Integrated complex part self-adaptive positioning and profile scanning device and coordinate conversion method

Abstract

The invention relates to an integrated complex part self-adaptive positioning and profile scanning device and a coordinate conversion method, and belongs to the technical field of complex workpiece precision machining. Comprising a flexible clamp, an adjustable scanning turntable and a scanning sensor, wherein the adjustable scanning turntable is horizontally arranged; the flexible clamp is horizontally mounted on the adjustable scanning turntable; a to-be-scanned workpiece is installed on the flexible clamp. The scanning sensor is mounted at the top end of the adjustable scanning turntable; by adjusting the position and angle of the flexible clamp on the adjustable scanning rotary table and the position and angle of the scanning sensor on the adjustable scanning rotary table, the scanning sensor is aligned with a to-be-scanned workpiece on the flexible clamp; the to-be-scanned workpiece is scanned through a scanning sensor; according to the method, high-precision matching and reverse modeling of a complex workpiece profile are carried out based on scanning point cloud data, and the bottlenecks in the aspects of adaptability, machining precision, efficiency and the like of a tool clamp are fundamentally solved.

Description

Technical Field

[0001] The invention belongs to the technical field of complex workpiece precision machining, and relates to an integrated complex part adaptive positioning and surface scanning device and a coordinate conversion method. Background Art

[0002] At present, there are a series of technical challenges and production efficiency bottlenecks in the field of complex workpiece processing. These problems seriously affect the quality of products and the competitiveness of enterprises. Specifically, they are manifested in the following aspects:

[0003] Diverse tooling and fixtures: Since complex workpieces often have complex geometric shapes, traditional fixed fixtures are often difficult to quickly adapt to the sizes and shapes of workpieces of different batches and specifications, resulting in the problem of "one generation of products, one generation of tooling". There are many types of fixtures and a large degree of waste of resources.

[0004] Low production efficiency: Before processing, tedious manual measurement and workpiece positioning are required, which is not only time-consuming but also prone to human errors. In addition, frequent trial cutting and adjustments in the traditional processing process extend the overall production cycle, increase costs, and limit the company's production efficiency and market response speed.

[0005] The existence of these problems not only restricts the technological progress and industrial upgrading of the complex material processing industry, but also directly affects the application effect and market satisfaction of downstream industries. The above-mentioned problems are not limited to the processing of complex workpieces, but are widely present in the manufacturing field of various high-precision and complex-shaped workpieces. These problems together constitute a major challenge to existing processing technology.

[0006] Therefore, there is an urgent need for an innovative processing technology system that can fundamentally solve the bottlenecks in tooling adaptability, processing accuracy and efficiency, and promote the processing industry of various high-precision and complex-shaped workpieces to develop in the direction of higher quality, higher efficiency and more intelligence. Summary of the invention

[0007] The technical problem solved by the present invention is: to overcome the shortcomings of the prior art, to propose an integrated complex part adaptive positioning and surface scanning device and a coordinate conversion method, to perform high-precision matching and reverse modeling of complex workpiece surfaces based on scanned point cloud data, and to fundamentally solve the bottlenecks in the adaptability, processing accuracy and efficiency of tooling and fixtures.

[0008] The solution of the present invention is:

[0009] Integrated complex parts adaptive positioning and surface scanning device, including flexible fixture, adjustable scanning turntable and scanning sensor;

[0010] Among them, the adjustable scanning turntable is horizontally set; the flexible fixture is horizontally installed on the adjustable scanning turntable; the workpiece to be scanned is installed on the flexible fixture; the scanning sensor is installed on the top of the adjustable scanning turntable; by adjusting the position and angle of the flexible fixture on the adjustable scanning turntable and the position and angle of the scanning sensor on the adjustable scanning turntable, the scanning sensor is aligned with the workpiece to be scanned on the flexible fixture; the workpiece to be scanned is scanned by the scanning sensor.

[0011] In the above-mentioned integrated complex part adaptive positioning and profile scanning device, the flexible fixture includes a flexible support component, two handles, a housing and two positioning pins;

[0012] Among them, the shell is a horizontally placed frame structure; the flexible support component is arranged on the upper surface of the shell; two handles are symmetrically arranged on the two side walls of the shell; and two positioning pins are symmetrically arranged on the two side walls of the shell.

