to the preset position and fix it, and use the ion cutting machine combined with the hole opening information to perform hole opening and groove processing at the specified position of the specified head.

[0032] Furthermore, the drilling module includes a plasma cutter, a servo motor and a movable guide rail, the movable guide rail is used to adjust the position of the plasma cutter, and the servo motor is used to adjust the inclination angle of the plasma cutter; the transfer station drilling method includes the following steps:

[0033] According to the position and size of the opening determined by the control module, the plasma cutting machine is started to open the hole in the head; the opening diameter of the plasma cutting machine is adjusted by moving the guide rail;

[0034] According to the inclination angle of the opening groove, the inclination angle of the plasma cutter is adjusted by the servo motor, and the relative position of the plasma cutter and the head is monitored in real time with the measurement module. If the surface is detected to be uneven, the inclination angle of the plasma cutter is further adjusted by the servo motor;

[0035] After completing the hole-drilling operation in the current area, the robot is transferred to the next area through the mobile platform and the hole-drilling action in the previous area is repeated until all the holes on the head are drilled.

[0036] Compared with the prior art, the present invention has the following advantages:

[0037] (1) In this solution, the measurement module scans the head workpiece to obtain the spatial point cloud model corresponding to the head workpiece, and determines the position, size and groove inclination of the hole in combination with the designed hole information. The hole opening module performs hole opening and groove beveling operations on the head according to the determined hole opening and groove information. The spatial posture and position of the measurement module and the hole opening module are adjusted through the control module, the mobile platform and the multi-axis robot arm.

[0038] Compared with the existing method of drilling holes in the head through manual positioning and fixed gantry, the robot operation integrating mobile measurement and drilling can realize the in-situ processing of the reactor head, without moving the head position, thereby improving the efficiency of reactor head drilling, enhancing the automation and digitalization level of the workshop, and the hole positioning accuracy on the head is higher.

[0039] (2) In this solution, the drilling module and the measuring module are integrated and installed on the moving guide rail at the end of the multi-axis robot arm, and the plasma cutting head is configured on the moving guide rail, so that the plasma cutting head can move along the fixed direction of the guide rail within a specific range. This allows the entire system to achieve continuous measurement and processing operations, reducing the operational errors caused by the separation of measurement and drilling equipment in traditional equipment.

[0040] (3) In this solution, a spring roller is specially designed and installed on the side of the plasma cutting head. The spring roller can maintain contact with the surface of the reactor head during the plasma cutting process, preventing the cutting head from directly colliding with the reactor head due to irregular surfaces or errors during the processing. This not only improves the safety of the cutting process, but also avoids the reduction of processing quality or damage to the equipment due to collision.

[0041] (4) In this scheme, based on the dimensional relationship between the head diameter and the arm span of the multi-axis robot arm, a fixed moving measurement method and a measurement method for constructing a point cloud model by moving the mobile platform and measuring the head from multiple angles are determined. In addition, the corresponding head opening and beveling are combined to adapt to the processing of heads of various sizes, with high flexibility and a wide range of applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 A schematic diagram of the structure of the mobile measurement and hole-opening integrated robot provided by the present invention;

[0043] Figure 2 A structural block diagram of the mobile measurement and hole-opening integrated robot provided by the present invention;

[0044] Figure 3 A flow chart of the robot measuring and opening operation provided by the present invention;

[0045] In the figure: 1. Mobile platform, 2. Multi-axis robotic arm, 3. Measurement module, 4. Drilling module, 5. Head, 31. Laser ranging sensor, 32. 3D structured light camera, 41. Plasma cutting machine, 42. Mobile guide rail. DETAILED DESCRIPTION

[0046] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0047] Therefore, the following detailed description of the embodiments of the present 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 present 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.

