Binocular vision time-sharing multi-station detection device and method for blades of shield tunneling machine

Abstract

The invention discloses a shield tunneling machine blade binocular vision time-sharing multi-station detection device, which comprises a bottom frame, the bottom frame is provided with a base, the base is upwards connected with a central cylinder, three sets of longitudinal moving devices are uniformly arranged on the bottom frame around the base, and the three sets of longitudinal moving devices are respectively provided with a longitudinal moving part; longitudinal moving parts of the three sets of longitudinal moving devices are upwards connected with scale gear disc devices, the scale gear disc devices are connected with a binocular camera bearing device, the binocular camera bearing device comprises a bearing frame, a motor for rotation is arranged on the bearing frame, and a driving gear is installed on an output shaft of the motor for rotation; the driving gear is in meshing transmission connection with the scale gear disc device and is used for driving the binocular camera bearing device to rotate around the scale gear disc device; and a binocular camera is arranged on the binocular camera bearing device. The invention also discloses a corresponding detection method, which comprises the following steps of: mounting, initializing, carrying out layered time-sharing multi-station shooting detection, and carrying out integrated detection, so that the defect part information and category information of the shield tunneling machine blade can be conveniently and quickly obtained, and guidance is provided for subsequent work.

Description

Technical Field

[0001] The invention relates to the technical field of construction equipment, and in particular to a detection technology for shield machine blades. Background Art

[0002] The shield machine blades mentioned in the present invention refer to the blades of the shield machine auger (screw conveyor), which are used to transport the soil and gravel excavated by the shield machine and provide support for the continuity of the shield machine excavation process.

[0003] 1. The necessity of testing the shield machine blades.

[0004] The shield machine blade is one of the key components of the shield machine (TBM), which is widely used in tunnel excavation operations in urban rail transit, subway tunnels, and highway underpasses. The shield machine blade is one of the core components, and the performance of the blade is directly related to the construction efficiency and engineering quality of the shield machine.

[0005] Shield machine blades are generally irregular and large-sized workpieces with a wide range of pitch and outer diameter, usually with pitch sizes ranging from 630mm (millimeter) to 1000mm and outer diameters ranging from φ600mm to φ1400mm. Since shield machine blades are formed using a hot pressing process, affected by factors such as hot pressing rebound and cooling shrinkage, the dimensional consistency of the blades is poor, resulting in the possibility of excessive or insufficient gaps in the blades during assembly.

[0006] Too large a gap may lead to reduced response between the blades and the cylinder and increased permeability, which will first reduce the slag discharge efficiency, increase the water output, and affect the construction quality; A gap that is too small may lead to assembly failure, or even the blade being unable to be installed into the barrel, causing mechanical failure and increasing the operating burden of the equipment.

[0007] In addition, if there are defects in the shield machine blades (such as cracks, unevenness, corroded areas, etc.), it may reduce cutting efficiency, increase the energy consumption of the shield machine, reduce construction speed, affect the surface quality of the tunnel, increase the risk of equipment failure, reduce the stability of the shield machine, increase maintenance costs, and so on.

[0008] Therefore, it is necessary to inspect the shield machine blades to ensure that there are no gaps that are too large or too small during assembly, and that there are no defects on the surface that affect construction.

[0009] 2. Problems in shield machine blade defect detection.

[0010] The surface of shield machine blades is mostly complex free-form surfaces with weak surface texture, difficult optical properties to capture, and large size, which brings great difficulties to the detection of blades.

[0011] Traditional contact detection methods (such as three-dimensional coordinate measuring machines) are often affected by space when inspecting large-sized and special-shaped blades, making it impossible to perform comprehensive and accurate measurements.

[0012] Although contact laser scanning technology or 3D laser scanner can obtain relatively accurate point cloud data, there is still the problem of being unable to effectively capture blade surface defects.

[0013] At present, blade inspection mostly adopts manual methods, which have problems such as low efficiency, poor accuracy, and low intelligence, and it is difficult to meet the requirements of modern high-end equipment manufacturing. Specifically, manual inspection is inefficient and easily affected by human factors, and it is difficult to avoid human errors and easy to miss inspections; manual inspection cannot fully cover large-sized blades, and it is difficult to ensure the inspection accuracy.

[0014] Traditional contact detection such as coordinate measuring machine (CMM) as a workpiece measurement tool widely affects the detection of workpiece size and shape, but its shortcomings are also obvious. CMM usually relies on the mechanical spindle to contact the workpiece surface for scanning, which is suitable for flat or simple geometric shapes. For shield machine blades with large size, shape and complex surface, CMM is often limited by space during use, and its operation process takes a lot of time, resulting in low detection efficiency.

[0015] Laser scanners and 3D laser scanning technologies can efficiently obtain 3D point cloud data on the blade surface, but are good at building 3D (three-dimensional) models of targets. Because they rely on the principle of optical reflection, when facing low-texture or smooth surfaces, their scanning results do not have the surface details of the target, making it difficult to perform effective surface defect detection. Especially when scanning objects with complex shapes such as shield machine blades, the density of the point cloud is not uniform enough, resulting in the inability to generate a complete 3D model, affecting subsequent defect identification and dimensional analysis.

[0016] In addition to traditional measurement methods, high-precision measurement equipment such as laser trackers can measure large-size workpieces, but they have higher requirements for the characteristic points on the blade surface. In the absence of sufficient texture, laser trackers are also difficult to complete effective surface defect detection of shield machine blades.

[0017] 3. Binocular vision technology is used to detect problems with the shape, size and surface defects of shield machine blades.

[0018] The surface of shield machine blades has low texture features, making it difficult for the binocular vision system to accurately capture the surface detail features of the shield machine blades.