[0013] In the above-mentioned integrated complex parts adaptive positioning and surface scanning device, the upper surface of the flexible support component is in direct contact with the workpiece to be scanned, and the upper surface of the flexible support component can adapt to workpieces of different shapes and sizes to be scanned through deformation, thereby ensuring stable fixation of the workpiece to be scanned during the processing process, while reducing the pressure on the surface of the workpiece to be scanned to avoid deformation; the handle facilitates the operator to adjust or move the position of the flexible clamp; the positioning pin realizes the precise positioning of the relative position of the flexible clamp and the adjustable scanning turntable.

[0014] In the above-mentioned integrated complex part adaptive positioning and profile scanning device, the adjustable scanning turntable includes a turntable, a turntable motor, a base, a position adjustable plate, a support frame, an angle adjustable plate and a sensor fixture;

[0015] Among them, the base is a horizontally placed flat plate structure; the turntable is installed on the upper surface of the base; the turntable motor is arranged on one side of the turntable; the position adjustable plate is installed on the upper surface of the base; the support frame is vertically arranged on the position adjustable plate; the angle adjustable plate is installed on the top side wall of the support frame, and the angle adjustable plate is rotatably connected to the support frame; the sensor fixture is installed on the angle adjustable plate.

[0016] In the above-mentioned integrated complex part adaptive positioning and surface scanning device, the flexible fixture is arranged on the upper surface of the turntable; the turntable motor drives the turntable to rotate; and the scanning sensor realizes a full range of automatic scanning of the workpiece to be scanned clamped on the flexible fixture.

[0017] In the above-mentioned integrated complex part adaptive positioning and surface scanning device, the scanning sensor is installed on the sensor fixture, and the scanning sensor is rotated in the pitch direction relative to the support frame through the angle adjustable plate to adjust the scanning angle of the scanning sensor.

[0018] In the above-mentioned integrated complex part adaptive positioning and surface scanning device, the position adjustable plate is slidably matched with the base; the support frame is fixedly connected to the position adjustable plate; the position adjustable plate drives the scanning sensor to move horizontally relative to the base.

[0019] The coordinate conversion method of the above-mentioned integrated complex part adaptive positioning and surface scanning device includes:

[0020] Mount the workpiece to be scanned on a flexible fixture;

[0021] The turntable rotates 360°, and the scanning sensor scans and extracts the point cloud data of the outline of the workpiece to be scanned, the relative position of the flexible fixture, and the relative position of the positioning pin; and establishes a scanning coordinate system;

[0022] Clamp the reference plate onto the machine table so that the two adjacent sides of the reference plate are parallel to the y2 axis and x2 axis of the machine respectively; measure the coordinates of the center of the upper surface of the pin hole on the reference plate for installing the positioning pin; measure the point 200mm away from the center of the upper surface of the pin hole on the reference plate in the z2 direction and use it as the tool path origin of the machining coordinate system;

[0023] Realize the coordinate conversion between scanning coordinate system and processing coordinate system.

[0024] In the above coordinate conversion method, the method for establishing the scanning coordinate system is:

[0025] According to the point cloud data, the intersection of the left locating pin axis and the upper surface of the shell is fitted, and the intersection is set as the origin of the scanning coordinate system; the left locating pin axis is set as the z1 axis; the line connecting the intersection of the left and right locating pin axes and the upper surface of the shell is defined as the y1 axis; according to the right-hand rule, the x1 axis is determined.

[0026] In the above coordinate conversion method, in the machining coordinate system, the y2 axis and x2 are two adjacent sides of the machine tool; the origin is the intersection of the y2 axis and x2; and z2 is the vertical upward direction.

[0027] The beneficial effects of the present invention compared with the prior art are:

[0028] (1) The present invention innovatively integrates a 3D scanner with a flexible fixture, and uses a 3D scanner fixed on a frame to accurately capture the morphological data of the workpiece to be processed. This setting allows high-precision scanning of the actual workpiece before processing, ensuring that subsequent processing is based on accurate physical data;

[0029] (2) The present invention uses a turntable in combination with a flexible fixture to fix the workpiece firmly and flexibly. The point cloud data obtained by scanning is then compared with the theoretical model of the workpiece to identify the deviation, so that necessary corrections can be made before processing to ensure processing accuracy.

