Automatic grinding control system and method for rotor support longitudinal welding seam robot

Abstract

The invention belongs to the technical field of robot control, and particularly relates to an automatic grinding control system and method for a rotor support longitudinal welding seam robot, the system comprises a visual inspection unit, a point cloud integration unit, a path planning unit and the like, all the units work cooperatively, and automatic grinding of a curved surface structural part welding seam is achieved. The system further has the functions of collision analysis, self-inspection, process programming, fault alarm and the like, the grinding efficiency, quality and system safety are effectively improved, the defects in the prior art are overcome, and development of related industries is promoted. The method comprises the steps of workpiece positioning, scanning, data processing, trajectory planning, simulation verification, grinding operation, fault processing and the like. Workpiece information is obtained through far-end and near-end scanning, a grinding track is accurately planned, and track adduction is carried out by considering the radius of a tool. According to the technical scheme, the problems that existing rotor support welding seam polishing depends on manual operation, and a traditional automatic polishing system has defects and cannot meet the polishing requirements of complex structural parts are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of robot control, and particularly relates to a robot automatic grinding control system and method for longitudinal welds of a rotor bracket. Background Art

[0002] As an important component, the structure of the rotor bracket is welded by a central cylinder, large vertical ribs, and circumferential rib plates. During the welding process, the longitudinal weld (abbreviated as longitudinal weld) formed between the central cylinder and the large vertical ribs, and the circumferential weld (abbreviated as circumferential weld) formed between the circumferential rib plates and the central cylinder and the large vertical ribs play a key role in the quality of the rotor bracket. At present, the grinding of the welds of the rotor bracket mainly relies on manual operation, which has many disadvantages, such as consuming a large amount of manpower, long grinding time, high working intensity of workers, and poor working environment. At the same time, it is difficult to guarantee the quality of the longitudinal welds after grinding, and urgent automation transformation is needed to improve production efficiency and grinding quality.

[0003] Traditional automatic grinding systems usually consist of a manipulator, a force control unit, a grinding device, and a control system. In actual operation, it is necessary to manually operate the robot to move along the weld track to ensure that the grinding tool fits the weld with appropriate force, select multiple points for robot trajectory teaching, then store the recorded weld track into the robot program, and finally the control system calls the program to complete the grinding. Although this method realizes automation to a certain extent, the manual teaching process is cumbersome and has high professional requirements for operators.

[0004] In terms of patented technology, the Chinese invention patent with the application number CN202210506792.4 discloses an automatic flexible grinding system and method for welds of plate-like structural parts. In addition to the manipulator, the force control unit, the grinding device, and the control system, this system also adds a line-scanning laser sensor. Its grinding method includes steps such as weld input, parsing, on-site contour acquisition, pose-changing grinding, and active floating grinding. This invention realizes automatic grinding by importing theoretical weld data in the form of parameters, without manual teaching, reducing the usage difficulty, and ordinary operators can operate the equipment to run. However, this patented technology has limitations. It has good effects when grinding the welds of planar plate-like structural parts, but when grinding curved structural parts, the grinding effect is poor and it cannot meet the grinding requirements of complex structural parts.

[0005] In summary, the current rotor bracket weld grinding technology has deficiencies in terms of automation level and grinding effect. There is an urgent need for an efficient automatic weld grinding technology that can be applied to various structural parts, especially curved structural parts, to solve the problems existing in the prior art and promote the development of related industries. Summary of the Invention

[0006] The object of the present invention is to propose a robot automatic grinding control system and method for the longitudinal weld of a rotor bracket in view of the deficiencies of the above-mentioned existing technologies, realizing the automatic grinding of the weld of the curved surface structural part.

[0007] The above object is specifically achieved through the following technical solutions:

[0008] A robot automatic grinding control system for the longitudinal weld of a rotor bracket, comprising:

[0009] A vision detection unit, including a number of laser scanners and corresponding image acquisition devices, for scanning the rotor bracket workpiece, completing the surface model reconstruction of the rotor bracket workpiece, and obtaining the original image data of the surface of the rotor bracket workpiece.

[0010] A point cloud integration unit, for receiving the original image data collected by the vision detection unit through a data bus, and performing preprocessing on the original image data including resolution calculation, coordinate transformation and filtering, converting the original image data into ordered and processable point cloud data, and performing grid processing, and outputting to a file.

[0011] A path planning unit, for receiving the near-end point cloud data from the point cloud integration unit, constructing a three-dimensional model of the rotor bracket workpiece, analyzing the geometric shape and weld position of the rotor bracket workpiece, generating environmental data, and calculating the end surface trajectory suitable for grinding, thereby generating trajectory information.

[0012] An execution unit, for reading the trajectory information generated by the path planning unit, planning the specific motion trajectory of the robot according to the kinematic principle of the robot, and sending the motion trajectory data to the robot for grinding operation.

[0013] A database, for storing the operation data of the robot automatic grinding control system, as well as the intermediate data and result data generated by each functional unit.

[0014] An interface main control unit, for reading the status information of each functional unit in real time, and visually displaying these status information on the interface; at the same time providing an operation interface for the operator to perform operations on the robot automatic grinding control system including parameter setting and start-stop control.

[0015] Preferably, it further includes an external interface unit, and the external interface unit provides a production system interface and a turntable interface; wherein, the production system interface is used for information interaction and coordinated work with the entire production system; the turntable interface is used for establishing communication and control between the robot automatic grinding control system and the turntable.

[0016] Preferably, the execution unit includes a grinding module and a chipping grinding module, which are respectively used for automatically generating the end grinding trajectory and the end chipping grinding trajectory based on the three-dimensional point cloud data in combination with the grinding process requirements.

[0017] Preferably, it further includes a collision analysis and obstacle avoidance unit, which is used to perform operation simulation verification through a simulation function before the robot performs grinding operations to rule out the possibility of collisions. Among them, if the simulation verification fails, it is necessary to call the path planning unit to re-plan the path or call the execution unit to optimize and adjust the trajectory. If the simulation verification passes, the execution unit is triggered to send the motion trajectory data to the robot for grinding operations.

[0018] Preferably, it further includes a self-check and status detection unit, which is used to perform self-check on the system operation, including monitoring the robot status and position parameters, the external axis status and position, and the grinding pressure.

[0019] Preferably, it further includes an integrated process programming unit, which is used to edit the grinding process steps and adjust the grinding process parameters according to the process requirements.

[0020] Preferably, it further includes a fault alarm unit, which is used to monitor the system fault conditions during the grinding operation process. When the robot automatic grinding control system fails and interrupts, the sound and light alarm unit gives a sound and light alarm reminder, and triggers the system to continue task execution from the interrupted position after the fault is eliminated.