[0019] The shield machine blades are large in size and complex in shape, which means that the existing binocular vision system has blind spots when photographing the shield machine blades. Mobile photography is required, and it is difficult to capture the surface defects and shape and size defects of the shield machine blades in an orderly and comprehensive manner during mobile photography. Summary of the invention

[0020] The purpose of the present invention is to provide a shield machine blade detection device based on binocular vision time-sharing multi-station technology, design a structure that supports time-sharing multi-station technology, provide a basis for obtaining comprehensive detailed features of shield machine blades through time-sharing multi-station technology, and be used for orderly, all-round and blind-angle-free collection of shield machine blade images.

[0021] To achieve the above-mentioned purpose, the shield machine blade detection device based on binocular vision time-sharing multi-station technology of the present invention comprises a base frame, a base is provided in the middle of the base frame, a central cylinder for positioning the shield machine blade is fixedly connected upward from the center of the base frame, three sets of longitudinal movement devices are evenly arranged around the base on the base frame, and the three sets of longitudinal movement devices all have longitudinal movement parts; the longitudinal movement parts of the three sets of longitudinal movement devices are connected upward to a scale gear plate device, and the scale gear plate device is connected to a binocular camera bearing device, The center of the scale gear disk device is located on the axis of the central tube; the binocular camera carrying device includes a carrying frame, the carrying frame is provided with a rotating motor, a driving gear is installed on the output shaft of the rotating motor, the driving gear is meshed and transmission-connected with the scale gear disk device and is used to drive the binocular camera carrying device to rotate around the scale gear disk device; A binocular camera is provided on the binocular camera supporting device. The binocular camera is horizontally arranged and its shooting direction is toward the shield machine blade positioned by the central tube.

[0022] Each set of longitudinal movement devices has the same structure, which is a ball screw device or a linear motor; The nut of the ball screw device or the mover of the linear motor serves as the driving part for up and down movement, and the longitudinal movement part includes a horizontal support plate fixedly connected to the driving part and a diagonal support fixedly connected between the driving part and the lower surface of the horizontal support plate; when the longitudinal movement device adopts a ball screw device, the screw shaft of the ball screw device is connected to a longitudinal movement motor; the selectively used longitudinal movement motor or linear motor is collectively referred to as a longitudinal movement drive device, and the longitudinal movement drive device and the rotation motor are both connected to the industrial control computer.

[0023] The outer contour of the chassis is an equilateral triangle, and the three sets of longitudinal movement devices are respectively located at a vertex position of the equilateral triangle.

[0024] The graduated gear disc device comprises a graduated disc, the radial outer end of the upper surface of the graduated disc is provided with scales for indicating angles along the circumferential direction; the upper surface of the graduated disc is upwardly protruding and integrally provided with an outer gear ring; The output shaft of the rotating motor is downwardly connected with a driving gear, which is meshed with the outer gear ring and is used to drive the binocular camera carrying device to rotate along the outer gear ring; A snap ring is fixedly connected to the top surface of the outer gear ring upwards, and the centers of the snap ring, the outer gear ring and the scale plate are all located on the axis of the center tube; The carrier frame is downwardly connected with an outer clamping wheel and an inner clamping wheel, the wheel axles of the outer clamping wheel and the inner clamping wheel are both arranged vertically, and the circumferential outer surfaces of the outer clamping wheel and the inner clamping wheel are both recessed toward the wheel axle direction to form a clamping groove; The radial inner end of the snap ring extends into the clamping groove of the inner clamping wheel, and the radial outer end of the snap ring extends into the clamping groove of the outer clamping wheel, so that the snap ring is restricted between the outer clamping wheel and the inner clamping wheel; more than two sets of the outer clamping wheel and the inner clamping wheel are provided in a one-to-one correspondence; A linear motion device is provided on the carrier frame, and the linear motion device is an electric push rod or a linear motor or a ball screw device driven by a motor. The binocular camera is installed on the linear motion device and driven by the linear motion device. The telescopic displacement direction of the binocular camera driven by the linear motion device is a radial direction; the linear motion device is used to match shield machine blades of different diameters and to send the binocular camera to the surface defects of the shield machine blades for close-up shooting, so as to obtain detailed images of the surface defects of the shield machine blades; the linear motion device is connected to an industrial control computer.