[0048] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0049] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, or are the directions or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0050] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0051] In addition, the terms "horizontal", "vertical" and the like do not mean that the components are required to be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0052] Example 1

[0053] like Figure 1 and Figure 2 As shown, this embodiment provides a reactor head mobile measurement and hole-opening integrated robot, including a control module and a mobile platform 1, a multi-axis robotic arm 2, a measurement module 3 and a hole-opening module 4 connected to the control module; one end of the multi-axis robotic arm 2 is installed on the mobile platform 1, and the measurement module 3 and the hole-opening module 4 are integrated at the other end of the multi-axis robotic arm 2;

[0054] The mobile platform 1 is used to drive the robot to move, and the multi-axis robot arm 2 adjusts the position and posture of the measuring module 3 and the hole-opening module 4 according to the instructions of the control module. The measuring module 3 is used to perform point cloud scanning on the head, and the hole-opening module 4 is used to open holes and bevel the head. The control module is used to receive data collected by the measuring module and determine the hole opening position of the head. The control module is also used to control the movement of the robot, the measurement path of the measuring module 3, and the hole-opening posture of the hole-opening module 4.

[0055] The measuring module scans the end cap workpiece to obtain the corresponding spatial point cloud model of the end cap workpiece, and determines the position, size and groove inclination of the hole in combination with the designed hole information. The hole opening module performs hole opening and groove beveling operations on the end cap according to the determined hole opening and groove information. The spatial posture and position of the measuring module and the hole opening module are adjusted through the control module, the mobile platform and the multi-axis robotic arm.

[0056] Compared with the existing method of drilling holes in the head through manual positioning and fixed gantry, the robot operation integrating mobile measurement and drilling can realize the in-situ processing of the reactor head, without moving the head position, thereby improving the efficiency of reactor head drilling, enhancing the automation and digitalization level of the workshop, and the hole positioning accuracy on the head is higher.

[0057] In a preferred embodiment, the measuring module 3 includes a laser distance sensor 31 and a 3D structured light camera 32. The 3D structured light camera 32 is used to collect the three-dimensional shape of the end cap, generate corresponding point cloud information, and transmit the point cloud information to the control module; the laser distance sensor 31 is used to locate the measuring module 3 and the hole opening module 4. The 3D structured light camera 31 is equipped with a dust cover, which is sealed when the hole opening module 4 is performing the hole opening device to reduce the contamination of the 3D structured light camera lens.

[0058] Among them, the hole opening module 4 includes a plasma cutter 41 and a movable guide rail 42, the movable guide rail 42 is installed at the end of the multi-axis robot arm 2, the measuring module 3 and the plasma cutter 41 are respectively movably installed on the movable guide rail 42, and the movable guide rail 42 is used to adjust the position of the plasma cutter 41; the plasma cutter 41 is also connected to a servo motor, and the servo motor is used to adjust the inclination angle of the plasma cutter 41.

[0059] The hole-opening module and the measuring module are integrated and installed on the moving guide rail at the end of the multi-axis robot arm. The plasma cutting head is configured on the moving guide rail, which allows the plasma cutting head to move along the fixed direction of the guide rail within a specific range. The entire system can achieve continuous measurement and processing operations, reducing the operational errors caused by the separation of measurement and hole-opening equipment in traditional equipment. The servo motor for angle adjustment at the rear of the plasma cutting head can adjust the position of the cutting head through telescopic action according to the depth and angle requirements of the groove, and cooperate with the posture adjustment of the robot arm to achieve cutting of different areas of the workpiece, thereby achieving the expected groove shape.

[0060] Optionally, a spring roller is installed on one side of the plasma cutting machine 41, and when the plasma cutting machine 41 is in operation, the spring roller contacts the surface of the head. The spring roller is specially designed and installed on the side of the plasma cutting head, and the spring roller can keep in contact with the surface of the reactor head during the plasma cutting process, preventing the cutting head from directly colliding with the reactor head due to irregular surfaces or errors during the processing, which not only improves the safety of the cutting process, but also avoids the degradation of processing quality or damage to the equipment due to collision.

[0061] Specifically, the mobile platform 1 is provided with an inertial measurement unit, a visual camera and a laser radar, which are used for environmental perception and dynamic obstacle avoidance of the mobile platform 1; wheels are provided at the lower end of the mobile platform, and locking members are provided on the wheels, which are used to fix the movement of the wheels.