[0021] A method for controlling the automatic grinding of the longitudinal weld of a rotor bracket by a robot adopts the automatic grinding control system for the longitudinal weld of a rotor bracket of the present technical solution, including the following steps:

[0022] S1. The rotor bracket workpiece is in place, and the rotor bracket workpiece is manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld; S2. The vision detection unit is started to scan the rotor bracket workpiece, and the surface model of the rotor bracket workpiece is reconstructed to obtain the original image data of the surface of the rotor bracket workpiece.

[0023] S3. The point cloud integration unit receives the original image data collected by the vision detection unit through the data bus, and performs preprocessing on the original image data including calculation, coordinate transformation, and filtering, converts the original image data into ordered and processable point cloud data, and performs grid processing, and outputs it to a file.

[0024] S4. The path planning unit receives the near-end point cloud data from the point cloud integration unit, constructs a three-dimensional model of the rotor bracket workpiece, analyzes the geometric shape and weld position of the rotor bracket workpiece, generates environmental data, and calculates the end surface trajectory suitable for grinding, thereby generating trajectory information.

[0025] S5. The execution unit reads the trajectory information and plans the specific motion trajectory of the robot according to the kinematic principle of the robot.

[0026] S6. Perform simulation verification on the motion trajectory through the collision analysis and obstacle avoidance unit. If the simulation verification fails, it is necessary to call the path planning unit to re-plan the path or call the execution unit to optimize and adjust the trajectory. If the simulation verification passes, trigger the execution unit to send the motion trajectory data to the robot for grinding operation.

[0027] S7. During the grinding operation, monitor the failure situation of the monitoring system in real time. When the robot automated grinding control system fails and interrupts, control the sound and light alarm unit to give a sound and light alarm reminder, and trigger the system to continue task execution from the interrupted position after the fault is eliminated.

[0028] S8. Use the roller rack automatic position-changing device to rotate the rotor bracket workpiece to the next weld position, and repeat the above steps S1 - S7 until the grinding of all welds of the current rotor bracket workpiece is completed.

[0029] Preferably, in step S2, scanning the rotor bracket workpiece includes one distal scan and one proximal scan. Among them, the distal scan is to detect the posture of the rotor bracket workpiece and preliminarily locate the grinding points, and the proximal scan is to accurately measure the grinding points.

[0030] Preferably, in step S4, generating the trajectory information includes the following steps:

[0031] S41. Obtain two segmentation lines L1 and L2 through edge detection based on the point cloud data, and use the segmentation lines L1 and L2 to segment the point cloud. The area between the two lines is the grinding area, and the areas outside the two lines are two plane areas.

[0032] S42. Perform plane segmentation fitting on the point cloud data in the grinding area to obtain two extended intersecting planes P1 and P2, and calculate the normal vectors Normol1 and Normol2 of the planes P1 and P2 respectively.

[0033] S43. Calculate the intersection line I of the planes P1 and P2, and obtain the direction vector Direction of the intersection line I according to the cross product of the normal vectors Normol1 and Normol2.

[0034] S44. According to the structure of the area to be ground on the rotor bracket workpiece, preset the grinding arc radius R. Take a point N on the intersection line I i , let point i = 0, and make N i be the smallest point in the direction of the vector Direction in the grinding area.

[0035] S45. Based on the arc radius R and the point N i obtain the center O of the grinding arc and the grinding arcs M1 i M2 i ;

[0036] S46. Determine the single-step grinding trajectory, that is, passing through point N i Construct the perpendicular line V1 of the intersection line I in the plane P1 i , the perpendicular line V1 i intersects the dividing line L1 at point Q1 i ; passing through point N i Construct the perpendicular line V2 of the intersection line in the plane P2 i , the perpendicular line V2 i intersects the dividing line L2 at point Q2 i ; then a complete trajectory in the first section direction is successively the straight line Q1 i M1 i , the grinding arc M1 i M2 i and the straight line M2 i Q2 i ;

[0037] S47. Determine all grinding trajectories, that is, preset the extension distance parameter step, extend the current point N i along the direction vector Direction of the intersection line I by a distance of step, then let i = i + 1, and return to step S45 after obtaining the new point Ni until all grinding trajectories on all sections are obtained;

[0038] S48. Move the straight line trajectories on the planes P1 and P2 inward by a distance of R(t) along their respective normal directions, and move the arc trajectories inward by a distance of R(t) towards the center O of the circle. The lines obtained after inward movement are the trajectory information generated by the path planning unit.

[0039] Preferably, in the step S43, obtaining the center O of the grinding arc and the grinding arcs M1 i M2 i includes the following steps:

[0040] S451. With point N i as the center, make a circle with a virtual radius D. The intersection points of this circle with the planes P1 and P2 are M1 i and M2 i ;

[0041] S452. Pass through M1 i and extend along the normal vector Normol1 by a distance of R, pass through M2 i and extend along the normal vector Normol2 by a distance of R, so that the normal vector Normol1 and the normal vector Normol2 intersect at point O with a length of R respectively, that is, the center O of the grinding arc;

[0042] S453. Based on the center O and the arc radius R, make a circle to obtain the grinding arcs M1 i M2 i; At this time, the included angle between the normal vectors Normol1 and Normol2 is θ, and the virtual radius D = R * tan(θ / 2).

[0043] Preferably, in the step S5, the method for planning the specific motion trajectory of the robot is as follows: Store the robot trajectory information in a text file, with each point position data recorded on a separate line. Each line records the X, Y, Z, A, B, and C values of the robot, and the values are separated by spaces. Use the SDK provided by the robot to convert the text file in this data format into an executable program for the robot, that is, the specific motion trajectory program. Among them, X, Y, and Z represent the axis position coordinates of the robot's end tool in space, and A, B, and C represent the attitude angles of the robot's end tool on the X-axis, Y-axis, and Z-axis to determine the orientation of the robot's end tool. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld.

[0044] Compared with the prior art, the advantages of this technical solution are as follows:

[0045] First, the degree of automation is significantly improved.

[0046] Get rid of the dependence on manual teaching: Through the vision detection unit, point cloud integration unit, and path planning unit, the present invention automatically completes the surface model reconstruction of the rotor bracket workpiece, point cloud data processing, and grinding trajectory generation without manual teaching, reducing the operation difficulty. Ordinary operators can also easily use it, greatly improving the degree of automation and production efficiency.

[0047] Full-process automated operation: From workpiece placement, scanning, trajectory planning, simulation verification to grinding operation, and then to fault handling and continuous grinding of multiple welds, the entire process realizes a high degree of automation. The system can automatically identify the weld position, plan the grinding trajectory, verify the safety of the trajectory, and automatically alarm and resume operation in case of a fault, reducing manual intervention and improving the continuity and stability of production.