[0025] The present invention also discloses a detection method using the shield machine blade detection device based on binocular vision time-sharing multi-station technology. A target detection model is stored in an industrial control computer. The following steps are performed: The first step is installation, which involves lifting the shield machine blades with a sling, putting the shield machine blades on the center tube and fixing the shield machine blades and the center tube together; The second step is initialization, which includes longitudinal initialization, radial initialization and circumferential initialization. Longitudinal initialization is: the industrial control computer synchronously starts each longitudinal movement motor to make the binocular camera move longitudinally to the top or bottom of the shield machine blade; Radial initialization is: using an industrial computer to control the linear motion device to move the binocular camera to a radial position that matches the shield machine blade to be tested; Circumferential initialization: The industrial computer controls the start-up of the rotation motor, drives the active gear to rotate along the outer gear ring, and drives the binocular camera to move circumferentially to the position facing the top or bottom of the shield machine blade; The third step is layered and time-sharing multi-station shooting detection; Layered means that the shooting and testing of the shield machine blades is carried out in layers along the axis direction of the central tube, that is, in the up and down direction, specifically from top to bottom or from bottom to top, to ensure that the shield machine blades are fully photographed and tested; the distance between two adjacent layers is based on the overlap of the shooting areas of the binocular cameras in the two adjacent layers; Each layer of shooting and detection is carried out according to the following sub-steps: The first sub-step is to start shooting detection, shooting the shield machine blade image at the current binocular camera position, the industrial control computer receives and stores the shield machine blade image, and the target detection model detects the current image to obtain information on whether there are defects in the current image, the type of defects and the location of the defects; If the current image does not have defects, jump to the third sub-step; If the current image has defects, the second sub-step, detail correction, is performed: According to the position information of the defect, the industrial control computer controls the linear motion device to drive the binocular camera to move radially to the defect position, takes a close-up photo of the defect position of the shield machine blade, and obtains a detailed image of the defect position of the shield machine blade. The industrial control computer receives and stores the detailed image of the shield machine blade, and the target detection model detects the current detailed image to confirm or correct the type information of the current defect; the industrial control computer controls the linear motion device to drive the binocular camera to radially reset to the position before the detail correction operation, and ends the detail correction operation; After the second sub-step is completed, the third sub-step is performed; the third sub-step is a rotation shooting operation; The rotation shooting operation is: the industrial control computer controls the rotation motor to drive the driving gear to rotate along the outer gear ring, driving the binocular camera to move a step angle in the circumferential direction. The step angle is 15°-60°, and 360° is an integer multiple of the step angle. The integer multiple is N times, and N is 24-6; the step angle is based on the overlap of the shooting areas of the binocular cameras at two adjacent angles; After each rotation shooting operation, if there is no defect in the current image, the rotation shooting operation is performed cyclically until the binocular camera completes N shots at the current height; After each rotation shooting operation, if there are defects in the current image, the detail correction operation is performed, and then the rotation shooting operation is performed again until the binocular camera completes N shots at the current height; After the binocular camera completes N shots at the current height, the rotation shooting operation of the current layer is ended, and the shooting and detection of the next layer is carried out until the shooting and detection tasks of all predetermined layers are completed, and a comprehensive image of the current shield machine blade is obtained, and the fourth step is executed; The fourth step is to integrate the testing operations; The industrial control computer integrates all the images of the current shield machine blade taken by multiple stations in layers and at different times into a complete 3D image of the current shield machine blade. The target detection model performs an overall detection on the complete 3D image to obtain the quantity information, location information and defect type information of the overall defects of the current shield machine blade, and integrates it with the local defect information obtained in the third step. If the overall detection result does not find any defects other than the local defect information obtained in the third step, then the final overall defect quantity information, location information and defect type information of the current shield machine blade are obtained; If the overall inspection result finds new defects other than the local defect information obtained in the third step, a detail correction operation is performed one by one corresponding to these new defects, and the target detection model detects the obtained detail image to confirm or correct the corresponding defect type information to obtain the final shape of the current shield machine blade. The detail image obtained by the detail correction operation is integrated with the complete 3D image of the current shield machine blade to obtain the quantity information, location information and type information of the defects.

[0026] The present invention has the following advantages: The shape of the shield machine blade is complex, and it is not possible to capture the entire image from one or two positions. When changing the position to shoot, there is no technology in the prior art to stabilize the radial distance, axial height, and circumferential angle of the camera relative to the shield machine blade, and it is impossible to capture the defects of the shield machine blade in an orderly and comprehensive manner. Since the radial distance, axial height, and circumferential angle of the camera relative to the shield machine blade cannot be kept stable and orderly, it is very difficult to integrate the captured local images into a complete image of the shield machine blade (the ratio of the pixel distance of each image to the actual distance is inconsistent, and the shooting angle is unstable and the image cannot be directly spliced ​​and integrated).

[0027] The shield machine blades are sleeved on the center tube, so the shield machine blades are coaxial with the center tube; the center of the graduated gear disk device is located on the axis of the center tube, so when the binocular camera rotates around the graduated gear disk device, it is also rotating around the axis of the shield machine blades, thus ensuring that the distance between the binocular camera and the axis of the shield machine blades remains constant when photographing the shield machine blades at different angles; the graduated gear disk device and the binocular camera can be raised and lowered as a whole smoothly under the drive of the longitudinal movement device, providing a basis for the time-sharing, multi-station, and multi-angle collection of images of shield machine blades at different axial positions, thereby achieving orderly and comprehensive capture of shield machine blade defects.

[0028] The graduated gear disk device makes it easy for designers to determine and adjust the size of the step angle through experiments. It also makes it easy for workers to monitor the rotation and shooting operations during actual inspection operations. In case of any abnormality, timely manual intervention can be carried out to ensure that the inspection work is carried out effectively.

[0029] The longitudinal movement device adopts a ball screw device or a linear motor, which is convenient for the industrial control computer to synchronously control each longitudinal movement motor or each linear motor to perform synchronous lifting.

[0030] There are more than two sets of outer clamping wheels and inner clamping wheels corresponding to each other, forming a firm rotation positioning structure, which can firmly restrict the binocular camera bearing device and the clamp ring together, allowing the binocular camera bearing device to rotate along the clamp ring and the outer gear ring, and keep the binocular camera in a horizontal state during rotation, and avoid the binocular camera bearing device from separating from the clamp ring during rotation. No matter to which angle the binocular camera bearing device rotates along the clamp ring and the outer gear ring, the rotation positioning structure can stably maintain the posture of the binocular camera bearing device and the position relative to the scale gear disk device, providing a basis for the time-sharing multi-station acquisition of shield machine blade images.

[0031] The binocular camera is driven by a linear motion device and can be extended and retracted radially (radial direction of the dial and center tube). It can meet the needs of photographing shield machine blades of different diameters. After initially detecting surface defects of the shield machine blades, it can extend to the surface defects for close-up photography to obtain detailed images of the surface defects.

