Vertical three-axis flame cutting device and process

Abstract

The invention relates to the technical field of flame cutting, in particular to a vertical three-axis flame cutting device and process, the cutting process comprises the following steps of finished product model input, semi-finished product data collection, data processing, difference detection, path marking and ignition cutting, the cutting device matched with the process comprises a support, and an operation table is fixed to the support; an infrared camera shooting assembly is arranged around the operation table, an integrated control system is arranged behind the operation table, an xyz three-axis sliding assembly is arranged in the support, and a cutting assembly is fixedly connected to the lower portion of the y-axis sliding assembly. A cutting path is automatically generated through infrared camera shooting recognition and data processing, cutting, modifying and reprocessing of a product which is in a complete or semi-finished state and cannot return to a numerical control cutting line can be achieved, three-dimensional point cloud is generated through stereo matching three-dimensional reconstruction in the data processing process, a cutting arm is controlled in cooperation with a three-axis stepping sliding table, and the cutting precision is improved. And the device is suitable for three-dimensional element processing and high in automation degree.

Description

Technical Field

[0001] The present invention relates to the field of flame cutting technology, and in particular to a vertical three-axis flame cutting device and process. Background Art

[0002] CNC cutting machine is a kind of equipment that uses digital control technology to perform automatic cutting. This equipment controls the action of the cutting head through a pre-written program, thereby achieving precise cutting of materials. CNC cutting machines are widely used in metal processing, shipbuilding, automobile manufacturing, aerospace and various manufacturing production lines.

[0003] However, if a finished or semi-finished product needs to be cut, modified, opened, etc., the established shape will change and the clamping form will also change accordingly. The established cutting route of the CNC cutting machine on the original production line cannot be adjusted according to the actual situation and may no longer be applicable. At this time, if manual line cutting is used, the cutting efficiency and cutting quality are affected by human factors, and the appearance after cutting is uneven, which requires additional manpower and material resources to improve.

[0004] Therefore, in order to solve the above problems, a related facility that better meets the usage requirements is needed. Summary of the invention

[0005] In view of this, the purpose of the present invention is to provide a vertical three-axis flame cutting machine to solve the problem of cutting, modification and opening of products that are already completed or semi-finished and cannot be returned to the CNC cutting line.

[0006] Based on the above purpose, the present invention provides a vertical three-axis flame cutting device, including a bracket, an operating table is fixedly connected to the bottom of the bracket, an integrated control system is arranged behind the operating table, infrared camera components are arranged in all directions around the operating table, z-axis sliding components are arranged on both sides of the bracket, an x-axis sliding component is slidably connected to the front of the z-axis sliding component, a y-axis sliding component is slidably connected below the x-axis sliding component, and a cutting component is arranged below the y-axis sliding component.

[0007] Furthermore, the support (1) comprises four columns and a cross beam between the columns, the four columns are respectively a front left column (101), a front right column (102), a rear left column (103) and a rear right column (104), the front left column (101), the front right column (102), the rear left column (103) and the rear right column (104) are arranged in a rectangular shape and are fixedly connected to a bottom plate (9) at the bottom, and an upper cross beam (105) and a lower cross beam (106) are fixedly connected to the upper and lower ends of the rear left column (103) and the rear right column (104).

[0008] Furthermore, the z-axis sliding assembly is provided with two groups, and the two groups of z-axis sliding assemblies are respectively located outside the front left column and the front right column, each group of z-axis sliding assemblies includes a z-axis servo motor fixedly connected to the top of the base plate, and the output end of the z-axis servo motor is fixedly connected to the z-axis lead screw, and the front of the front left column (101) and the front right column (102) are provided with z-axis slide rails.

[0009] Furthermore, the x-axis sliding assembly includes an x-axis crossbeam slidably connected between two groups of z-axis sliding assemblies, two groups of z-axis threaded sleeves and z-axis sliders are fixedly connected on both sides of the rear of the x-axis crossbeam, the z-axis threaded sleeves are adapted and sleeved on the z-axis lead screw, the z-axis slider is slidably connected in the z-axis slide rail, an x-axis servo motor is fixedly connected to the front of the x-axis crossbeam, the x-axis lead screw is fixedly connected to the output end of the x-axis servo motor, and an x-axis slide rail is opened on the bottom surface of the x-axis crossbeam.