[0048] Second, it is suitable for grinding complex curved surface structural parts.

[0049] Solve the problem of grinding complex curved surfaces: Through advanced vision detection and point cloud processing technologies, the present invention can accurately reconstruct the surface model of complex curved surface structural parts such as rotor brackets, and generate the end surface trajectory suitable for grinding in combination with the path planning algorithm, effectively solving the problem of grinding complex curved surface structural parts and broadening the application scope of the system.

[0050] Precise trajectory planning: In step S4, manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld seam. Through a series of operations such as precise segmentation of the grinding area, plane fitting, intersection line calculation, and arc determination, an accurate grinding trajectory can be generated according to the geometric shape of the curved surface structural part and the weld seam position. At the same time, considering the radius of the grinding tool, the trajectory is adjusted inward to ensure the consistency and accuracy of the grinding effect.

[0051] III. The system has rich and perfect functions

[0052] Multi-module collaborative work: The system includes multiple functional units such as a vision detection unit, a point cloud integration unit, a path planning unit, an execution unit, a database, and an interface main control unit. It is also equipped with functional modules such as an external interface unit, a collision analysis and obstacle avoidance unit, a self-check and status detection unit, an integrated process programming unit, and a fault alarm unit. Each functional module cooperates with each other to form a complete closed-loop control system, which can realize the comprehensive monitoring and precise control of the grinding process.

[0053] Ensure the safety and reliability of the system: The collision analysis and obstacle avoidance unit conducts simulation verification before the robot performs grinding operations to eliminate collision risks. If the verification fails, the trajectory can be re-planned or optimized to ensure that the robot works in a safe environment. The self-check and status detection unit real-time monitors parameters such as the robot status, external axis status, and grinding pressure, and discovers potential problems in a timely manner. The fault alarm unit alarms in a timely manner when a system failure occurs and can continue to execute tasks from the interrupted position after the fault is eliminated, ensuring the reliability and stability of the system.

[0054] IV. Strong process flexibility and customizability

[0055] Integrated process programming unit: The integrated process programming unit allows operators to edit the grinding process steps and adjust process parameters according to different process requirements, and can meet diverse grinding needs. Operators can flexibly adjust the grinding process according to the material of the rotor bracket, the type of weld seam, and the grinding quality requirements, improving the adaptability and flexibility of the system.

[0056] Multi-mode scanning: The vision detection unit combines remote scanning and proximal scanning. The remote scanning preliminarily locates the grinding points, and the proximal scanning performs precise measurement. It can be flexibly adjusted according to the actual situation of the workpiece, improving the grinding accuracy and efficiency. Description of the drawings

[0057] Figure 1 It is a preferred structural schematic diagram of a robot automatic grinding control system for the longitudinal weld of a rotor bracket;

[0058] Figure 2 It is a preferred implementation flowchart of a robot automatic grinding control method for the longitudinal weld of a rotor bracket;

[0059] Figure 3 It is a schematic diagram of the connection structure between the central cylinder and the large vertical rib of the rotor bracket workpiece;

[0060] Figure 4 It is a schematic diagram of the structure for dividing the point cloud with dividing lines L1 and L2;

[0061] Figure 5 It is a schematic diagram of the structure for obtaining extended intersecting planes P1 and P2 by plane segmentation fitting of point cloud data;

[0062] Figure 6 It is to obtain the center O of the grinding arc and the grinding arc M1 i M2 i of the schematic principle.

[0063] In the figure:

[0064] 1. Longitudinal weld; 2. Large vertical rib; 3. Central cylinder. Specific implementation manners

[0065] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. It should not be understood that the present invention is limited to the following examples. Without departing from the concept of the present invention, the deformations and improvements of the present invention in this field should be included within the protection scope of the claims of the present invention.

[0066] Unless otherwise defined, the technical terms or scientific terms used in this disclosure should have the ordinary meanings understood by those of ordinary skill in the field to which this disclosure belongs. The words such as "or" and "comprising" used in this disclosure mean that the elements or objects appearing before the word cover the elements or objects listed after the word and their equivalents, without excluding other elements or objects.

[0067] Embodiment 1

[0068] This embodiment discloses a robot automatic grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation manner of this embodiment, as Figure 1 shown, it includes:

[0069] The vision detection unit includes several laser scanners and corresponding image acquisition devices, which are based on the requirement of being able to meet the scanning of the rotor bracket workpiece. The vision detection unit scans the rotor bracket workpiece and can be installed on an adjustable robotic arm or a fixed mount to ensure covering the entire surface of the workpiece. Inside the vision detection unit, a high-performance image processing chip is equipped to process the image information obtained by scanning, supporting multiple scanning modes such as line scanning and surface scanning, so as to more precisely complete the reconstruction of the workpiece surface model and obtain the original image data of the surface of the rotor bracket workpiece;

[0070] The point cloud integration unit has a powerful data processing chip and a large-capacity memory to handle the large amount of raw data collected by the laser scanner. The point cloud integration unit is connected to the data bus and supports multiple data transmission protocols such as Ethernet and CAN bus, etc., to ensure the stable transmission of data, and is used to receive the raw image data collected by the vision detection unit through the data bus. The point cloud integration unit contains special calculation modules, coordinate transformation modules and filtering modules, and these modules can adopt hardware acceleration technology to improve the data processing speed, and are used to preprocess the raw image data including calculation, coordinate transformation and filtering, convert the raw image data into ordered and processable point cloud data, and perform meshing processing and output to a file.

[0071] The path planning unit uses advanced 3D modeling software and algorithm libraries to construct a 3D model of the rotor bracket workpiece according to the received proximal point cloud data. The path planning unit is embedded with a trajectory calculation algorithm, considering factors such as the size, shape and grinding accuracy of the grinding tool, as well as the geometric shape and weld position of the rotor bracket workpiece, generates environmental data, and calculates the end surface trajectory suitable for grinding, thereby generating trajectory information;

[0072] The execution unit includes an industrial robot controller (referred to as the controller) and a robot body (referred to as the robot). The robot is usually a multi-axis articulated robot, with high precision, high speed and high load capacity, and can adapt to rotor bracket workpieces of different sizes and weights. The controller integrates a trajectory planning algorithm and a kinematics algorithm, and is used to accurately plan the motion trajectory of the robot according to the read trajectory information. To sum up, the execution unit is used to read the trajectory information generated by the path planning unit, plan the specific motion trajectory of the robot according to the kinematics principle of the robot, and send the motion trajectory data to the robot for grinding operations.