[0032] After each rotation shooting operation, if there are defects in the current image, a detail correction operation is performed. Compared with the overall shooting and detection, the detail correction operation is performed in that the binocular camera can be directly driven to move radially without having to adjust the vertical height and plane angle of the binocular camera first, and then drive the binocular camera to move radially after aligning with the defect position, thereby improving efficiency and reducing energy consumption; By adopting the present invention, it is possible to conveniently and quickly obtain the defect location information and defect category information of the shield machine blades, and the shield machine blades without defects or with very minor defects that do not affect the use are classified as qualified products. For shield machine blades that are detected to have defects that affect the use, they are discarded or repaired accordingly according to the defect category information of the location information of the defect location, such as grinding for minor scratches, and welding repairs and grinding for cracks. In short, after the specific defect information of the shield machine blades is detected by the present invention, the problems caused by too large or too small assembly gaps can be avoided in a targeted manner, and the problem of surface defects of the shield machine blades affecting the construction of the shield machine can be avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a structural schematic diagram of a shield machine blade detection device based on binocular vision time-sharing multi-station technology of the present invention.

[0034] Figure 2 yes Figure 1 Top view of the .

[0035] Figure 3 yes Figure 1DD cross-sectional view.

[0036] Figure 4 yes Figure 3 Enlarged view of point A in the middle.

[0037] Figure 5 It is a three-dimensional structural schematic diagram of a shield machine blade detection device based on binocular vision time-sharing multi-station technology of the present invention.

[0038] Figure 6 yes Figure 5 Enlarged view of point E in the middle.

[0039] Figure 7 yes Figure 1 AA section view.

[0040] Figure 8 yes Figure 7 Enlarged view of point F in the middle. DETAILED DESCRIPTION

[0041] In view of the problem of using binocular vision technology to detect the shape, size and surface defects of shield machine blades (detailed introduction in the background technology), the present invention designs a structure and method that supports time-sharing multi-station technology, obtains detailed features of the surface of the shield machine blades through the time-sharing multi-station technology, and uses mechanisms such as a graduated gear plate device to enable the binocular camera to collect images of the shield machine blades in an orderly and all-round manner without blind spots, thereby meeting the needs of shooting large-size objects and shooting images at time-sharing multiple stations.

[0042] like Figures 1 to 8 As shown, the present invention provides a shield machine blade detection device based on binocular vision time-sharing multi-station technology, including a base frame 1, a base 2 is provided in the middle of the base frame 1, a central tube 4 for positioning the shield machine blade 3 is fixedly connected (welded or clamped, etc.) upward from the center of the base 2, and three sets of longitudinal movement devices 5 are evenly arranged on the base frame 1 around the base 2, and the three sets of longitudinal movement devices 5 all have longitudinal movement parts; the longitudinal movement parts of the three sets of longitudinal movement devices 5 are connected upward with a scale gear plate device, and the scale gear plate device is connected with a binocular camera bearing device, The center of the scale gear disk device is located on the axis of the central tube 4; the binocular camera carrying device includes a carrying frame 6, on which a rotating motor 7 is provided, and a driving gear 8 is installed on the output shaft of the rotating motor 7, and the driving gear 8 is meshed and connected with the scale gear disk device and is used to drive the binocular camera carrying device to rotate around the scale gear disk device; A binocular camera 9 is provided on the binocular camera carrying device. The binocular camera 9 is horizontally arranged and its shooting direction is toward the shield machine blade 3 positioned by the central tube 4.

[0043] The principle of the present invention is: the shield machine blade 3 is sleeved on the central tube 4, so the shield machine blade 3 is coaxial with the central tube 4; the center of the scale gear disk device is located on the axis of the central tube 4, so when the binocular camera 9 rotates around the scale gear disk device, it also rotates around the axis of the shield machine blade 3, thus ensuring that the distance between the binocular camera 9 and the axis of the shield machine blade 3 remains constant when photographing the shield machine blade 3 at different angles; the scale gear disk device and the binocular camera 9 can be raised and lowered as a whole smoothly under the drive of the longitudinal movement device 5, providing a basis for collecting images of different axial positions of the shield machine blade 3 at multiple stations and multiple angles in a time-sharing manner.

[0044] The graduated gear disk device makes it easy for designers to determine and adjust the size of the step angle through experiments. It also makes it easy for workers to monitor the rotation and shooting operations during actual inspection operations. In case of any abnormality, timely manual intervention can be carried out to ensure that the inspection work is carried out effectively.

[0045] Each set of longitudinal movement devices 5 has the same structure, and is a ball screw device or a linear motor; The nut (linear motion component) of the ball screw device or the mover (linear motion component) of the linear motor serves as a driving part 10 that moves up and down, and the longitudinal moving part includes a horizontal support plate 11 fixedly connected to the driving part 10 and a diagonal brace 12 fixedly connected between the driving part 10 and the lower surface of the horizontal support plate 11 (the diagonal brace 12 is used to enhance the structural strength); When the longitudinal movement device 5 adopts a ball screw device, the screw shaft of the ball screw device is connected to a longitudinal movement motor; the longitudinal movement motor or linear motor selectively adopted is collectively referred to as a longitudinal movement drive device 13, and the longitudinal movement drive device 13 and the rotation motor 7 are both connected to an industrial control computer. The industrial control computer is a prior art and is not shown in the figure.

[0046] The longitudinal movement device 5 adopts a ball screw device or a linear motor, which is convenient for the industrial control computer to synchronously control each longitudinal movement motor or each linear motor to perform synchronous lifting.