[0010] Furthermore, the y-axis sliding assembly includes a y-axis skateboard slidably connected to the bottom of the x-axis sliding assembly, the top of the y-axis skateboard is fixedly connected to the x-axis threaded sleeve and the x-axis slider, the x-axis threaded sleeve is adapted and sleeved on the x-axis lead screw, the x-axis slider is slidably connected to the x-axis slide rail, the front of the y-axis skateboard is fixedly connected to the y-axis servo motor, the output end of the y-axis servo motor is fixedly connected to the y-axis lead screw, and the bottom surface of the y-axis skateboard is provided with a y-axis slide rail.

[0011] Furthermore, the cutting assembly includes a cutting arm slidably connected to the bottom of the y-axis sliding assembly, a y-axis threaded sleeve and a y-axis slider are fixedly connected to the top of the cutting arm, the y-axis threaded sleeve is adapted and sleeved on the y-axis screw rod, the y-axis slider is slidably connected to the y-axis slide rail, a cutting nozzle is detachably provided at the front of the cutting arm, and an ultrasonic sensor is fixed to the bottom surface of the cutting arm, and the ultrasonic sensor is used to measure the thickness of the processing element.

[0012] Furthermore, a reduction gear set is provided at the output ends of the z-axis servo motor, the x-axis servo motor and the y-axis servo motor.

[0013] Furthermore, the infrared camera assembly includes a left infrared camera fixedly connected to the right side of the rear left pillar, a right infrared camera fixedly connected to the left side of the rear right pillar, an upper infrared camera fixedly connected to the bottom surface of the upper beam, and a front infrared camera fixedly connected to the back side of the x-axis beam.

[0014] A vertical three-axis flame cutting process implemented by the vertical three-axis flame cutting device includes the following steps: S1: Finished product model input: import the three-dimensional model of the finished product model into the integrated control system; S2: Semi-finished product data collection: Use infrared camera components to capture images of semi-finished products to be cut from various angles to determine the material, position, edge and key reference points of the semi-finished products; S3: Data processing: grayscale and denoising are performed on the collected images, edge detection and contour extraction are performed on the components in the images, stereo matching is performed based on images from different angles, and a three-dimensional point cloud is generated; S4: Difference detection: The difference between the semi-finished product model and the finished product model is obtained through point cloud registration and difference detection. For semi-finished products that can be processed by cutting, the A* algorithm is used to plan the optimal cutting path. Those that cannot be processed into finished products are considered defective products. S5: Path marking: convert the optimal path into control instructions for the sliding component and the cutting component, replace the cutting nozzle with chalk or a marker, run the control instructions to draw the cutting path on the semi-finished product model, determine the thickness of the semi-finished component on the cutting path through the ultrasonic sensor, compare the marked path with the finished product three-dimensional model through the infrared camera component, and continuously adjust and determine the cutting path; S6: Ignition cutting: According to the material information obtained by the infrared camera component and the thickness information on the cutting path obtained by the ultrasonic sensor, select the appropriate cutting nozzle and fuel gas flame type, and perform ignition cutting operations according to the determined cutting path.

[0015] Beneficial effects of the present invention: 1. The present invention collects semi-finished product model data through infrared camera recognition and compares it with the finished product model, automatically generates a cutting path, and can realize cutting, modification and reprocessing of products that are already completed or semi-finished and cannot be returned to the CNC cutting line. Compared with manual marking and cutting, it saves manpower and material costs and improves production efficiency; 2. The data processing process of the present invention adopts stereo matching three-dimensional reconstruction to generate three-dimensional point cloud, and the cutting process adopts a three-axis stepping slide to control the cutting arm, so that the process can be used for complex three-dimensional component processing, with a wide range of applications. Compared with the horizontal structure, it occupies a smaller area and is easier for the operator to observe.

[0016] 3. The present invention collects semi-finished product material information through an infrared camera and collects semi-finished product thickness information through an ultrasonic sensor to assist in selecting a suitable cutting nozzle and gas flame type, which is energy-saving and efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A front axonometric view of an embodiment of the present invention; Figure 2 A rear axonometric view of an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a cutting assembly according to an embodiment of the present invention; Figure 4 This is a cutting process flow chart of an embodiment of the present invention.