[0073] The database adopts a distributed database architecture to ensure the reliability and scalability of data storage. It has a dedicated data storage area for storing the operation data of the robot automated grinding control system, as well as the intermediate data and result data generated by each functional unit (i.e., vision detection unit, point cloud integration unit, path planning unit, execution unit, etc.), including but not limited to vision scanning data, system operation logs, robot motion trajectory data, etc.

[0074] The interface master control unit may include an industrial computer and a high-resolution display screen. The industrial computer has powerful computing power and graphics processing capabilities. The interface master control unit has an intuitive operation interface, which is convenient for users to operate and monitor each functional unit. That is, the interface master control unit is used to read the status information of each functional unit in real time and display this status information intuitively on the interface; at the same time, it provides an operation interface for operators to perform operations on the robot automated grinding control system, including parameter setting and start / stop control.

[0075] Based on the above structure, the working principle of this technical solution is as follows:

[0076] First, after the system is started, the vision detection unit first scans the rotor bracket workpiece to obtain the original image data of the workpiece surface.

[0077] Secondly, the original image data is transmitted to the point cloud integration unit through the data bus. The point cloud integration unit performs preprocessing such as data calculation, coordinate transformation, and filtering on the data, converts the disordered original data into ordered and processable point cloud data, and performs meshing processing, outputs it to a file, and at the same time stores the data in the database. The calculation process converts the original sensor data into spatial coordinate information; coordinate transformation can unify the data in different coordinate systems into a standard coordinate system for convenient subsequent processing; filtering is used to remove noise points and abnormal points to improve data quality. The meshing operation converts the processed point cloud data into a three-dimensional mesh model for subsequent path planning and storage.

[0078] Then, based on the meshed point cloud data, the path planning unit constructs a three-dimensional workpiece model of the rotor bracket workpiece, analyzes the geometric features and weld positions of the workpiece. Based on the grinding process requirements, such as grinding depth, width, roughness, etc., it generates the end surface trajectory of the robot grinding. The trajectory takes into account the working space of the robot, kinematic constraints, and the physical characteristics of the grinding tool to ensure the consistency and reliability of the grinding effect.

[0079] Furthermore, after receiving the trajectory information, the execution unit converts the end surface trajectory of the grinding into a motion trajectory recognizable by the robot according to the kinematic model of the robot.

[0080] Finally, during the operation of the entire system, the database stores a large amount of visual scanning data and system operation data, providing data support for system performance evaluation, fault diagnosis, and process optimization. The interface master control unit monitors the operation status of the system in real time. Operators can set system parameters, schedule tasks, and query the status through the interface. When abnormal situations occur, timely intervention and adjustment can be carried out to ensure the stable operation of the system.

[0081] Embodiment 2

[0082] This embodiment discloses a robot automatic grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Embodiment 1, it further includes an external interface unit, and the external interface unit provides a production system interface and a positioner interface.

[0083] The production system interface is used to interact with the entire production system and coordinate work. Standard industrial communication protocols can be adopted, such as industrial Ethernet (for example, manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; PROFINET, Ethernet / IP) or fieldbus (for example, manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; PROFIBUS, DeviceNet) to achieve connection with other devices on the production line. The functions of the production system interface include receiving task instructions from the production system, such as signals to start the grinding task, identification information of the rotor bracket workpiece, and processing requirements, etc. At the same time, feedback the status information of the grinding control system (such as preparation status, running status, completion status) to the production system for task scheduling and monitoring. In addition, the production system interface can synchronize the material flow information with the production system to ensure that the rotor bracket workpiece to be ground is transported to the working position of the grinding control system at the appropriate time and remove the ground workpiece, realizing seamless connection of the entire production process.

[0084] Thus, the automated grinding control system can be connected to devices such as programmable logic controllers (PLCs) or manufacturing execution systems (MES) in the production system through the production system interface. When manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; for PLC, manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; during connection, it can receive digital or analog control signals sent by them, such as start and stop signals for grinding tasks; when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; for MES, manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; during connection, it can receive more detailed production task information, such as the batch number of the workpiece, processing process parameters, etc. At the same time, various status information of the grinding system (such as task completion status, equipment operation status, fault information, etc.) is fed back to the production system, enabling the production system to comprehensively understand the situation of the grinding system and achieve automated management of the production process.

[0085] The positioner is a device used to change the position and attitude of the workpiece during welding and processing. In this grinding control system, the positioner interface allows the system to communicate with and control the positioner. The positioner interface can use a dedicated control signal protocol, such as analog signals (e.g., when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; 4 - 20mA when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; current signal or when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; 0 - 10V when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; voltage signal) or digital signals (such as high and low level signals), or it can also use more advanced communication protocols, such as when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; CAN when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; bus or when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; Modbus when manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld seam; protocol to achieve precise control of the positioner. The function of the positioner interface is to control actions such as the rotation and flipping of the positioner to adjust the rotor bracket workpiece to the optimal grinding position. For example, according to the workpiece attitude information provided by the vision detection unit, control instructions are sent to the positioner through the positioner interface to make the longitudinal weld of the workpiece in the most favorable position and angle for grinding. At the same time, it can also receive the status information of the positioner (such as the current position, attitude, motion state, etc.) to ensure the safety and effectiveness of the grinding operation.

[0086] Thus, the automated grinding control system can communicate with the controller of the positioner through the positioner interface. Send control commands to the controller of the positioner, such as rotation angle, speed, direction, etc., so that the positioner adjusts the posture of the rotor bracket workpiece according to the requirements of the grinding system. At the same time, receive the current position and status information feedback by the positioner to ensure that the positioner is in the correct position and status when the grinding operation is carried out, avoiding affecting the grinding quality and safety due to the misoperation of the positioner.

[0087] Embodiment 3

[0088] This embodiment discloses a robot automated grinding control system for the longitudinal weld of the rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Embodiment 1 or 2, its execution unit includes a grinding module and a chipping grinding module, which are respectively used to automatically generate the end grinding trajectory and the end chipping grinding trajectory based on the three-dimensional point cloud data combined with the grinding process requirements.

[0089] Among them, the grinding module includes a grinding motor, a grinding tool, a driving mechanism for the grinding tool, and related controllers. The grinding motor provides power for the grinding tool, and its power and speed can be adjusted according to the grinding process requirements. The grinding tool is usually a grinding wheel or grinding disc with high hardness and wear resistance, and different types of tools can be selected according to different grinding needs, such as surface grinding tools, fillet grinding tools, etc. The driving mechanism is responsible for precisely controlling the position and posture of the grinding tool, generally using high-precision servo motors and precision transmission mechanisms, such as ball screws, linear guides, etc., to ensure that the tool can accurately move along the generated end grinding trajectory.