[0047] The outer contour of the chassis 1 is an equilateral triangle, and the three sets of longitudinal movement devices 5 are respectively located at a vertex position of the equilateral triangle. The graduated gear plate device includes a graduated plate 14, and the radial outer end of the upper surface of the graduated plate 14 is provided with a scale for indicating an angle along the circumferential direction; the upper surface of the graduated plate 14 is upwardly protruding and integrally provided with an outer gear ring 15, and the circumferential outer surface of the outer gear ring 15 is provided with transmission teeth; in this embodiment, the outer gear ring 15 is integrally provided with the graduated plate 14, and of course the two can also be separately provided and fixedly connected together.

[0048] The output shaft of the rotating motor 7 is connected downwardly with a driving gear 8, which meshes with the outer gear ring 15 and is used to drive the binocular camera 9 carrying device to rotate along the outer gear ring 15; A snap ring 16 is fixedly connected to the top surface of the outer gear ring 15 upwards, and the centers of the snap ring 16, the outer gear ring 15 and the scale plate 14 are all located on the axis of the center tube 4; The carrier frame 6 is downwardly connected with an outer clamping wheel 17 and an inner clamping wheel 18, the wheel axles of the outer clamping wheel 17 and the inner clamping wheel 18 are both arranged vertically, and the circumferential outer surfaces of the outer clamping wheel 17 and the inner clamping wheel 18 are both recessed toward the wheel axle direction to form a clamping groove 19; The radial inner end of the snap ring 16 extends into the clamping groove 19 of the inner clamping wheel 18, and the radial outer end of the snap ring 16 extends into the clamping groove 19 of the outer clamping wheel 17, so that the snap ring 16 is restricted between the outer clamping wheel 17 and the inner clamping wheel 18; more than two sets of the outer clamping wheel 17 and the inner clamping wheel 18 are provided in a one-to-one correspondence; A linear motion device 20 is provided on the carrier 6. The linear motion device 20 is an electric push rod or a linear motor or a ball screw device driven by a motor. The binocular camera 9 is installed on the linear motion device 20 and driven by the linear motion device 20. The telescopic displacement direction of the binocular camera 9 driven by the linear motion device 20 is the radial direction. The linear motion device 20 is used to match shield machine blades 3 of different diameters and to send the binocular camera 9 to the surface defects of the shield machine blade 3 for close-up shooting, thereby obtaining a detailed image of the surface defects of the shield machine blade 3. The linear motion device 20 is connected to an industrial control computer.

[0049] There are more than two sets of outer clamping wheels 17 and inner clamping wheels 18 corresponding to each other, forming a firm rotation positioning structure, which can firmly restrict the binocular camera 9 carrying device and the clamp ring 16 together, allowing the binocular camera 9 carrying device to rotate along the clamp ring 16 and the outer gear ring 15, and keep the binocular camera 9 in a horizontal state during rotation, and avoid the binocular camera 9 carrying device from separating from the clamp ring 16 during rotation. No matter to which angle the binocular camera 9 carrying device rotates along the clamp ring 16 and the outer gear ring 15, the rotation positioning structure can stably maintain the posture of the binocular camera 9 carrying device and the position relative to the scale gear disk device, providing a basis for the time-sharing multi-station acquisition of shield machine blade 3 images.

[0050] The binocular camera 9 is driven by a linear motion device 20 and is retracted radially (radial direction of the dial 14 and the center tube 4), which can meet the needs of photographing shield machine blades 3 of different diameters. After initially detecting surface defects of the shield machine blades 3, the binocular camera 9 can be extended to the surface defects for close-up photography to obtain detailed images of the surface defects.

[0051] The present invention also provides a detection method using the shield machine blade detection device based on binocular vision time-sharing multi-station technology, wherein a target detection model is stored in the industrial control computer; the detection method is performed according to the following steps: The first step is installation, which involves lifting the shield machine blade 3 using a sling, sleeve the shield machine blade 3 on the center tube 4, and fix the shield machine blade 3 and the center tube 4 together; The second step is initialization, which includes longitudinal initialization, radial initialization and circumferential initialization. Longitudinal initialization is: the industrial control computer synchronously starts each longitudinal movement motor to move the binocular camera 9 longitudinally to the top or bottom of the shield machine blade 3; The radial initialization is: the linear motion device 20 is controlled by the industrial control computer to move the binocular camera 9 to a radial position matching the shield machine blade 3 to be tested; Circumferential initialization: The industrial control computer controls the rotation motor 7 to start, drives the driving gear 8 to rotate along the outer gear ring 15, and drives the binocular camera 9 to move in the circumferential direction to a position facing the top or bottom of the shield machine blade 3; matching the longitudinal initialization, if the binocular camera 9 moves to the top of the shield machine blade 3 during the longitudinal initialization, the binocular camera 9 is also moved in the circumferential direction to a position facing the top of the shield machine blade 3 during the circumferential initialization, otherwise it is moved to a position facing the bottom of the shield machine blade 3; The third step is layered and time-sharing multi-station shooting detection; Layered means that the shooting and testing of the shield machine blade 3 is carried out in layers along the axial direction of the central tube 4, that is, in the up-down direction, specifically, the shooting and testing is carried out in layers from top to bottom or from bottom to top, so as to ensure that the shield machine blade 3 is fully shot and tested; the spacing between two adjacent layers is based on the shooting areas of the binocular cameras 9 in the two adjacent layers just overlapping each other, that is, when shooting and testing the lower layer, the top area of ​​the image shot by the binocular camera 9 is the bottom area of ​​the image shot by the binocular camera 9 when shooting and testing the upper layer; Each layer of shooting and detection is carried out according to the following sub-steps: The first sub-step is to start shooting detection. The image of the shield machine blade 3 is shot at the current position of the binocular camera 9. The industrial control computer receives and stores the image of the shield machine blade 3, and the target detection model detects the current image to obtain information on whether there are defects in the current image, the type of defects and the location of the defects. The location information includes the height position (one-to-one corresponding to the layer information), axial position and radial position of the defective part; before the layered shooting detection of a certain model of shield machine blades, the layer spacing and the height of each layer are specified by the staff through experiments before the detection. For all shield machine blades of this model, a unified layer spacing and a unified layer height are adopted.