[0030] (3) The present invention performs high-precision matching and reverse modeling of complex workpiece surfaces based on scanned point cloud data, fundamentally solving bottlenecks in tooling and fixture adaptability, processing accuracy and efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the structure of the scanning device of the present invention;

[0032] Figure 2 It is a schematic diagram of the structure of the flexible clamp of the present invention;

[0033] Figure 3 It is a schematic diagram of the structure of the adjustable scanning turntable of the present invention;

[0034] Figure 4 It is a schematic diagram of the reference plate of the present invention;

[0035] Figure 5 This is a schematic diagram of point cloud data distribution in the present invention;

[0036] Figure 6 It is a schematic diagram of the machining coordinate system of the present invention. DETAILED DESCRIPTION

[0037] The present invention will be further described below in conjunction with the embodiments.

[0038] The present invention provides an integrated complex part adaptive positioning and surface scanning device and a coordinate conversion method. The present invention performs high-precision matching and reverse modeling of complex workpiece surfaces based on scanned point cloud data, fundamentally solving bottlenecks in tooling fixture adaptability, processing accuracy and efficiency.

[0039] Integrated complex parts adaptive positioning and surface scanning device, such as Figure 1 As shown, it specifically includes a flexible fixture 1, an adjustable scanning turntable 2 and a scanning sensor 3. Among them, the adjustable scanning turntable 2 is horizontally arranged; the flexible fixture 1 is horizontally mounted on the adjustable scanning turntable 2; the workpiece to be scanned is mounted on the flexible fixture 1; the scanning sensor 3 is mounted on the top of the adjustable scanning turntable 2; by adjusting the position and angle of the flexible fixture 1 on the adjustable scanning turntable 2, and the position and angle of the scanning sensor 3 on the adjustable scanning turntable 2, the scanning sensor 3 is aligned with the workpiece to be scanned on the flexible fixture 1; and the workpiece to be scanned is scanned by the scanning sensor 3.

[0040] like Figure 2 As shown, the flexible clamp 1 includes a flexible support component 11, two handles 12, a housing 13 and two positioning pins 14. The housing 13 is a horizontally placed frame structure; the flexible support component 11 is arranged on the upper surface of the housing 13; the two handles 12 are symmetrically arranged on the two side walls of the housing 13; and the two positioning pins 14 are symmetrically arranged on the two side walls of the housing 13.

[0041] The upper surface of the flexible support component 11 is in direct contact with the workpiece to be scanned. The upper surface of the flexible support component 11 can adapt to workpieces of different shapes and sizes to be scanned through deformation, thereby ensuring stable fixation of the workpiece to be scanned during the processing process, while reducing the pressure on the surface of the workpiece to be scanned to avoid deformation; the handle 12 facilitates the operator to adjust or move the position of the flexible clamp 1; the positioning pin 14 realizes the precise positioning of the relative position of the flexible clamp 1 and the adjustable scanning turntable 2.

[0042] like Figure 3 As shown, the adjustable scanning turntable 2 includes a turntable 21, a turntable motor 22, a base 23, a position adjustable plate 24, a support frame 25, an angle adjustable plate 26 and a sensor fixture 27. The base 23 is a horizontally placed flat plate structure; the turntable 21 is mounted on the upper surface of the base 23; the turntable motor 22 is arranged on one side of the turntable 21; the position adjustable plate 24 is mounted on the upper surface of the base 23; the support frame 25 is vertically arranged on the position adjustable plate 24; the angle adjustable plate 26 is mounted on the top side wall of the support frame 25, and the angle adjustable plate 26 is rotatably connected to the support frame 25; and the sensor fixture 27 is mounted on the angle adjustable plate 26.

[0043] The flexible fixture 1 is arranged on the upper surface of the turntable 21 ; the turntable motor 22 drives the turntable 21 to rotate; and the scanning sensor 3 is used to realize an all-round automatic scanning of the workpiece to be scanned clamped on the flexible fixture 1 .

