A secondary tool setting device for a fully automated gear-making machine based on vision recognition

Abstract

This invention belongs to the field of gear processing and relates to a vision-based fully automatic gear-making equipment secondary tool setting device, used to solve the problem of interrupted processing of intermediate parts in gear processing, where the original tool position cannot be re-set after disassembly. The invention includes: a controllable high-precision motor (1) connected to the gear-making equipment spindle (2) via a transmission; the gear (3) to be processed is mounted on the spindle (2); an industrial camera (5) is connected to a grating slide rail (4) and can slide up and down along the grating slide rail (4) to a position aligned with the center line of the gear-making equipment spindle (2), so that the center line of the lens of the industrial camera (5) is on the same straight line as the center line of the gear-making equipment spindle (2); the industrial camera (5) captures the angular position of the gear (3); the cable of the industrial camera (5) passes through the grating slide rail (4) and is connected to the controllable high-precision motor (1); the industrial camera (5) controls the rotation of the controllable high-precision motor (1) via the cable. This invention is applicable to secondary tool setting in gear processing.

Description

Technical Field

[0001] This invention belongs to the field of gear processing and relates to a secondary tool setting device for a fully automatic gear-making equipment based on vision recognition. Background Technology

[0002] Commonly used gear-making equipment on the market includes gear hobbing machines and gear shaping machines, both of which utilize the generating method and are driven by high-precision motors. However, these machines lack adequate secondary tool setting capabilities. During processing, parts are sometimes removed from the equipment for measurement or trial engagement. If secondary machining is required, the parts cannot be quickly and easily repositioned, resulting in scrap. Existing devices use mechanical alignment, which introduces accuracy errors and requires manual operation, heavily relying on operator skill and experience. This results in long tool setting cycles and prevents fully automated secondary tool setting. Summary of the Invention

[0003] The technical problem to be solved by the present invention is: a secondary tool setting device for a fully automatic gear making equipment based on vision recognition, which is used to solve the problem that the intermediate parts are interrupted during the gear processing and cannot be repositioned to their original positions after disassembly.

[0004] The technical solution of this invention is:

[0005] A secondary tool setting device for a fully automated gear-making equipment based on vision recognition includes: a controllable high-precision motor 1, a grating slide rail 4, and an industrial camera 5;

[0006] The controllable high-precision motor 1 is connected to the main shaft 2 of the gear-making equipment through a transmission. The gear 3 to be processed is installed on the main shaft 2 of the gear-making equipment. The industrial camera 5 is connected to the grating slide rail 4 and can slide up and down along the grating slide rail 4 to be aligned with the center line of the main shaft 2 of the gear-making equipment, so that the center line of the lens of the industrial camera 5 is on the same straight line as the center line of the main shaft 2 of the gear-making equipment. The industrial camera 5 captures the angular position of the gear 3 to be processed. The cable of the industrial camera 5 passes through the grating slide rail 4 and is connected to the controllable high-precision motor 1. The industrial camera 5 controls the rotation of the controllable high-precision motor 1 through the cable.

[0007] The industrial camera 5 has an accuracy of no less than 0.005mm and comes with its own light source, lens, light control and computing host.

[0008] The accuracy of the controllable high-precision motor 1 needs to be within the range of 0.002mm.

[0009] Before the gear 3 is removed after processing, the grating slide rail 4 runs to drive the industrial camera 5 to align with the gear 3. The center of the lens of the industrial camera 5 is on the same straight line as the main shaft 2 of the gear making equipment. The angular position of the gear 3 is recorded for the first time. The recorded position is the radial symmetrical bisector of the center of the gear 3 and the highest tooth in the vertical direction. After recording, the gear 3 can be removed.

[0010] After the gear 3 is reassembled, the grating slide rail 4 runs again, driving the industrial camera 5 to align with the gear 3 and record the second angular position of the gear 3. The recording position is still the radial symmetrical bisector of the center of the gear 3 and the highest tooth in the vertical direction. The bisector formed by the two recording positions will form an angle α with the center of the gear 3. The industrial camera 5 drives the controllable high-precision motor 1 to rotate, eliminating the angle α.