[0052] If the current image does not have defects, jump to the third sub-step; If the current image has defects, the second sub-step, detail correction, is performed: According to the position information of the defect, the industrial control computer controls the linear motion device 20 to drive the binocular camera 9 to move radially to the defect position (the spacing is the minimum distance at which the binocular camera 9 can clearly photograph the defect position, which can be 1-2 times of the minimum distance), and takes a close-up photo of the defect position of the shield machine blade 3 to obtain a detailed image of the defect position of the shield machine blade 3. The industrial control computer receives and stores the detailed image of the shield machine blade 3, and the target detection model detects the current detailed image to confirm or correct the type information of the current defect; the industrial control computer controls the linear motion device 20 to drive the binocular camera 9 to radially reset to the position before the detail correction operation, and ends the detail correction operation; After the second sub-step is completed, the third sub-step is performed; the third sub-step is a rotation shooting operation; The rotation shooting operation is: the industrial control computer controls the rotation motor 7 to drive the driving gear 8 to rotate along the outer gear ring 15, driving the binocular camera 9 to move a step angle in the circumferential direction, the step angle is 15°-60°, and 360° is an integer multiple of the step angle, the integer multiple is N times, N is 24-6; the step angle is based on the shooting areas of the binocular camera 9 at two adjacent angles just overlapping each other, that is, when shooting and testing at one step angle, the edge area of ​​the image shot by the binocular camera 9 overlaps with the edge area of ​​the image shot by the binocular camera 9 at the adjacent step angle. The image edges of the two image areas at adjacent step angles must overlap or just be able to butt together, and there must be no interval; for the sake of insurance, there should be overlapping parts; After each rotation shooting operation, if there is no defect in the current image, the rotation shooting operation is performed cyclically until the binocular camera 9 completes N shots at the current height; After each rotation shooting operation, if there are defects in the current image, a detail correction operation is performed, and then the rotation shooting operation is jumped and re-executed until the binocular camera 9 completes N shots at the current height; After the binocular camera 9 completes N shots at the current height, the rotation shooting operation of the current layer is ended, and the shooting detection of the next layer is carried out until the shooting detection tasks of all predetermined layers are completed, and a comprehensive image of the current shield machine blade 3 is obtained, and the fourth step is executed; The fourth step is to integrate the testing operations; The industrial control computer integrates all the images of the current shield machine blade 3 taken by multiple stations in layers and at different times into a complete 3D image of the current shield machine blade 3. The target detection model performs an overall detection on the complete 3D image to obtain the quantity information, location information and defect type information of the overall defects of the current shield machine blade 3, and integrates it with the local defect information obtained in the third step; If the overall detection result does not find any defects other than the local defect information obtained in the third step, the final overall defect quantity information, location information and defect type information of the current shield machine blade 3 are obtained; If the overall detection result finds new defects other than the local defect information obtained in the third step, a detail correction operation is performed one by one corresponding to these new defects, and the target detection model detects the obtained detail image to confirm or correct the corresponding defect type information to obtain the final image of the current shield machine blade 3. The detail image obtained by the detail correction operation is merged with the complete 3D image of the current shield machine blade 3 to obtain the quantity information, location information and type information of the defects.

[0053] After each rotation shooting operation, if there is a defect in the current image, a detail correction operation is performed. Compared with performing the detail correction operation after the overall shooting detection is completed, the advantage is that the binocular camera 9 can be directly driven to move radially without having to adjust the vertical height and plane angle of the binocular camera 9 first, and then drive the binocular camera 9 to move radially after aligning with the defect position, thereby improving efficiency and reducing energy consumption; By adopting the present invention, it is possible to conveniently and quickly obtain the defect location information and defect category information of the shield machine blade 3, and the shield machine blade 3 without defects or with very minor defects that do not affect the use can be classified as a qualified product. For the shield machine blade 3 that is detected to have defects that affect the use, the corresponding disposal or repair is made according to the defect category information of the location information of the defect location, such as grinding for minor scratches, welding repair and grinding for cracks. In short, after the specific defect information of the shield machine blade 3 is detected by the present invention, the problem caused by too large or too small assembly gap can be avoided in a targeted manner, and the problem of surface defects of the shield machine blade 3 affecting the construction of the shield machine can be avoided.

[0054] In the first step: the shield machine blade 3 is fixed to the central tube 4 by using any of the following two techniques: 1. After using the lifting device to put the shield machine blade 3 on the center tube 4, spot weld the shield machine blade 3 on the outer wall of the center tube 4, cut the spot welded part after inspection, and use the lifting device to lift out the shield machine blade 3. The radial inner end surface of the shield machine blade 3 is not its working surface, but its connection surface connected to the shaft. Therefore, the residual welding spot after cutting here does not affect the normal installation of the shield machine on the installation shaft of the screw conveyor of the shield machine, and does not affect the normal operation of the shield machine blade 3. Spot welding can firmly fix the shield machine blade 3 on the center tube 4 to prevent shaking from affecting the inspection results.