[0044] The scanning sensor 3 is mounted on the sensor fixture 27 , and the scanning sensor 3 is rotated in the pitch direction relative to the support frame 25 through the angle-adjustable plate 26 , so that the scanning angle of the scanning sensor 3 is adjusted.

[0045] The position-adjustable plate 24 is slidably matched with the base 23 ; the support frame 25 is fixedly connected to the position-adjustable plate 24 ; the position-adjustable plate 24 drives the scanning sensor 3 to move horizontally relative to the base 23 .

[0046] The coordinate transformation method based on the integrated complex part adaptive positioning and surface scanning device specifically includes the following steps:

[0047] The workpiece to be scanned is mounted on the flexible fixture 1 .

[0048] The turntable 21 rotates 360°, and the scanning sensor 3 scans and extracts the point cloud data of the outline of the workpiece to be scanned, the relative position of the flexible fixture 1, and the relative position of the positioning pin 14, such as Figure 5 As shown. And establish the scanning coordinate system. The method for establishing the scanning coordinate system is:

[0049] According to the point cloud data, the intersection of the axis of the left locating pin 14 and the upper surface of the shell 13 is fitted, and the intersection is set as the origin of the scanning coordinate system; the axis of the left locating pin 14 is set as the z1 axis; the line connecting the intersection of the axis of the locating pins 14 on the left and right sides and the upper surface of the shell 13 is defined as the y1 axis; according to the right-hand rule, the x1 axis is determined.

[0050] Reference board Figure 4 As shown. Clamp the reference plate onto the machine table so that the two adjacent sides of the reference plate are parallel to the y2 axis and x2 axis of the machine respectively; measure the coordinates of the center of the upper surface of the pin hole on the reference plate for installing the positioning pin 14; measure the point 200mm away from the center of the upper surface of the pin hole on the reference plate in the z2 direction and use it as the tool path origin of the machining coordinate system. In the machining coordinate system, the y2 axis and x2 are the two adjacent sides of the machine respectively; the origin is the intersection of the y2 axis and x2; z2 is the vertical upward direction, as shown in the figure. Figure 6 shown.

[0051] Realize the coordinate conversion between scanning coordinate system and processing coordinate system.

[0052] The flexible support component 11 of the present invention is in direct contact with the workpiece, and can adapt to workpieces of different shapes and sizes through its deformable design, thereby ensuring stable fixation of the workpiece during processing, while reducing pressure on the workpiece surface and avoiding deformation; the handles 12 are installed on both sides of the shell 13, so that the operator can easily adjust or move the position of the flexible clamp 1, thereby improving the convenience of loading and unloading the workpiece; the shell 13 serves as the frame of the flexible support component 11, providing the necessary structural strength and stability, and can also integrate control circuits or connect other components; the positioning pin 14 is used to accurately position the relative position of the flexible clamp 1 and the adjustable scanning turntable 2, thereby ensuring the consistency of the position of the workpiece from scanning to processing.

[0053] The turntable 21 is used to carry the flexible fixture 1, and the turntable motor 22 drives the turntable 21 to rotate, and the workpiece clamped on the flexible fixture 1 is automatically scanned in multiple angles and in all directions through the scanning sensor 3. The base 23 provides a stable installation platform for the turntable 21 and the turntable motor 22.

[0054] The angle-adjustable plate 26 further improves the flexibility of the scanning sensor 3. The scanning sensor 3 can be rotated around the center of the angle-adjustable plate 26 according to the specific shape of the workpiece, and the scanning angle of the scanning sensor 3 can be adjusted, thereby achieving an ideal distance setting from the surface of the workpiece to be scanned to obtain high-precision scanning data. The sensor fixture 27 is used to fix the scanning sensor 3 to ensure that the scanning sensor 3 remains stable during the scanning process.

[0055] The position-adjustable plate 24 is connected to the base 23 by bolts, forming a part of the support structure of the adjustable scanning turntable 2; the position-adjustable plate 24 and the support frame 25 are also connected by bolts, forming together an adjustment mechanism for the lateral position of the scanning sensor 3. The scanning sensor 3 can be adjusted in the horizontal direction of the base 23 to adapt to workpieces of different sizes clamped on the flexible fixture 1, and ensure that the scanning sensor 3 maintains an optimal distance from the workpiece.