[0018] The markings in the figure are: 1. bracket; 101. front left column; 102. front right column; 103. rear left column; 104. rear right column; 105. upper beam; 106. lower beam; 2. operating table; 3. integrated control system; 401. left infrared camera; 402. right infrared camera; 403. upper infrared camera; 404. front infrared camera; 501. z-axis servo motor; 502. z-axis screw rod; 503. z-axis slide rail; 601. x-axis beam; 602. 02, z-axis threaded sleeve; 603, z-axis slider; 604, x-axis servo motor; 605, x-axis lead screw; 606, x-axis slide rail; 701, y-axis slide plate; 702, x-axis threaded sleeve; 703, x-axis slider; 704, y-axis servo motor; 705, y-axis lead screw; 706, y-axis slide rail; 801, cutting arm; 802, y-axis threaded sleeve; 803, y-axis slider; 804, cutting nozzle; 805, ultrasonic sensor; 9, base plate. DETAILED DESCRIPTION

[0019] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with specific embodiments.

[0020] This embodiment proposes a vertical three-axis flame cutting device, such as Figure 1 and Figure 2 As shown, a bracket 1 is composed of four columns and beams between the columns. The four columns are arranged in a rectangular shape, namely, a front left column 101, a front right column 102, a rear left column 103 and a rear right column 104. A bottom plate 9 is fixedly connected to the bottom of each column. An upper beam 105 and a lower beam 106 are fixedly connected between the rear left column 103 and the rear right column 104. An operating table 2 is fixedly connected to the top of the lower beam 106. An integrated control system 3 is arranged behind the operating table 2. The integrated control system 3 integrates a visual system and a robot arm control system, and is used to process image information to generate a cutting path, and control the movement direction of a cutting nozzle 804 according to the cutting path. Infrared camera components are arranged in various directions around the operating table 2, including a left infrared camera 401, a right infrared camera 402, an upper infrared camera 403 and a front infrared camera 404. The infrared camera model used in this embodiment is Xenics Bobcat320, manufactured by Belgian company Xenics, is used to enter the appearance characteristics and material of semi-finished models into the integrated control system 3. An xyz three-axis sliding component is arranged between the front left column 101 and the front right column 102, and a cutting component is fixedly connected below the y-axis sliding component.

[0021] like Figure 1As shown, there are two groups of z-axis sliding components, which are separated on the outer sides of the front left column 101 and the front right column 102. Each group of z-axis sliding components includes a z-axis servo motor 501 fixedly connected to the top of the base plate 9, and the output end of the z-axis servo motor 501 is fixedly connected to the z-axis lead screw 502, and the front side of the front column is provided with a z-axis slide rail 503; the x-axis sliding component is slidably connected between the two groups of z-axis sliding components through two groups of z-axis threaded sleeves 602 and z-axis sliders 603 at the rear of the x-axis crossbeam 601, the front part of the x-axis crossbeam 601 is fixedly connected to the x-axis servo motor 604, the output end of the x-axis servo motor 604 is fixedly connected to the x-axis lead screw 605, and the bottom surface of the x-axis crossbeam 601 is provided with an x-axis slide rail 606, and the y-axis sliding component is connected to the x-axis at the top of the y-axis slide plate 701. The threaded sleeve 702, the x-axis slider 703 and the x-axis threaded sleeve 702 are slidably connected below the x-axis sliding assembly, and a y-axis servo motor 704 is fixedly connected to the front of the y-axis slide 701, and a y-axis lead screw 705 is fixedly connected to the output end of the y-axis servo motor 704. A y-axis slide rail 706 is provided on the bottom surface of the y-axis slide 701, and a reduction gear set is provided at the output end of each servo motor to reduce the speed of the servo motor output shaft and increase the torque. The functions and structures of conventional equipment such as servo motors and reduction gear sets are well known in the art, and the connection settings are also common knowledge, so no further explanation is given here, and it is not shown in the accompanying drawings. The xyz three-axis sliding assembly is controlled by an integrated control system 3, which can control the operation of the cutting assembly according to the cutting path to complete the cutting work.

[0022] like Figure 3 As shown, the cutting arm 801 in the cutting assembly is slidably connected to the bottom of the y-axis sliding assembly through the top y-axis threaded sleeve 802 and the y-axis slider 803. The front of the cutting arm 801 is detachably provided with a cutting nozzle 804, and the bottom surface of the cutting arm 801 is fixed with an ultrasonic sensor 805. The ultrasonic sensor 805 is used to measure the thickness of each part of the processing element, providing a reference for selecting a suitable cutting nozzle 804 model and a fuel gas model.