[0055] 2. A strong electromagnet is set in the center tube 4. After the shield machine blade 3 is mounted on the center tube 4, the center tube 4 forms a positioning support for the shield machine blade 3. However, the shield machine blade 3 may shake under the action of external force. At this time, the strong electromagnet is started to fix the shield machine blade 3 on the center tube 4 through magnetic adsorption to avoid shaking during the detection process and avoid shaking affecting the detection results. After the detection, the strong electromagnet is turned off and the shield machine blade 3 is pulled upward from the center tube 4 using a hoist.

[0056] The target detection model can use a two-stage detector (such as Faster R-CNN or R-CNN) or a single-stage detector, such as a YOLO series model or a RetinaNet model. Preferably, the YOLO V10 model is used. The present embodiment uses the YOLO V10 target detection model. For the task of shield machine blade 3 defect detection, local optimization adjustments can be made to the general YOLOV10 target detection model, such as introducing the Focal Modulation module to replace SPPF, using more CBAM attention modules, performing feature fusion through Add and Cat operations, performing multi-scale feature fusion, and using more convolutional layers and residual connections in the Bottlenneck structure. By using RestNet50 as the encoder network structure of U-Net, dilated convolution is used instead of traditional convolution to increase the receptive field, and introducing BN (Batch Normalization) operation in the decoder network structure to achieve the effect of standardizing the data distribution in the decoder network and improving the convergence speed of the network; adding a dropout layer to the fully connected layer to prevent the model from overfitting and improve the generalization ability of the detection model; replacing the feature concatenation operation (concat) in the detection model with a residual operation, while not changing the feature dimension, reducing the model's computational complexity and improving the model's ability to extract features, etc., to better match the task of shield machine blade 3 defect detection and improve detection accuracy and efficiency.

[0057] In the fourth step, the defect category can be freely defined by the user according to the specific situation of the corresponding model of the shield machine blade 3, and the training set, validation set and test set are correspondingly prepared by using the images of the shield machine blade 3 with artificial given classification to train and adjust the target detection model. For example, the following defect types can be defined: 1. Rolled-in-scale, usually in the form of small spots, fish scales, strips, and blocks, irregularly distributed on the entire or part of the upper and lower surfaces of the shield machine blade 3, often accompanied by a rough pitted surface. 2. Patches, flaky or large-area spots on the surface of the shield machine blade 3, in some cases, there are signs of outward radiation at a certain angle. 3. Pitted-Surface, the surface of the shield machine blade 3 has a local or continuous rough surface, which is orange peel-like in severe cases. It may appear on the upper and lower surfaces, and the density is uneven in the length direction of the entire shield machine blade 3. 4. Cracking, a discontinuous crack on the surface of the rolled piece, centered at a certain point, or radiating outward in a lightning shape. 5. Inclusions: thin layer folds on the surface of the shield machine blade 3. The defects are often grayish white, with different sizes and shapes, and are irregularly distributed on the surface. 6. Scratches: mechanical damage on the surface of the shield machine blade 3. The length, width, and depth vary, and they mainly appear along the rolling direction or perpendicular to the rolling direction. 7. Shape and size defects.

[0058] The above embodiments are only used to illustrate rather than limit the technical solutions of the present invention. Although the present invention is described in detail with reference to the above embodiments, those skilled in the art should understand that the present invention can still be modified or replaced by equivalents. Any modification or partial replacement that does not depart from the spirit and scope of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A binocular vision time-sharing multi-station detection device for shield machine blades, comprising a base frame, a base being provided in the middle of the base frame, and characterized in that: A central cylinder for positioning the shield machine blades is fixedly connected upward from the center of the base. Three sets of longitudinal movement devices are evenly arranged around the base on the chassis. The three sets of longitudinal movement devices all have longitudinal movement parts. The longitudinal movement parts of the three sets of longitudinal movement devices are connected upward to a scale gear plate device, and the scale gear plate device is connected to a binocular camera carrying device. The center of the scale gear disk device is located on the axis of the central tube; the binocular camera carrying device includes a carrying frame, the carrying frame is provided with a rotating motor, a driving gear is installed on the output shaft of the rotating motor, the driving gear is meshed and transmission-connected with the scale gear disk device and is used to drive the binocular camera carrying device to rotate around the scale gear disk device; A binocular camera is provided on the binocular camera supporting device. The binocular camera is horizontally arranged and its shooting direction is toward the shield machine blade positioned by the central tube.

2. The shield machine blade binocular vision time-sharing multi-station detection device according to claim 1 is characterized in that: Each set of longitudinal movement devices has the same structure, which is a ball screw device or a linear motor; The nut of the ball screw device or the mover of the linear motor serves as the driving part for up and down movement, and the longitudinal movement part includes a horizontal support plate fixedly connected to the driving part and a diagonal support fixedly connected between the driving part and the lower surface of the horizontal support plate; when the longitudinal movement device adopts a ball screw device, the screw shaft of the ball screw device is connected to a longitudinal movement motor; the selectively used longitudinal movement motor or linear motor is collectively referred to as a longitudinal movement drive device, and the longitudinal movement drive device and the rotation motor are both connected to the industrial control computer.

3. The shield machine blade binocular vision time-sharing multi-station detection device according to claim 1 is characterized in that: The outer contour of the chassis is an equilateral triangle, and the three sets of longitudinal movement devices are respectively located at a vertex position of the equilateral triangle.