[0090] Trajectory generation of the grinding module: Based on the scanned three-dimensional point cloud data and the grinding process requirements, the grinding module automatically generates the end grinding trajectory. First, analyze the three-dimensional point cloud data to determine the area and surface features that need to be ground, such as the surface roughness and flatness requirements of the rotor bracket workpiece. According to the grinding process, consider parameters such as grinding depth, grinding speed, and grinding direction, and combine the kinematic and dynamic characteristics of the robot to calculate the optimal movement trajectory of the grinding tool in space. For example, for a planar area that needs to reach a specific surface roughness, according to the grinding process requirements, calculate the feed speed, grinding depth, and number of grinding passes of the grinding tool, and generate the corresponding trajectory to ensure uniform grinding in this area and achieve the required surface quality. When generating the end grinding trajectory, the radius and shape of the grinding tool will also be considered to avoid over-cutting or under-cutting phenomena caused by the tool size and shape. Through the precise analysis of the three-dimensional point cloud data, ensure that the grinding tool can accurately fit the workpiece surface and avoid interference with the workpiece.

[0091] The scraping and grinding module includes scraping and grinding tools, such as scraping knives or special scraping and grinding cutters, as well as their driving and control parts. The shape and size of the scraping and grinding tools are designed according to the scraping and grinding requirements of the longitudinal weld of the rotor bracket workpiece, and usually have special geometric shapes to adapt to welds of different shapes and sizes. The driving mechanism of the scraping and grinding tools also uses high-precision motors and transmission components to ensure the accuracy and stability of the scraping and grinding operations.

[0092] Trajectory generation of the scraping and grinding module: The principle of trajectory generation of the scraping and grinding module is similar to that of the grinding module, but it focuses more on the processing of longitudinal welds. By analyzing the weld part in the three-dimensional point cloud data, information such as the shape, width, depth, and position of the weld is determined. According to the scraping and grinding process, such as the requirements for scraping depth, width, and angle, the movement trajectory of the scraping cutter is calculated. Scraping operations usually require precise cutting of the weld. Therefore, when generating the trajectory, the cutting-in and cutting-out angles of the scraping cutter are precisely controlled to ensure the scraping effect. For example, for a V-shaped weld, according to its geometric shape and scraping and grinding process requirements, calculate the movement trajectory of the scraping cutter in the V-shaped weld to ensure that the excess part of the weld is completely removed, while ensuring the flatness of the scraped surface and the smooth transition with the surrounding surface.

[0093] Thus, the working process of the execution unit is as follows:

[0094] First, the execution unit obtains the preliminary trajectory information and grinding process requirements from the path planning unit, and obtains the scanned three-dimensional point cloud data from the system.

[0095] Secondly, the grinding module and the scraping and grinding module respectively refine and optimize the preliminary trajectory according to their own tool characteristics and process requirements to generate accurate end grinding trajectories and end scraping and grinding trajectories.

[0096] Then, the generated trajectory is sent to the robot controller, and at the same time, the grinding and scraping and grinding operations are started. The grinding and scraping and grinding tools move along the trajectory under the control of the driving mechanism to grind the workpiece.

[0097] Furthermore, during the grinding process, according to the feedback information from the robot controller, the grinding parameters and trajectory are continuously adjusted to ensure the grinding quality and safety.

[0098] Finally, after the grinding operation is completed, the final grinding data and results are fed back to other units of the system, such as the interface main control unit and the database, for recording and subsequent analysis.

[0099] Example 4

[0100] This embodiment discloses a robot automatic grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation of this embodiment, that is, based on Embodiment 1, 2 or 3, it further includes a collision analysis and obstacle avoidance unit. The collision analysis and obstacle avoidance unit includes a simulation software module, a collision detection algorithm module, and an obstacle avoidance strategy module, which are used to perform operation simulation verification through the simulation function before the robot performs grinding operations to rule out the possibility of collisions. Among them, if the simulation verification fails, it is necessary to call the path planning unit to re-plan the path or call the execution unit to optimize and adjust the trajectory; if the simulation verification passes, the execution unit is triggered to send the motion trajectory data to the robot for grinding operations.

[0101] Simulation software module: It includes a three-dimensional physics engine and can accurately simulate the robot and its surrounding environment. The simulation software module can establish a virtual simulation scenario according to the physical parameters of the robot (such as shape dimensions, joint movement ranges, mass, inertia, etc.) and the working environment (including the three-dimensional models of workpieces, positioners, workbenches, etc.). It supports importing various three-dimensional model file formats, such as manually adjusting the rotor bracket workpiece to a predetermined position and locking it, and moving the robot to the initial position of the weld; STL, STEP, IGES, etc., so as to import the geometric models of the robot, workpiece and other equipment into the simulation environment. At the same time, it can also receive the grinding trajectory information from the path planning unit and apply it to the motion simulation of the robot.

[0102] Collision detection algorithm module: It adopts efficient collision detection algorithms, such as the Bounding Volume Hierarchy (BVH) algorithm, the Spatial Partitioning algorithm, etc. These algorithms divide the robot and surrounding objects into different levels or regions to quickly judge whether collisions may occur between objects. It can monitor in real time the distance and position relationship between each component of the robot (such as the robotic arm, grinding tool, cable, etc.) and surrounding objects during the execution of the grinding trajectory, with an accuracy of up to millimeter level or even higher. When the distance is less than the safety threshold, it is determined that a collision may occur.

[0103] Collision avoidance strategy module: Once a possible collision risk is detected, the collision avoidance strategy module formulates corresponding collision avoidance plans according to different situations. These strategies can include modifying the robot's motion trajectory, adjusting the robot's posture, pausing the robot's motion, or even re-planning the grinding trajectory. Optimized collision avoidance trajectories can be generated based on the kinematic and dynamic characteristics of the robot to ensure that while avoiding collisions, the efficiency and quality of the grinding operation are not affected as much as possible.

[0104] Thus, the working principle of the collision analysis and avoidance unit is as follows:

[0105] Scene establishment: First, the collision analysis and avoidance unit obtains relevant information from the system. Extract the detailed physical parameters and kinematic parameters of the robot from the database, obtain the grinding trajectory from the path planning unit, and obtain the three-dimensional model information of the workpiece and the surrounding environment from the vision detection unit or other relevant units. Import this information into the simulation software module to establish a complete virtual simulation scene, including the initial state of the robot, the position and posture of the workpiece, and other equipment and environmental factors that may affect the robot's motion.