[0062] Among them, the control module includes a data processing system and a control system interconnected with the mobile platform 1, the multi-axis robot 2, the measurement module 3 and the hole opening module 4. The data processing system is used to receive data from each component and perform data processing, and transmit the data to the control system, which controls the operation of each component.

[0063] In this embodiment, high-precision, multi-level, and multi-state control of the robot arm can be achieved. High precision means that the actuators installed at the end of the robot arm can realize the precise identification, measurement, and hole-opening operations of the reactor head; multi-level means that from the overall measurement to the generation of point cloud data, to the precise local measurement, multi-level measurement is completed by accurately positioning the center hole and setting the reference point (calibration plate, ball gauge); multi-state means that the robot arm can plan the trajectory of visual camera scanning for workpieces of different sizes during the working process, and can also perform hole-opening operations according to different workpieces in real time after scanning and matching the model library after mobile operation.

[0064] Compared with the existing processing method of a fixed gantry frame configured robot, this mobile robot can realize mobile operations and in-situ processing of the workpiece to be processed. It has higher processing flexibility and can provide a better solution for the processing of large and complex components. However, it has higher requirements on the accuracy and difficulty of mobile measurement and positioning.

[0065] like Figure 3 As shown, this embodiment also provides an operation method of the reactor head mobile measurement and hole opening integrated robot based on the above-mentioned method, which is characterized by comprising the following steps:

[0066] Obtain the diameter of the end cap and the arm span of the multi-axis robot 2, and compare the arm span of the multi-axis robot 2 with the diameter of the end cap to determine the measurement method and the hole opening method of the hole opening position on the end cap;

[0067] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot 2 is less than or equal to the first threshold, the position of the hole on the end cap is determined by the measurement module 3 using a fixed point measurement method, and the key feature points are calibrated;

[0068] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot 2 is greater than the first threshold, the position of the hole on the end cap is determined by using a multiple station transfer measurement method in cooperation with the mobile platform 1 through the measurement module 3, and the key feature points are calibrated;

[0069] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot 2 is less than or equal to the second threshold, the hole opening module 4 uses a fixed point hole opening method to perform hole opening and beveling operations at the calibrated key feature point position;

[0070] If the ratio of the diameter of the end cap to the arm span of the multi-axis robot 2 is greater than a second threshold, the drilling module 4 cooperates with the mobile platform 1 to adopt a transfer drilling method to perform drilling and beveling operations at the calibrated key feature point position.

[0071] According to the dimensional relationship between the head diameter and the arm span of the multi-axis robot arm, a fixed moving measurement method and a measurement method for constructing a point cloud model by moving the mobile platform and measuring the head from multiple angles are determined. In addition, the corresponding head openings and beveling are provided to adapt to the processing of heads of various sizes, with high flexibility and a wide range of applications.

[0072] The fixed point measurement method includes the following steps:

[0073] The structural contour of the end cap is obtained by a 3D structured light camera 32; the structural contour of the end cap is divided into three sector-shaped areas with the center of the circle, and the center angle of each sector-shaped area is 120°; starting from the center of the structural contour of the end cap, the multi-axis robot arm 2 is moved in the three sector-shaped areas in turn;

[0074] Each sector area is scanned by a 3D structured light camera 32, and the scanned data in each sector area is spliced ​​in real time; a complete point cloud model of the head is generated based on the scanned data of the three sector areas;

[0075] The complete point cloud model data of the head is transmitted to the control module. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed of the head are determined, and the key feature points are calibrated.

[0076] Specifically, if the diameter of the reactor head is within 0.8 times the arm span of the robotic arm, the mobile robot can be fixed in place, and the overall contour of the head is determined by the 3D structured light camera. The head is divided into three equal areas in units of 120°, marked as A1, A2, and A3 in a clockwise direction. The robotic arm takes the center of the contour as the starting point and moves in areas A1, A2, and A3 respectively (the order of the areas has no effect). The control system controls the 3D structured light camera to perform point cloud scanning and stitching, and the data processing system generates complete point cloud data. By comparing it with the CAD model of the workpiece, the exact coordinate position of the area to be processed is determined, and the coordinate data of the key feature points are calibrated.