[0011] The industrial camera 5 drives the controllable high-precision motor 1 to rotate, eliminating the included angle α specifically as follows:

[0012] The images captured by the industrial camera 5 through the lens are post-processed by vision software, and compared with the two gear images captured before and after. At this time, the parallelism between the end face of the gear cutting equipment spindle 2 and the end face of the gear 3 when the gear 3 is clamped needs to be considered. The horizontal angle between the lens and the plane of the gear 3 is calculated to obtain the horizontal alignment constant α. By comparing each tooth profile of the two gear images captured before and after, the boundary blur constant α can be obtained for blur compensation. After compensation by combining the horizontal alignment constant and the boundary blur constant, the angle α1 is calculated. At this time, the host of the industrial camera feeds the α1 feedback signal to the controllable high-precision motor 1. The controllable high-precision motor 1 drives the gear cutting equipment spindle 2 to rotate by an angle of α1 to complete the secondary tool setting action of the gear being processed.

[0013] Feedback angle calculation formula: α1=α±α 水平 ±α 模糊补偿 .

[0014] Where α is the included angle calculated from two image capture measurements, α 水平 For leveling constants, α 模糊补偿 It is a constant with fuzzy boundaries.

[0015] If the offset angle is too large during the second clamping of the gear 3 being processed, or if the camera cannot be aligned, the indicator light of the industrial camera 5 will light up, and the feedback signal will stop the equipment from starting.

[0016] The beneficial effects of this application are as follows: This device adopts an image recognition and capture method. By comparing the angle differences between images before and after disassembly and after installation, and combining this with the calculation of compensation, it realizes the secondary tool setting function of the gear-making equipment. This eliminates the reliance on manual labor for secondary tool setting in gear-making equipment, greatly saving manual labor. It is also compatible with different types of machined parts such as gears and turbines, and is compatible with different types of equipment such as gear hobbing machines and gear shaping machines. The secondary tool setting accuracy can typically reach around 0.005, and the accuracy can be further improved by combining the capabilities of the applied components. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention.

[0018] Figure 2 This is a front view and a centering diagram of the present invention. Detailed Implementation

[0019] The present application will be further described in detail below with reference to the accompanying drawings of the embodiments.

[0020] Figure 1 This is a schematic diagram of the secondary tool setting device of a fully automatic gear-making equipment based on vision recognition. The controllable high-precision motor 1 is connected to the main shaft 2 of the gear-making equipment through transmission. The gear 3 to be processed is installed on the main shaft 2 of the gear-making equipment. The grating slide rail 4 helps the industrial camera 5 to align the gear 3 to be processed. The industrial camera 5 integrates a light source, lens, light control and host, and can accurately capture the angular position of the gear 3 to be processed.

[0021] Figure 2 The image shows the positions of the gear 3 before it was removed from the machine and the gear 3' after it was re-clamped, captured by an industrial camera. The two positions are shown in the image as rotated by an angle α.

[0022] Figure 2 The α angle captured by the camera is processed into signal α1 by the host of the industrial camera 5 and fed back to the controllable high-precision motor of component 1. The motor drives the spindle of the gear-making equipment to rotate, thus completing the secondary tool setting action.

[0023] The present invention is designed to address the situation where the processing of intermediate parts is interrupted during gear machining, and the original position of the tool cannot be repositioned after disassembly. This device can be used in conjunction with gear hobbing machines, gear shaping machines, and other equipment that use the involute method to process gears, efficiently and accurately locating the position of the part before disassembly and completing the secondary tool setting action.

[0024] like Figure 1 , 2 As shown, the embodiments of the present invention include: a controllable high-precision motor 1, a grating slide rail 4, and an industrial camera 5;

[0025] The controllable high-precision motor 1 is connected to the main shaft 2 of the gear-making equipment through a transmission. The gear 3 to be processed is installed on the main shaft 2 of the gear-making equipment. The industrial camera 5 is connected to the grating slide rail 4 and can slide up and down along the grating slide rail 4 to be aligned with the center line of the main shaft 2 of the gear-making equipment, so that the center line of the lens of the industrial camera 5 is on the same straight line as the center line of the main shaft 2 of the gear-making equipment. The industrial camera 5 captures the angular position of the gear 3 to be processed. The cable of the industrial camera 5 passes through the grating slide rail 4 and is connected to the controllable high-precision motor 1. The industrial camera 5 controls the rotation of the controllable high-precision motor 1 through the cable.