[0106] Collision analysis process: In the simulation environment, the robot moves according to the planned grinding trajectory. The collision detection algorithm module will track the robot's motion in real time and perform collision detection on the geometric shapes of the robot and its components and surrounding objects. For each time step or motion node, calculate the relative position and distance between the robot and the surrounding objects, and use algorithms such as hierarchical bounding boxes to quickly screen out the areas where collisions may occur, and then perform precise geometric calculations to determine whether a real collision occurs. For example, for a multi-axis robot, check whether each joint and its connecting components will collide with the workpiece, positioner, or other equipment during motion.

[0107] Collision avoidance operation: When a collision risk is detected, the collision avoidance strategy module will be activated. According to the specific collision situation, it can adopt different collision avoidance strategies. If there is only a slight interference risk, the robot's motion trajectory may be slightly adjusted, such as changing the motion speed of the robot joints, adjusting the motion direction, or modifying some path points of the trajectory, so that the robot bypasses the potential collision area. In more complex situations, it may be necessary to re-plan the robot's motion trajectory, considering changing the robot's posture so that the robot approaches or bypasses the obstacle in a safer posture. At the same time, the requirements of the grinding process will be comprehensively considered to ensure that the collision avoidance operation does not have a significant impact on the grinding quality.

[0108] Embodiment 5

[0109] This embodiment discloses a robot automatic grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation of this embodiment, that is, based on Embodiments 1, 2, 3, or 4, it further includes a self-check and status detection unit. The self-check and status detection unit includes a sensor module (including a robot status sensor, an external axis status sensor, and a grinding pressure sensor), a data acquisition and processing module, and a status evaluation and alarm module, which are used to perform self-check on the system operation, including monitoring the robot status and position parameters, the external axis status and position, and the grinding pressure.

[0110] Robot status sensor: It includes joint angle sensors, joint torque sensors, motor encoders, etc., which are used to measure the angles of each joint of the robot, the torque borne, and the rotational position of the motor. These sensors can accurately feedback the motion state of the robot and provide a basis for subsequent status evaluation and control. For example, joint angle sensors usually use high-precision rotary encoders, which can accurately measure the rotation angle of the robot joints, and their measurement accuracy can reach ±0.1° or even higher, ensuring the accuracy and stability of the robot motion. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld.

[0111] External axis status sensor: For external axes (such as positioners, etc.), corresponding position sensors and speed sensors are equipped. The position sensor can be a linear encoder or a rotary encoder, which is used to measure the displacement or rotation angle of the external axis; the speed sensor can measure the motion speed of the external axis to ensure that the position and speed of the external axis are within the set range and accuracy, so as to accurately monitor the working state of the external axis.

[0112] Grinding pressure sensor: It is usually installed between the grinding tool and the end effector of the robot and is used to measure the pressure during the grinding process. Common grinding pressure sensors include strain gauge sensors or piezoresistive sensors, which can monitor the grinding pressure in real time to ensure that the grinding pressure meets the process requirements and avoid affecting the grinding quality or damaging the workpiece due to excessive or too little pressure.

[0113] Data acquisition and processing module: It is responsible for collecting data from each sensor and performing preprocessing on it. This module will convert the analog signals output by the sensors (such as the voltage signal of the pressure sensor) into digital signals, and then perform operations such as filtering, amplification, and linearization to ensure the accuracy and availability of the data. At the same time, it will perform preliminary analysis and sorting on the data, such as averaging multiple collected data points and removing outliers, etc., to improve the reliability of the data.

[0114] Status Evaluation and Alarm Module: Based on the collected and processed data, it evaluates parameters such as the robot status, external axis status, and grinding pressure. It is set with a series of status thresholds, such as the maximum and minimum allowable ranges of the robot joint torque, the limit positions of the external axis positions, and the reasonable range of the grinding pressure, etc. When the monitored parameters exceed or are lower than these thresholds, corresponding alarm mechanisms will be triggered, such as emitting audible and visual alarm signals and displaying alarm information on the interface main control unit to prompt the operator to handle it.

[0115] Thus, the working principle of the self-check and status detection unit is as follows:

[0116] Data Acquisition: The sensor module continuously measures parameters such as the robot status and position, external axis status and position, and grinding pressure. For example, the robot joint angle sensor will continuously monitor the angle changes of each joint of the robot, the joint torque sensor will measure the torque borne by the joints during the movement and grinding of the robot, the external axis position sensor will track the position changes of the external axis, and the grinding pressure sensor will sense the pressure exerted by the grinding tool on the workpiece. These sensors will send the measured data to the data acquisition and processing module in different signal forms (such as voltage, current, pulse, etc.).

[0117] Data Processing and Analysis: The data acquisition and processing module processes the sensor data. For analog signals, first, perform analog-to-digital conversion to convert it into a digital signal that can be processed by a computer. Then, filter the digital signal to remove noise and interference, such as using a low-pass filter to filter out high-frequency noise to ensure the smoothness of the data. At the same time, perform linearization processing to establish an accurate correspondence between the output of the sensor and the actual physical quantity. For example, convert the voltage signal of the pressure sensor into the actual pressure value. Analyze the processed data, such as calculating the change rate of the robot joint angle over a period of time to evaluate the movement speed of the robot; check whether the external axis position reaches the preset limit position; analyze whether the grinding pressure is stable or meets the process requirements.

[0118] Status Evaluation and Alarm: The status evaluation and alarm module evaluates the processed data according to preset status thresholds. Taking the joint torque of the robot as an example, if the measured joint torque exceeds the set safety upper limit, it may indicate that the robot has encountered abnormal resistance during movement, possibly due to mechanical failure or collision; if the grinding pressure exceeds the specified range, it may affect the grinding quality or damage the workpiece. When an abnormal status is detected, the alarm mechanism will be triggered. The alarm can be by popping up an alarm window on the interface main control unit, displaying specific abnormal information (such as manually adjusting the rotor bracket workpiece to the predetermined position and locking it, moving the robot to the initial position of the weld seam; "The joint torque of the robot is too large, there may be a fault"), and at the same time emitting a sound or light signal to remind the operator to handle it in time.

[0119] Embodiment 6

[0120] This embodiment discloses an automated grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Embodiment 1, 2, 3, 4 or 5, it further includes an integrated process programming unit, and the integrated process programming unit includes a process editing module, a process parameter adjustment module, and a process storage and call module, which are used to edit the grinding process steps and adjust the grinding process parameters according to the process requirements.

[0121] Process Editing Module: Provide a user-friendly graphical interface or text editing interface that allows users to input and edit the grinding process steps according to specific process requirements. This interface contains various preset grinding operations, such as the starting position of grinding, the grinding path mode (straight line, curve, circle, etc.), the number of grinding times, etc. Users can customize the grinding process steps through intuitive operations or input corresponding instructions. It has functions of adding, deleting, modifying, and sorting process steps. Users can flexibly adjust the operation sequence of grinding according to the characteristics of the longitudinal weld of different rotor bracket workpieces and the grinding requirements. For example, for complex welds, a rough grinding step can be added first, and then a fine grinding step can be added to achieve a better grinding effect.