[0077] Furthermore, the multiple station transfer measurement method comprises the following steps:

[0078] The structural profile of the end cap is obtained through the measurement module 3; the structural profile of the end cap is divided into three sector-shaped areas with the center angle of each sector-shaped area being 120°; three corresponding calibration plates are arranged outside the three sector-shaped areas of the end cap, and the external calibration plates are calibrated for internal and external parameters to obtain corresponding calibration parameters;

[0079] The measuring module 3 is driven to move by the mobile platform 1, and the three calibration plates are scanned with the measuring module 3 to determine the relative position between the measuring module 3 and the end cap, and a point cloud scan is performed on the first sector area; the measuring module 3 is driven to move by the mobile platform 1, and the scanning action in the first sector area is repeated to obtain point cloud scans of the second and third sector areas;

[0080] The point cloud scanning data of the three fan-shaped areas are fused to obtain a complete point cloud model of the head. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed in the head are determined, and the key feature points are calibrated.

[0081] Specifically, the diameter of the head is greater than 0.8 times the arm span of the robot, and the mobile robot performs hole drilling on the head by means of transfer processing. Three calibration plates (B1, B2, B3) are placed externally on the A1, A2, and A3 areas of the head at every 120°. First, the external calibration plates are calibrated for internal and external parameters. According to the calibrated parameters, the robot is moved to a certain position P0 in front of the head, and B1, B2, and B3 are scanned respectively. The state variables of the end of the robot arm are solved by solving the posture state of the robot, and then the point cloud data of the A1 area is measured using a 3D mechanism optical camera.

[0082] After the robot moves to the processing position P1 on the other side of the head, it scans B2, B1 and B3 respectively, and calculates the position relationship of the end of the robot arm relative to the external calibration plate again. The state variables of the end of the robot arm are repeatedly solved, and then the 3D mechanical optical camera is used to measure the point cloud data of the A2 area.

[0083] Repeat the above steps to complete the scanning of the A3 area. Through the scanning of three measurement points, the system fuses the data from various perspectives to create a complete 3D point cloud model of the workpiece. The point cloud data is transmitted to the data processing system. By comparing the workpiece's CAD model or preset design drawings, the system determines the exact location of the area to be processed and calibrates the coordinate data of the key feature points.

[0084] Furthermore, the fixed point opening method includes the following steps:

[0085] Obtain the measurement results of the measurement module 3 and the design drawings of the head, and calculate the coordinates, depth and groove angle of each opening on the head;

[0086] According to the hole opening information, the moving path of the multi-axis robot arm 2 is planned by the control module, and the ion cutting machine 41 is driven to move by the multi-axis robot arm 2;

[0087] The mobile platform is moved to a preset position and then fixed, and the ion cutting machine 41 is used to perform hole opening and groove processing at a designated position of the designated head in combination with the hole opening information.

[0088] After the control system receives the information, if the diameter of the head is smaller than the arm span of the robot (it can be processed in the original position), the mobile robot can perform the drilling operation by fixed-point drilling. According to the determined processing point position, the control system sends the determined point position to the controller of the robot arm. Combined with the multi-degree-of-freedom movement of the robot arm, the system optimizes the movement path by adjusting the angles of multiple axes in real time.

[0089] The transfer station opening method includes the following steps:

[0090] According to the position and size of the opening determined by the control module, the plasma cutting machine 41 is started to open the hole in the head; the opening diameter of the plasma cutting machine 41 is adjusted by moving the guide rail 42;

[0091] According to the inclination angle of the opening groove, the inclination angle of the plasma cutter 41 is adjusted by the servo motor, and the relative position of the plasma cutter 41 and the end cap is monitored in real time in cooperation with the measuring module 3. If the surface is detected to be uneven, the inclination angle of the plasma cutter 41 is further adjusted by the servo motor;

[0092] After completing the hole-drilling operation in the current area, the robot is transferred to the next area through the mobile platform 1, and the hole-drilling operation in the previous area is repeated until all the holes on the head are drilled.