[0056] The combination of the base 23, the position-adjustable plate 24, the support frame 25, and the angle-adjustable plate 26 greatly enhances the adaptability of the device integrating complex part adaptive positioning and surface scanning to workpieces of different sizes and shapes.

[0057] The reference plate is used in conjunction with the flexible fixture 1, and the distribution of the positioning pin holes on it is consistent with the turntable 21 of the adjustable scanning turntable 2, so that the positioning pins 14 are used to accurately locate the relative position of the flexible fixture 1 and the adjustable scanning turntable 2 or the reference plate. After the reference plate and the flexible fixture 1 are positioned by the positioning pins 14, they are placed on the machine table to achieve high-precision repeated positioning of the workpiece and the tooling; at this time, the two adjacent right-angled edges of the reference plate are straightened and aligned to complete the alignment of the workpiece, which plays the role of consistency between the scanning reference and the processing reference.

[0058] The high-precision surface matching and reverse modeling method based on scanning point cloud data specifically includes the following steps:

[0059] Step 1: Use the ICP (approximate convex hull matching) algorithm to accurately align the scanned complex workpiece blank point cloud data with the workpiece theoretical digital model to ensure that the two are aligned in space;

[0060] Step 2: Through multiple iterations, the ICP algorithm is used to gradually reduce the minimum segmentation distance between the paired points until the accuracy requirements are met, and the deviation area and deviation scale of the workpiece blank relative to the theoretical numerical model are solved;

[0061] Step 3: Based on the optimized blank point cloud data, use the automatic drawing function of software (such as UG-NX) to build the blank CAD model;

[0062] Step 4: Prepare a machining program based on the CAD model of the blank and the theoretical digital model of the workpiece. The G54 of the program should be consistent with the machining G54 of claim 7.

[0063] Finally, the repeated trial cutting operations of the blank before processing are eliminated, and after the machine tool aligns the reference plate, the processing program is directly called to perform surface processing of complex workpieces.

[0064] The present invention innovatively integrates a 3D scanner with a flexible fixture, and uses a 3D scanner fixed on a frame to accurately capture the morphological data of the workpiece to be processed. This setting allows high-precision scanning of the actual workpiece before processing, ensuring that subsequent processing is based on accurate physical data.

[0065] In the present invention, the workpiece is firmly and flexibly fixed by the combined use of a turntable and a flexible clamp, and then the point cloud data obtained by scanning is compared with the theoretical model of the workpiece to identify deviations, so that necessary corrections can be made before processing to ensure processing accuracy.

[0066] Although the present invention has been disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope of the technical solution of the present invention.

Claims

1. Integrated complex parts adaptive positioning and surface scanning device, characterized by: It comprises a flexible fixture (1), an adjustable scanning turntable (2) and a scanning sensor (3); The adjustable scanning turntable (2) is arranged horizontally; the flexible fixture (1) is mounted horizontally on the adjustable scanning turntable (2); the workpiece to be scanned is mounted on the flexible fixture (1); the scanning sensor (3) is mounted on the top of the adjustable scanning turntable (2); by adjusting the position and angle of the flexible fixture (1) on the adjustable scanning turntable (2) and the position and angle of the scanning sensor (3) on the adjustable scanning turntable (2), the scanning sensor (3) is aligned with the workpiece to be scanned on the flexible fixture (1); and the workpiece to be scanned is scanned by the scanning sensor (3).

2. The integrated complex parts adaptive positioning and surface scanning device according to claim 1, characterized in that: The flexible clamp (1) comprises a flexible support component (11), two handles (12), a housing (13) and two positioning pins (14); The shell (13) is a horizontally placed frame structure; the flexible support component (11) is arranged on the upper surface of the shell (13); two handles (12) are symmetrically arranged on the two side walls of the shell (13); and two positioning pins (14) are symmetrically arranged on the two side walls of the shell (13).