[0122] Process Parameter Adjustment Module: Allow users to adjust the grinding process parameters, which may include the grinding depth, grinding speed, feed speed of the grinding tool, grinding angle, etc. This module will perform range checks and legality verifications on the input parameters to ensure that the input parameters are within the range allowed by the equipment and process. Provide a real-time preview function of the parameters. When users adjust the parameters, they can intuitively see the impact of parameter changes on the grinding effect, such as showing the grinding effect under different parameters through an animation or chart simulating grinding to help users optimize the parameter settings.

[0123] Process storage and call module: Stores the grinding process steps and parameters edited by the user, which can be stored in the local database or file system. The stored information includes the name of the process, the applicable workpiece types, the detailed process steps and parameter lists, etc., facilitating the user to reuse them in subsequent grinding operations. Supports quick call of processes. The user can select the corresponding process program from the stored process library according to the workpiece type and grinding requirements, avoiding repeated input and adjustment.

[0124] Thus, the working principle of the integrated process programming unit is as follows:

[0125] Process editing process: Through the process editing module, the user formulates the grinding process steps according to the shape, size, material of the longitudinal weld of the rotor bracket and the final grinding requirements. First, select a suitable starting position for grinding, considering the geometric shape of the workpiece and the accessibility of the robot to ensure that the grinding operation can completely cover the weld area to be processed. Then determine the grinding path mode. For example, for a long straight weld, select a straight grinding path mode; for a circular or arc-shaped weld, select a circular or curved grinding path mode. During the editing process, the specific details of each grinding step can be set. For example, in a straight grinding path, specify the length and direction of grinding.

[0126] Process parameter adjustment: Based on the grinding process steps, the user uses the process parameter adjustment module to adjust the specific parameters. For the grinding depth, set it according to the depth of the weld and the grinding quality requirements. Considering the material removal amount and surface roughness, determine a reasonable grinding depth value. When adjusting the grinding speed and the feed speed of the grinding tool, consider the hardness of the material and the performance of the tool to ensure the balance of efficiency and quality in the grinding process. At the same time, the adjustment of the grinding angle should be based on the shape of the weld and the geometric shape of the grinding tool to ensure the best contact between the tool and the workpiece during grinding, avoiding over-cutting or under-cutting. The adjustment of these parameters will display the possible effects on the interface by simulating the grinding process according to the preset algorithms and physical models, and the user can continuously optimize the parameters according to the simulation results.

[0127] Process storage and call: When the process editing and parameter adjustment are completed, the process storage and call module stores the entire process information. The stored processes can be classified according to information such as process name and workpiece type for convenient subsequent retrieval. In subsequent grinding operations, the user can call the corresponding process program from the stored process library according to the information of the new workpiece. When calling, the stored process steps and parameter information will be sent to the execution unit and the path planning unit to provide specific guidance for the grinding operation.

[0128] Embodiment 7

[0129] This embodiment discloses a robot automatic grinding control system for the longitudinal weld of a rotor bracket. As a preferred implementation of this embodiment, that is, based on Embodiments 1, 2, 3, 4, 5, or 6, it further includes a fault alarm unit. The fault alarm unit includes a fault recording and storage module and a fault recovery and task recovery module, which are used to monitor the system fault conditions during the grinding operation. When the robot automatic grinding control system fails and interrupts, the sound and light alarm unit gives a sound and light alarm reminder, and triggers the system to continue task execution from the interrupted position after the fault is eliminated.

[0130] Fault monitoring module: Establish communication connections with each unit in the system (such as the execution unit, vision detection unit, point cloud integration unit, etc.), and collect their status information and operation data in real time. This information may include but is not limited to the motion state of the robot, the working state of the grinding tool, the measurement data of the sensor, the result of data processing, and the communication state of each unit. It has a fault judgment logic, and judges whether an abnormal situation occurs by analyzing the collected data. For example, monitor whether the joint torque of the robot exceeds the normal range, whether the rotation speed of the grinding tool is abnormal, whether the data transmission is interrupted, etc. At the same time, it will judge whether the standard for triggering a fault alarm is reached according to the preset fault thresholds and conditions.

[0131] Fault recording and storage module: Once a fault is detected, this module will store the fault information (including the time of fault occurrence, fault type, fault location, relevant parameters, etc.) in the local storage device or database. The stored information can be used as the basis for subsequent fault analysis and system maintenance, which helps technicians find the root cause of the fault and optimize the system performance. The fault information can be classified and stored. For example, faults can be classified into mechanical faults, electrical faults, software faults, communication faults, etc., which is convenient for subsequent query and statistics.

[0132] Fault recovery and task recovery module: After the fault is eliminated, according to the location where the fault occurred and the system state at the time of the fault, this module is responsible for coordinating the system to continue task execution from the interrupted position. It will cooperate with the execution unit, path planning unit, etc. to restore the running state of the system, ensuring that the system can resume the grinding operation from the position where the fault interrupted. Different recovery strategies may need to be formulated according to different types of faults. For simple faults, such as a temporary communication interruption, the recovery strategy may be to re-establish the communication connection and continue the task; for complex faults, such as a grinding tool fault, it may be necessary to wait for the tool to be replaced or repaired, and then re-plan the subsequent tasks according to the existing trajectory and task progress.

[0133] Thus, the working principle of the fault alarm unit is as follows:

[0134] Fault Monitoring and Alarm Triggering: The fault monitoring module continuously monitors the operating status and data of each unit of the system. For example, when the robot is performing a grinding operation, it monitors information such as the joint torque, speed, and position of the robot. If it is found that the joint torque suddenly increases beyond the set threshold, it may mean that the robot has encountered abnormal resistance, which may be caused by workpiece position deviation or grinding tool failure. When the monitored abnormal situation reaches the fault alarm standard, the fault monitoring module will trigger a fault alarm operation, send a corresponding control signal to the acoustic-optic alarm unit, and make it emit an acoustic-optic alarm. At the same time, the fault information is transmitted to the fault recording and storage module for storage.

[0135] Acoustic-optic Alarm Operation: After receiving the control signal from the fault alarm unit, the acoustic-optic alarm unit will perform an acoustic-optic alarm according to the preset alarm mode. The acoustic-optic alarm can use different sound frequencies, sound intensities, and light colors to distinguish different types of faults, so that the operator can quickly identify the severity of the fault. For example, for a serious fault, it may emit a high-frequency loud sound and a flashing red light; for a minor fault, it emits a low-frequency soft sound and a yellow light.