[0093] If the diameter of the head is larger than the arm span of the robot (in-situ processing is not possible), the mobile robot will perform hole drilling on the head by means of station transfer processing. The station transfer process of the robot for hole drilling is the same as the robot's multiple station transfer measurement planning. That is, after the mobile robot performs station transfer measurement, the relative position between the reactor head and the end of its own robot arm is solved to obtain the coordinate relationship of the processing hole position. At this time, after the mobile robot completes the station transfer measurement, the plasma cutting head is started. Through the calculated hole opening point, the control system controls the robot arm and the servo motor at the rear of the plasma cutting head to jointly complete the hole opening and groove processing of the head.

[0094] The angle adjustment of the plasma cutting head during groove processing is completed by an electric servo motor. The system accurately adjusts the inclination angle of the cutting head through the angle adjustment motor according to the preset groove angle. The system monitors the relative position of the cutting head and the workpiece surface in real time through the laser rangefinder sensor in the measurement and positioning device. If the sensor detects that the workpiece surface is uneven or tilted, the system will adjust the angle of the cutting head in real time to ensure the accuracy of the groove angle.

[0095] In combination with the above preferred implementation, this embodiment also provides a more specific implementation, and the specific detection process includes the following steps:

[0096] S1: If the reactor head component is within the working range of the mobile measurement and opening integrated robot, the in-situ measurement method is used for measurement and identification.

[0097] The measuring device includes a 3D structured light camera and a laser ranging sensor. The 3D structured light camera in the measuring device performs structured light scanning on the reactor head. The reactor head is divided into three equal areas, and the point cloud data of the reactor head as a whole is scanned and collected to obtain image information of the area to be detected.

[0098] The data processing system performs point cloud fitting on the collected point cloud data, and after reverse modeling and point calculation, compares the reactor head drawing with the established point cloud model to perform center point matching operations.

[0099] After the comparison with the head drawing is completed, the control system controls the robotic arm and the end hole opening device to perform hole opening operations on the reactor head.

[0100] When the plasma cutting head is performing a hole-making operation, the tool at the end of the robotic arm is aligned with the point to be drilled, and the guide rail where the plasma cutting head is located will extend and contract according to the hole position to be processed to avoid loss caused by the back and forth movement of the robotic arm.

[0101] S2: If it is not within the working range of the robot arm, an external calibration plate (reference point) is placed in the determined three-division area to divide the workpiece into three equal parts, so that the AGV can perform mobile measurement based on the reference point. After the measurement range is divided, the robot arm performs planning operations.

[0102] A distance measurement calibration plate is placed at the equally divided position of the reactor head. The laser rangefinder and structured light camera in the measuring device at the end of the robotic arm obtain the relative position between the calibration plate and the reactor head by scanning the center position of the calibration plate.

[0103] The 3D structured light camera in the measurement module repeats the operation in S1 to perform structured light scanning on the workpiece to be processed, collects point cloud data of the processed object through several scans, and obtains image information of the area to be detected.

[0104] The robot moves to the transfer station. During the movement, the laser rangefinder and 3D structured light camera obtain their relative positions again by scanning the center position of the calibration plate.

[0105] Use 3D structured light cameras and laser ranging sensors to complete comprehensive measurement of the workpiece to obtain the three-dimensional shape and position data of the workpiece, transmit the measurement data to the data processing system, perform data processing and reverse modeling, and generate a three-dimensional model of the workpiece.

[0106] On the generated 3D model, path planning is performed according to the preset hole position and size, and the operation instructions of the robot arm are generated. The control system adjusts the position and angle of the robot arm and the end tool according to the path planning results, and prepares for the hole opening operation.

[0107] The robot arm moves to the predetermined hole opening position according to the generated operation instructions, and starts the plasma cutting head at the end to open the hole.

[0108] Through the wireless communication module, operators can remotely monitor the operating status of the system and perform remote operations or adjustments as needed.