3. The integrated complex parts adaptive positioning and surface scanning device according to claim 2, characterized in that: The upper surface of the flexible support component (11) is in direct contact with the workpiece to be scanned. The upper surface of the flexible support component (11) can be deformed to adapt to workpieces of different shapes and sizes to be scanned, thereby ensuring that the workpiece to be scanned is stably fixed during the processing process, while reducing the pressure on the surface of the workpiece to be scanned to avoid deformation; the handle (12) facilitates the operator to adjust or move the position of the flexible clamp (1); and the positioning pin (14) realizes the precise positioning of the relative position of the flexible clamp (1) and the adjustable scanning turntable (2).

4. The integrated complex parts adaptive positioning and surface scanning device according to claim 2, characterized in that: The adjustable scanning turntable (2) comprises a turntable (21), a turntable motor (22), a base (23), a position adjustable plate (24), a support frame (25), an angle adjustable plate (26) and a sensor fixture (27); The base (23) is a flat plate structure placed horizontally; the turntable (21) is mounted on the upper surface of the base (23); the turntable motor (22) is arranged on one side of the turntable (21); the position adjustable plate (24) is mounted on the upper surface of the base (23); the support frame (25) is vertically arranged on the position adjustable plate (24); the angle adjustable plate (26) is mounted on the top side wall of the support frame (25), and the angle adjustable plate (26) is rotatably connected to the support frame (25); and the sensor fixture (27) is mounted on the angle adjustable plate (26).

5. The integrated complex parts adaptive positioning and surface scanning device according to claim 4, characterized in that: The flexible clamp (1) is arranged on the upper surface of a turntable (21); a turntable motor (22) drives the turntable (21) to rotate; and a scanning sensor (3) is used to realize an all-round automatic scanning of a workpiece to be scanned that is clamped on the flexible clamp (1).

6. The integrated complex parts adaptive positioning and surface scanning device according to claim 4, characterized in that: The scanning sensor (3) is mounted on a sensor fixture (27), and the scanning sensor (3) is rotated in a pitch direction relative to the support frame (25) through an angle-adjustable plate (26), thereby adjusting the scanning angle of the scanning sensor (3).

7. The integrated complex parts adaptive positioning and surface scanning device according to claim 4, characterized in that: The position adjustable plate (24) is slidably matched with the base (23); the support frame (25) is fixedly connected to the position adjustable plate (24); and the position adjustable plate (24) drives the scanning sensor (3) to move in a horizontal direction relative to the base (23).

8. The coordinate conversion method of the integrated complex part adaptive positioning and surface scanning device according to claim 4, characterized in that: include: Mounting the workpiece to be scanned on a flexible fixture (1); The turntable (21) rotates 360 degrees, and the scanning sensor (3) is used to scan and extract point cloud data of the outline of the workpiece to be scanned, the relative position of the flexible fixture (1), and the relative position of the positioning pin (14); and a scanning coordinate system is established; Clamp the reference plate onto the machine table so that two adjacent sides of the reference plate are parallel to the y2 axis and the x2 axis of the machine respectively; measure the coordinates of the center of the upper surface of the pin hole on the reference plate for installing the positioning pin (14); measure the point 200 mm away from the center of the upper surface of the pin hole on the reference plate in the z2 direction and use it as the tool path origin of the machining coordinate system; Realize the coordinate conversion between the scanning coordinate system and the processing coordinate system.

9. The coordinate conversion method according to claim 8, characterized in that: The method for establishing the scanning coordinate system is: The intersection of the axis of the left positioning pin (14) and the upper surface of the shell (13) is fitted according to the point cloud data, and the intersection is set as the origin of the scanning coordinate system; the axis of the left positioning pin (14) is set as the z1 axis; the line connecting the intersection of the axis of the positioning pins (14) on the left and right sides and the upper surface of the shell (13) is defined as the y1 axis; and the x1 axis is determined according to the right-hand rule.

10. The coordinate conversion method according to claim 8, characterized in that: In the machining coordinate system, the y2 axis and the x2 axis are two adjacent sides of the machine tool; the origin is the intersection of the y2 axis and the x2 axis; and the z2 axis is the vertical upward direction.

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