4. The shield machine blade binocular vision time-sharing multi-station detection device according to claim 2 is characterized in that: The graduated gear disc device comprises a graduated disc, the radial outer end of the upper surface of the graduated disc is provided with scales for indicating angles along the circumferential direction; the upper surface of the graduated disc is upwardly protruding and integrally provided with an outer gear ring; The output shaft of the rotating motor is downwardly connected with a driving gear, which is meshed with the outer gear ring and is used to drive the binocular camera carrying device to rotate along the outer gear ring; A snap ring is fixedly connected to the top surface of the outer gear ring upwards, and the centers of the snap ring, the outer gear ring and the scale plate are all located on the axis of the center tube; The carrier frame is downwardly connected with an outer clamping wheel and an inner clamping wheel, the wheel axles of the outer clamping wheel and the inner clamping wheel are both arranged vertically, and the circumferential outer surfaces of the outer clamping wheel and the inner clamping wheel are both recessed toward the wheel axle direction to form a clamping groove; The radial inner end of the snap ring extends into the clamping groove of the inner clamping wheel, and the radial outer end of the snap ring extends into the clamping groove of the outer clamping wheel, so that the snap ring is restricted between the outer clamping wheel and the inner clamping wheel; more than two sets of the outer clamping wheel and the inner clamping wheel are provided in a one-to-one correspondence; A linear motion device is provided on the carrier frame, and the linear motion device is an electric push rod or a linear motor or a ball screw device driven by a motor. The binocular camera is installed on the linear motion device and driven by the linear motion device. The telescopic displacement direction of the binocular camera driven by the linear motion device is a radial direction; the linear motion device is used to match shield machine blades of different diameters and to send the binocular camera to the surface defects of the shield machine blades for close-up shooting, so as to obtain detailed images of the surface defects of the shield machine blades; the linear motion device is connected to an industrial control computer.

5. The detection method using the shield machine blade binocular vision time-sharing multi-station detection device described in claim 4 is performed, and a target detection model is stored in the industrial control computer; Features Follow these steps: The first step is installation, which involves lifting the shield machine blades with a sling, putting the shield machine blades on the center tube and fixing the shield machine blades and the center tube together; The second step is initialization, which includes longitudinal initialization, radial initialization and circumferential initialization. Longitudinal initialization is: the industrial control computer synchronously starts each longitudinal movement motor to make the binocular camera move longitudinally to the top or bottom of the shield machine blade; Radial initialization is: using an industrial computer to control the linear motion device to move the binocular camera to a radial position that matches the shield machine blade to be tested; Circumferential initialization: The industrial computer controls the rotation motor to start, driving the active gear to rotate along the outer gear ring, driving the binocular camera to move circumferentially to the position facing the top or bottom of the shield machine blade; The third step is layered and time-sharing multi-station shooting detection; Layered means that the shooting and testing of the shield machine blades is carried out in layers along the axis direction of the central tube, that is, in the up and down direction, specifically from top to bottom or from bottom to top, to ensure that the shield machine blades are fully photographed and tested; the distance between two adjacent layers is based on the overlap of the shooting areas of the binocular cameras in the two adjacent layers; Each layer of shooting and detection is carried out according to the following sub-steps: The first sub-step is to start shooting detection, shooting the shield machine blade image at the current binocular camera position, the industrial control computer receives and stores the shield machine blade image, and the target detection model detects the current image to obtain information on whether there are defects in the current image, the type of defects and the location of the defects; If the current image does not have defects, jump to the third sub-step; If the current image has defects, the second sub-step, detail correction, is performed: According to the position information of the defect, the industrial control computer controls the linear motion device to drive the binocular camera to move radially to the defect position, takes a close-up photo of the defect position of the shield machine blade, and obtains a detailed image of the defect position of the shield machine blade. The industrial control computer receives and stores the detailed image of the shield machine blade, and the target detection model detects the current detailed image to confirm or correct the type information of the current defect; the industrial control computer controls the linear motion device to drive the binocular camera to radially reset to the position before the detail correction operation, and ends the detail correction operation; After the second sub-step is completed, the third sub-step is performed; the third sub-step is a rotation shooting operation; The rotation shooting operation is: the industrial control computer controls the rotation motor to drive the driving gear to rotate along the outer gear ring, driving the binocular camera to move a step angle in the circumferential direction. The step angle is 15°-60°, and 360° is an integer multiple of the step angle. The integer multiple is N times, and N is 24-6; the step angle is based on the overlap of the shooting areas of the binocular cameras at two adjacent angles; After each rotation shooting operation, if there is no defect in the current image, the rotation shooting operation is performed cyclically until the binocular camera completes N shots at the current height; After each rotation shooting operation, if there are defects in the current image, the detail correction operation is performed, and then the rotation shooting operation is performed again until the binocular camera completes N shots at the current height; After the binocular camera completes N shots at the current height, the rotation shooting operation of the current layer is ended, and the shooting and detection of the next layer is carried out until the shooting and detection tasks of all predetermined layers are completed, and a comprehensive image of the current shield machine blade is obtained, and the fourth step is executed; The fourth step is to integrate the testing operations; The industrial control computer integrates all the images of the current shield machine blade taken by multiple stations in layers and at different times into a complete 3D image of the current shield machine blade. The target detection model performs an overall detection on the complete 3D image to obtain the quantity information, location information and defect type information of the overall defects of the current shield machine blade, and integrates it with the local defect information obtained in the third step. If the overall detection result does not find any defects other than the local defect information obtained in the third step, then the final overall defect quantity information, location information and defect type information of the current shield machine blade are obtained; If the overall inspection result finds new defects other than the local defect information obtained in the third step, a detail correction operation is performed one by one corresponding to these new defects, and the target detection model detects the obtained detail image to confirm or correct the corresponding defect type information to obtain the final shape of the current shield machine blade. The detail image obtained by the detail correction operation is integrated with the complete 3D image of the current shield machine blade to obtain the quantity information, location information and type information of the defects.

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