[0109] The digital information of the workpiece can be matched by importing Excel data into the system.

[0110] After the hole is drilled, the control system returns the robot arm to its initial position and sets the system to standby mode, ready for the next operation.

[0111] This embodiment abandons global measurement and relies on local measurement formed by 3D vision cameras and laser ranging sensors. It performs mobile measurement and processing of large components through measurement operation planning and hole opening operation planning of multi-axis robotic arms under visual guidance, thereby improving processing accuracy and operating efficiency.

[0112] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A reactor head mobile measurement and hole opening integrated robot, characterized in that: The invention comprises a control module and a mobile platform (1), a multi-axis mechanical arm (2), a measuring module (3) and a hole-opening module (4) connected to the control module; one end of the multi-axis mechanical arm (2) is mounted on the mobile platform (1), and the measuring module (3) and the hole-opening module (4) are integrated and arranged at the other end of the multi-axis mechanical arm (2); The mobile platform (1) is used to drive the robot to move; the multi-axis robot arm (2) adjusts the position and posture of the measuring module (3) and the hole-opening module (4) according to the instructions of the control module; the measuring module (3) is used to perform point cloud scanning on the end cap; the hole-opening module (4) is used to open holes and groove the end cap; the control module is used to receive data collected by the measuring module and determine the hole-opening position of the end cap; and the control module is used to control the movement of the robot, the measuring path of the measuring module (3) and the hole-opening posture of the hole-opening module (4).

2. The reactor head mobile measurement and hole opening integrated robot according to claim 1, characterized in that: The measuring module (3) comprises a laser distance measuring sensor (31) and a 3D structured light camera (32); the 3D structured light camera (32) is used to collect the three-dimensional shape of the end cap, generate corresponding point cloud information, and transmit the point cloud information to the control module; the laser distance measuring sensor (31) is used to position the measuring module (3) and the hole opening module (4).

3. The integrated robot for measuring movement and drilling of reactor heads according to claim 1, characterized in that: The hole opening module (4) comprises a plasma cutter (41) and a movable guide rail (42), wherein the movable guide rail (42) is mounted at the end of a multi-axis mechanical arm (2), and the measuring module (3) and the plasma cutter (41) are respectively movably mounted on the movable guide rail (42), wherein the movable guide rail (42) is used to adjust the position of the plasma cutter (41); the plasma cutter (41) is also connected to a servo motor, and the servo motor is used to adjust the inclination angle of the plasma cutter (41).

4. The integrated robot for measuring movement and drilling of reactor heads according to claim 3 is characterized in that: A spring roller is installed on one side of the plasma cutting machine (41); when the plasma cutting machine (41) is in operation, the spring roller contacts the surface of the end cap.

5. The reactor head mobile measurement and hole opening integrated robot according to claim 1, characterized in that: The mobile platform (1) is provided with an inertial measurement unit, a visual camera and a laser radar, which are used for environmental perception and dynamic obstacle avoidance of the mobile platform (1); wheels are provided at the lower end of the mobile platform, and locking members are provided on the wheels, and the locking members are used to fix the movement of the wheels.

6. An operation method of a reactor head mobile measurement and hole opening integrated robot based on any one of claims 1-5, characterized in that: The following steps are involved: Obtaining the diameter of the end cap and the arm span of the multi-axis mechanical arm (2), and comparing the arm span of the multi-axis mechanical arm (2) with the diameter of the end cap to determine the measurement method and the hole opening method of the hole opening position on the end cap; If the ratio of the diameter of the end cap to the arm span of the multi-axis mechanical arm (2) is less than or equal to a first threshold, the position of the opening on the end cap is determined by a fixed point measurement method using a measurement module (3), and key feature points are calibrated; If the ratio of the diameter of the end cap to the arm span of the multi-axis mechanical arm (2) is greater than a first threshold, the position of the hole on the end cap is determined by using a multiple station transfer measurement method in cooperation with the mobile platform (1) through the measurement module (3), and the key feature points are calibrated; If the ratio of the diameter of the end cap to the arm span of the multi-axis mechanical arm (2) is less than or equal to a second threshold, a hole-opening module (4) uses a fixed-point hole-opening method to perform hole-opening and groove-cutting operations at the calibrated key feature point position; If the ratio of the diameter of the end cap to the arm span of the multi-axis mechanical arm (2) is greater than a second threshold value, a hole-opening module (4) cooperates with the mobile platform (1) to adopt a station-transfer hole-opening method to perform hole-opening and groove-cutting operations at the calibrated key feature point position.