[0026] Before the gear is disassembled after processing, the device operates via a grating slide rail, driving an industrial camera to align with the gear being processed. The center of the industrial camera lens is aligned with the rotation center of the gear being processed, i.e., the spindle of the gear-making equipment. The first recording of the gear's angular position is taken at the radial symmetrical bisector of the center of the gear and the highest tooth in the vertical direction. After recording, the gear can be disassembled for measurement or meshing transmission tests. During the second processing, the gear can be mounted on the spindle of the gear-making equipment at any angular position. The grating slide rail operates again, driving the industrial camera to align with the gear being processed, and recording the gear's angular position a second time. The recording position is again taken at the radial symmetrical bisector of the center of the gear and the highest tooth in the vertical direction. The bisector formed by the two recording positions forms an angle α with the center of the gear.

[0027] The images captured by the industrial camera through the lens are post-processed by vision software, and the two captured gear images are compared. At this time, the parallelism between the end face of the gear-making equipment spindle and the end face of the gear being processed must be taken into account when the part is clamped. The horizontal angle between the lens and the plane of the gear being processed is calculated to obtain the constant α for horizontal alignment. 水平 By comparing the tooth profiles of the two captured gear images, the boundary blur constant α can be obtained. 模糊补偿 After compensating for the horizontal alignment constant and the boundary fuzziness constant, the included angle α1 is calculated. At this time, α1 is an accurate value obtained through a series of calculations such as direct capture, horizontal alignment, and boundary fuzziness compensation, which can avoid errors caused by the precision of the industrial camera, the light source, and the algorithm. At this time, the host of the industrial camera feeds the α1 feedback signal to the controllable high-precision motor. This controllable high-precision motor is usually a high-precision servo motor or a worm gear transmission system driven by a motor to ensure transmission accuracy. The motor drives the spindle of the gear cutting equipment to rotate by an angle of α1. At this time, it is necessary to control the motor speed and reduce the action speed to reduce the moment of inertia, so as to complete the angular adjustment of the gear being processed. At this time, the tool spindle of the gear cutting equipment remains stationary, and the secondary tool setting action of the gear being processed can be completed.

[0028] Feedback angle calculation formula: α1=α±α 水平 ±α 模糊补偿

[0029] The rotation angle α1 of the gear being machined after the second clamping, adjusted by the device, is α calculated through two image capture measurements, and is also a constant α for horizontal alignment. 水平 Boundary fuzzy constant α 模糊补偿 It was obtained through joint calculation.

[0030] The industrial camera must have an accuracy of 0.005mm and come with its own light source, lens, light control, and computing host.

[0031] The grating guide rail must ensure that the industrial camera lens can be directly facing the end face of the gear being processed, allowing for a complete observation of the gear's involute profile. Simultaneously, any offset caused by the grating guide rail and camera position must be corrected by a horizontally calibrated constant α. 水平 Compensation will be provided.

[0032] The device can provide feedback on the clamping status of the gear being processed. If the gear being processed experiences problems such as excessive offset angle or camera misalignment during secondary clamping, the industrial camera indicator light will illuminate, and the feedback signal will stop the equipment from starting.

[0033] The accuracy of the controllable high-precision motor needs to be within 0.002mm to ensure the final alignment accuracy.

[0034] The device can be used to align the tool position of parts twice, and is compatible with different machined parts such as gears and turbines, as well as gear making equipment such as gear hobbing machines and gear shaping machines.

[0035] The device needs to be installed inside the equipment, leveled, and the accuracy of the camera's image acquisition needs to be ensured. The program needs to be embedded in the original equipment control module and directly drive the controllable high-precision motor.

[0036] The overall accuracy of the structure can still be improved as the precision of the industrial cameras and controllable high-precision motors used in the application increases.