[0023] like Figure 4 As shown, a vertical three-axis flame cutting process implemented by using the above-mentioned vertical three-axis flame cutting device includes the following steps: S1: Finished product model input: importing the three-dimensional model of the finished product model into the integrated control system 3; S2: Semi-finished product data collection: Use infrared camera components to capture images of semi-finished products to be cut from various angles to determine the material, position, edge and key reference points of the semi-finished products; S3: Data Processing S31: Preprocessing: converting the color image into a grayscale image, performing grayscale processing, and using median filtering or Gaussian filtering to remove noise in the image; S32: Feature extraction: Use the Canny edge detection algorithm or the Sobel operator to detect edges in the image, and use the contour detection function of OpenCV to extract contours; S33: 3D reconstruction: Use StereoBM or StereoSGBM stereo matching algorithm to calculate the disparity map and generate 3D point cloud data based on the disparity map; S4: Difference detection: The difference between the semi-finished product model and the finished product model is obtained through point cloud registration and difference detection. For semi-finished products that can be processed by cutting, the A* algorithm is used to plan the optimal cutting path. Those that cannot be processed into finished products are considered defective products. S5: Path marking: convert the optimal path into control instructions for the sliding component and the cutting component, replace the cutting nozzle 804 with chalk or a marker, run the control instructions to draw the cutting path on the semi-finished product model, determine the thickness of the semi-finished product component on the cutting path through the ultrasonic sensor 805, compare the marked path with the finished product three-dimensional model through the infrared camera component, and continuously adjust and determine the cutting path; S6: Ignition cutting: According to the material information obtained by the infrared camera assembly and the thickness information on the cutting path obtained by the ultrasonic sensor 805, a suitable cutting nozzle 804 and fuel gas flame type are selected, and an ignition cutting operation is performed according to the determined cutting path.

[0024] Working principle: The device of the present invention is a vertical structure, which occupies a smaller area than the horizontal structure, and the operator can more easily observe and control the cutting process. The cutting arm 801 is controlled by a three-axis stepping slide to perform three-axis mobile cutting, which is suitable for the processing of complex three-dimensional components. An infrared camera is set to identify and collect semi-finished product model data, and it can cope with different actual situations with the integrated control system 3. The semi-finished product thickness information is collected by the ultrasonic sensor 805 to assist in selecting the appropriate cutting nozzle 804 and gas flame type. The process of the present invention generates a three-dimensional point cloud through stereo matching three-dimensional reconstruction, and identifies defective products and processable semi-finished products through difference detection, with a high degree of automation.

Claims

1. A vertical three-axis flame cutting device, comprising a bracket (1), characterized in that: The bottom of the support (1) is fixedly connected to an operating table (2), an integrated control system (3) is arranged behind the operating table (2), an infrared camera assembly is arranged around the operating table (2), z-axis sliding assemblies are arranged on both sides of the support (1), an x-axis sliding assembly is slidably connected in front of the z-axis sliding assembly, a y-axis sliding assembly is slidably connected below the x-axis sliding assembly, and a cutting assembly is arranged below the y-axis sliding assembly.

2. The vertical three-axis flame cutting device according to claim 1 is characterized in that: The bracket (1) comprises four columns and a cross beam between the columns. The four columns are respectively a front left column (101), a front right column (102), a rear left column (103) and a rear right column (104). The front left column (101), the front right column (102), the rear left column (103) and the rear right column (104) are arranged in a rectangular shape and are fixedly connected to a bottom plate (9) at the bottom. The upper and lower ends of the rear left column (103) and the rear right column (104) are fixedly connected to an upper cross beam (105) and a lower cross beam (106).

3. The vertical three-axis flame cutting device according to claim 2 is characterized in that: The z-axis sliding assembly is provided in two groups, and the two groups of z-axis sliding assemblies are respectively located outside the front left column (101) and the front right column (102), each group of z-axis sliding assemblies comprises a z-axis servo motor (501) fixedly connected to the top of the base plate (9), the output end of the z-axis servo motor (501) is fixedly connected to the z-axis lead screw (502), and the front sides of the front left column (101) and the front right column (102) are provided with z-axis slide rails (503).