7. The method according to claim 6, characterized in that The measuring module (3) comprises a 3D structured light camera (32), and the 3D structured light camera (32) is used to collect the three-dimensional shape of the end cap and generate corresponding point cloud information. The fixed point measurement method comprises the following steps: The structural contour of the end cap is obtained by a 3D structured light camera (32); the structural contour of the end cap is divided into three sector-shaped areas with the center of the circle being 120°; and the multi-axis robot arm (2) is moved in the three sector-shaped areas in sequence starting from the center of the structural contour of the end cap; Scanning each sector area with a 3D structured light camera (32), and splicing the scanned data in each sector area in real time; generating a complete point cloud model of the head according to the scanned data of the three sector areas; The complete point cloud model data of the head is transmitted to the control module. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed of the head are determined, and the key feature points are calibrated.

8. The method according to claim 6, characterized in that The multiple station transfer measurement method comprises the following steps: The structural profile of the end cap is obtained by a measurement module (3); the structural profile of the end cap is divided into three sector-shaped areas with the center of the circle being 120°; three corresponding calibration plates are arranged outside the three sector-shaped areas of the end cap, and the external calibration plates are calibrated for internal and external parameters to obtain corresponding calibration parameters; The measuring module (3) is driven to move by the mobile platform (1), and the measuring module (3) is used to scan three calibration plates to determine the relative position of the measuring module (3) and the end cap, and a point cloud scan is performed on the first sector-shaped area; the measuring module (3) is driven to move by the mobile platform (1), and the scanning action in the first sector-shaped area is repeated to obtain point cloud scans of the second and third sector-shaped areas; The point cloud scanning data of the three fan-shaped areas are fused to obtain a complete point cloud model of the head. Combined with the preset position and size of the opening, the specific coordinates of the area to be processed in the head are determined, and the key feature points are calibrated.

9. The method according to claim 6, characterized in that The hole opening module (4) comprises a plasma cutting machine (41), and the fixed point hole opening method comprises the following steps: Obtain the measurement results of the measurement module (3) and the design drawings of the head, and calculate the coordinates, depth and groove angle of each opening on the head; According to the hole opening information, the moving path of the multi-axis robot arm (2) is planned by the control module, and the ion cutting machine (41) is driven to move by the multi-axis robot arm (2); The mobile platform is moved to a preset position and then fixed, and an ion cutting machine (41) is used to perform hole opening and groove processing at a designated position of a designated head in combination with hole opening information.

10. The method according to claim 6, characterized in that The hole-opening module (4) comprises a plasma cutter (41), a servo motor and a movable guide rail (42), wherein the movable guide rail (42) is used to adjust the position of the plasma cutter (41), and the servo motor is used to adjust the inclination angle of the plasma cutter (41); the transfer station hole-opening method comprises the following steps: According to the position and size of the opening determined by the control module, the plasma cutting machine (41) is started to open the hole in the head; and the opening diameter of the plasma cutting machine (41) is adjusted by moving the guide rail (42); According to the inclination angle of the opening groove, the inclination angle of the plasma cutting machine (41) is adjusted by the servo motor, and the relative position of the plasma cutting machine (41) and the end cap is monitored in real time in cooperation with the measuring module (3). If the surface is detected to be uneven, the inclination angle of the plasma cutting machine (41) is further adjusted by the servo motor; After completing the hole-opening operation in the current area, the robot is transferred to the next area through the mobile platform (1) and the hole-opening operation in the previous area is repeated until all the holes on the head are opened.

Images