[0037] This invention solves the problem that gear-making equipment cannot complete a secondary tool setting to the original position and continue the original machining after gear disassembly for measurement and meshing tests. It utilizes a fully automatic secondary tool setting method, overcoming the reliance on manual experience and low efficiency of mechanical secondary tool setting devices. The fully automatic alignment process is not limited to any particular type of gear-making equipment; it is applicable to all gear-making equipment driven by controllable high-precision motors. After simple installation, the equipment itself can complete the entire tool setting process. Because the device is driven by a controllable high-precision motor, the tool setting accuracy is extremely high.

Claims

1. A secondary tool setting device for a fully automated gear-making equipment based on vision recognition, characterized in that, include: Controllable high-precision motor (1), grating slide rail (4), industrial camera (5); the controllable high-precision motor (1) is connected to the gear-making equipment spindle (2) through transmission, and the gear (3) to be processed is installed on the spindle of the gear-making equipment spindle (2); the industrial camera (5) is connected to the grating slide rail (4) and can slide up and down along the grating slide rail (4) to be aligned with the center line of the gear-making equipment spindle (2), so that the center line of the lens of the industrial camera (5) is on the same straight line as the center line of the gear-making equipment spindle (2), and the angular position of the gear (3) to be processed is captured by the industrial camera (5), the cable of the industrial camera (5) passes through the grating slide rail (4) and is connected to the controllable high-precision motor (1), and the industrial camera (5) controls the rotation of the controllable high-precision motor (1) through the cable; Before the gear (3) is removed after processing, the grating slide rail (4) runs to drive the industrial camera (5) to align with the gear (3). The center of the lens of the industrial camera (5) is on the same straight line as the main shaft (2) of the gear making equipment. The angular position of the gear (3) is recorded for the first time. The recording position is the radial symmetrical bisector of the center of the gear (3) and the highest tooth in the vertical direction. After recording, the gear (3) can be removed. After the gear (3) is reassembled, the grating slide rail (4) runs again, driving the industrial camera (5) to align with the gear (3) and record the second angular position of the gear (3). The recording position is still the radial symmetrical bisector of the center of the gear (3) and the highest tooth in the vertical direction. The bisector formed by the two recording positions will form an angle α with the center of the gear (3). The industrial camera (5) drives the controllable high-precision motor (1) to rotate, eliminating the angle α.

2. The secondary tool setting device for a fully automated gear-making equipment based on vision recognition as described in claim 1, characterized in that, The industrial camera (5) has an accuracy of not less than 0.005mm and comes with its own light source, lens, light control and computing host.

3. The secondary tool setting device for a fully automated gear-making equipment based on vision recognition as described in claim 1, characterized in that, The accuracy of the controllable high-precision motor (1) needs to be within the range of 0.002mm.

4. The secondary tool setting device for a fully automated gear-making equipment based on vision recognition as described in claim 1, characterized in that, The industrial camera (5) drives the controllable high-precision motor (1) to rotate, eliminating the included angle α specifically as follows: The image captured by the industrial camera (5) through the lens is post-processed by vision software and compared with the two gear images captured before and after. At this time, the parallelism between the end face of the gear cutting equipment spindle (2) and the end face of the gear (3) when the gear (3) is clamped needs to be considered. The horizontal angle between the lens and the plane of the gear (3) is calculated to obtain the horizontal alignment constant α. The boundary blur constant α is obtained by comparing the tooth profiles of the two gear images captured before and after. After compensation by combining the horizontal alignment constant and the boundary blur constant, the angle α1 is calculated. At this time, the host of the industrial camera feeds the α1 feedback signal to the controllable high-precision motor (1). The controllable high-precision motor (1) drives the gear cutting equipment spindle (2) to rotate by α1 angle to complete the secondary tool setting action of the gear.

5. The secondary tool setting device for a fully automated gear-making equipment based on vision recognition as described in claim 4, characterized in that, Feedback angle calculation formula: α1=α±α 水平 ±α 模糊补偿 , Where α is the included angle calculated from two image capture measurements, α 水平 For leveling constants, α 模糊补偿 It is a constant with fuzzy boundaries.

6. The secondary tool setting device for a fully automated gear-making equipment based on vision recognition as described in claim 1, characterized in that, If the offset angle is too large during the second clamping of the gear (3) and the camera cannot be aligned, the indicator light of the industrial camera (5) will light up and the feedback signal will stop the equipment from starting.

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