4. The vertical three-axis flame cutting device according to claim 3 is characterized in that: The x-axis sliding assembly comprises an x-axis crossbeam (601) slidably connected between two groups of z-axis sliding assemblies; two groups of z-axis threaded sleeves (602) and z-axis sliders (603) are fixedly connected to both sides of the rear of the x-axis crossbeam (601); the z-axis threaded sleeves (602) are adapted to and sleeved on the z-axis lead screw (502); the z-axis slider (603) is slidably connected in the z-axis slide rail (503); an x-axis servo motor (604) is fixedly connected to the front of the x-axis crossbeam (601); an x-axis lead screw (605) is fixedly connected to the output end of the x-axis servo motor (604); and an x-axis slide rail (606) is provided on the bottom surface of the x-axis crossbeam (601).

5. The vertical three-axis flame cutting device according to claim 4 is characterized in that: The y-axis sliding assembly comprises a y-axis slide plate (701) slidably connected to the bottom of the x-axis sliding assembly; the top of the y-axis slide plate (701) is fixedly connected to an x-axis threaded sleeve (702) and an x-axis slider (703); the x-axis threaded sleeve (702) is adapted to and sleeved on an x-axis lead screw (605); the x-axis slider (703) is slidably connected to an x-axis slide rail (606); the front of the y-axis slide plate (701) is fixedly connected to a y-axis servo motor (704); the output end of the y-axis servo motor (704) is fixedly connected to the y-axis lead screw (705); and the bottom surface of the y-axis slide plate (701) is provided with a y-axis slide rail (706).

6. The vertical three-axis flame cutting device according to claim 5, characterized in that: The cutting assembly comprises a cutting arm (801) slidably connected to the bottom of the y-axis sliding assembly, a y-axis threaded sleeve (802) and a y-axis slider (803) are fixedly connected to the top of the cutting arm (801), the y-axis threaded sleeve (802) is adapted to and sleeved on the y-axis lead screw (705), the y-axis slider (803) is slidably connected to the inside of the y-axis slide rail (706), a cutting nozzle (804) is detachably provided at the front of the cutting arm (801), and an ultrasonic sensor (805) is fixed to the bottom surface of the cutting arm (801), and the ultrasonic sensor (805) is used to measure the thickness of the processing element.

7. The vertical three-axis flame cutting device according to claim 6, characterized in that: The output ends of the z-axis servo motor (501), the x-axis servo motor (604) and the y-axis servo motor (704) are all provided with a reduction gear set.

8. The vertical three-axis flame cutting device according to claim 4, characterized in that: The infrared camera assembly comprises a left infrared camera (401) fixedly connected to the right side of the rear left column (103), a right infrared camera (402) fixedly connected to the left side of the rear right column (104), an upper infrared camera (403) fixedly connected to the bottom surface of the upper crossbeam (105), and a front infrared camera (404) fixedly connected to the back side of the x-axis crossbeam (601).

9. A vertical three-axis flame cutting process, using the vertical three-axis flame cutting device according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: Finished product model input: import the three-dimensional model of the finished product model into the integrated control system (3); S2: Semi-finished product data collection: Use infrared camera components to capture images of semi-finished products to be cut from various angles to determine the material, position, edge and key reference points of the semi-finished products; S3: Data processing: grayscale and denoising are performed on the collected images, edge detection and contour extraction are performed on the components in the images, stereo matching is performed based on images from different angles, and a three-dimensional point cloud is generated; S4: Difference detection: The difference between the semi-finished product model and the finished product model is obtained through point cloud registration and difference detection. For semi-finished products that can be processed by cutting, the A* algorithm is used to plan the optimal cutting path. Those that cannot be processed into finished products are considered defective products. S5: path marking: converting the optimal path into control instructions for the sliding component and the cutting component, replacing the cutting nozzle (804) with chalk or a marker, running the control instructions to draw a cutting path on the semi-finished product model, determining the thickness of the semi-finished product component on the cutting path through the ultrasonic sensor (805), comparing the marked path with the finished product three-dimensional model through the infrared camera component, and continuously adjusting and determining the cutting path; S6: Ignition cutting: According to the material information obtained by the infrared camera component and the thickness information on the cutting path obtained by the ultrasonic sensor (805), a suitable cutting nozzle (804) and fuel gas flame type are selected, and an ignition cutting operation is performed according to the determined cutting path.

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