[0136] Task Recovery after Fault Elimination: When the operator eliminates the fault, the system will feedback the information of fault elimination to the fault recovery and task recovery module. This module will first read the fault record and analyze the fault type and the system status at the time of fault occurrence. For task recovery, it will cooperate with the execution unit and the path planning unit. If it is interrupted accidentally during the grinding process, it will obtain the robot position, grinding trajectory, and process progress information before the interruption from the database, coordinate the execution unit to adjust the robot to the interrupted position, and continue to execute the subsequent grinding task according to the existing grinding trajectory and process requirements.

[0137] Embodiment 8

[0138] This embodiment discloses a control method for automatic grinding of the longitudinal weld of a rotor bracket by a robot. As a preferred implementation manner of this embodiment, the automatic grinding control system of the longitudinal weld of the rotor bracket in any one of the foregoing Embodiments 1 to 7 is adopted, and specifically includes the following steps:

[0139] S1. The rotor support workpiece is positioned. Manually place the rotor support workpiece in the predetermined position and lock it. This step mainly relies on the experience and skills of the operator to accurately place the rotor support workpiece in a position suitable for subsequent automated grinding operations, ensuring the stability and accuracy of its position. The predetermined position adjusted manually is determined according to the layout of the equipment and the requirements of the grinding process. For example, it is necessary to ensure that the longitudinal weld of the rotor support workpiece is within the working range of the vision inspection unit and the robot, and there will be no position deviation or instability during the subsequent grinding process. The locking operation can be achieved through mechanical fixing devices such as jigs and bolts to prevent the rotor support workpiece from shifting due to vibration or other external forces during the grinding process.

[0140] S2. Start the vision inspection unit to scan the rotor support workpiece, complete the surface model reconstruction of the rotor support workpiece, and obtain the original image data of the surface of the rotor support workpiece. The vision inspection unit scans the weld of the rotor support workpiece twice to complete the surface model reconstruction of the workpiece. The first scan may be a preliminary overall scan of the entire rotor support workpiece, aiming to obtain the general contour and basic geometric information of the workpiece, providing a basis for subsequent detailed scans and processing. The second scan will focus more on the weld area of the rotor support workpiece to improve the scanning accuracy and details, so as to better reconstruct the surface model of the workpiece.

[0141] S3. The point cloud integration unit receives the original image data collected by the vision inspection unit through the data bus, and performs preprocessing on the original image data including calculation, coordinate transformation, and filtering, converts the original image data into ordered and processable point cloud data, and performs meshing processing, and outputs it to a file. The calculation process is to convert the original image data into point cloud data with spatial coordinates, and convert the original signal of the laser scanner into three-dimensional coordinate information with practical significance. The coordinate transformation operation unifies the point cloud data obtained from different scanners or different scanning stages into a standard coordinate system for subsequent processing. The filtering operation can remove noise points and abnormal points to improve the data quality, and algorithms such as Gaussian filtering and median filtering can be used. Meshing is to convert the processed point cloud data into a three-dimensional mesh model, that is, to connect the discrete point clouds into a mesh, which is convenient for subsequent calculations and analyses, and is also convenient for storage and visualization. The meshed file can be a common three-dimensional file format, such as manually adjusting the rotor support workpiece to the predetermined position and locking it, moving the robot to the initial position of the weld; STL, OBJ manually adjusting the rotor support workpiece to the predetermined position and locking it, moving the robot to the initial position of the weld; etc.

[0142] S4. The path planning unit receives the near-end point cloud data from the point cloud integration unit, constructs a three-dimensional model of the rotor bracket workpiece, analyzes the geometric shape and weld positions of the rotor bracket workpiece, generates environmental data, and calculates the end-surface trajectory suitable for grinding, thereby generating trajectory information. The workpiece model constructed using the near-end point cloud data is more accurate and can reflect the detailed features of the workpiece. The generation of the environmental data takes into account the environmental information around the workpiece, including the layout of the equipment, the working space of the robot, etc., to ensure that the grinding operation does not interfere with the surrounding environment. The calculation of the end-surface trajectory for grinding is based on the grinding process requirements, such as the depth and width of grinding, the shape and size of the grinding tool, etc., and combines the workpiece model and the environmental data to generate the movement trajectory of the end of the robot grinding tool. This trajectory ensures that the grinding tool can accurately fit the weld surface while meeting the quality requirements of grinding.

[0143] S5. The execution unit reads the trajectory information and plans the specific movement trajectory of the robot according to the kinematic principle of the robot.

[0144] S6. The movement trajectory is verified through simulation by the collision analysis and obstacle avoidance unit; if the simulation verification fails, it is necessary to call the path planning unit to re-plan the path or call the execution unit to optimize and adjust the trajectory; if the simulation verification passes, the execution unit is triggered to send the movement trajectory data to the robot for grinding operation.

[0145] S7. During the grinding operation, the fault situation of the monitoring system is monitored in real time; when the robot automatic grinding control system fails and interrupts, the audible and visual alarm unit is controlled to give an audible and visual alarm reminder, and after the fault is eliminated, the system is triggered to continue the task execution from the interrupted position. The faults may include robot faults, sensor faults, communication faults, etc. Once a fault occurs, the fault alarm unit will trigger an audible and visual alarm to notify the operator. After the fault is excluded, the system will restore the system to the state before the fault according to the stored information (such as the interrupted position of the robot, the completed grinding trajectory, etc.), ensuring that the grinding operation continues from the interrupted position and guaranteeing the coherence and integrity of the entire grinding process.

[0146] S8. The rotor bracket workpiece is rotated to the next weld position by using the roller rack automatic position-changing device, and the above steps S1 - S7 are repeated until the grinding of all welds of the current rotor bracket workpiece is completed.

[0147] In this technical solution, the entire grinding control method is a cyclic process. Starting from the positioning of the rotor bracket workpiece, a series of steps are used to complete the grinding of one weld seam, and then the rotor bracket workpiece is rotated to the position of the next weld seam for continuous grinding until all weld seams are completed. During the whole process, the coordinated work of multiple functional units is involved, such as the visual detection unit, the point cloud integration unit, the path planning unit, the execution unit, the fault alarm unit, etc. These units complete their respective tasks in sequence according to the above steps, and at the same time cooperate with each other and transmit information to jointly achieve the automated grinding operation.

[0148] Embodiment 9

[0149] This embodiment discloses a robot automated grinding control method for the longitudinal weld seam of a rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Embodiment 8, in step S2, the scanning of the rotor bracket workpiece includes one distal scan and one proximal scan.

[0150] When performing the distal scan, the main purpose is to detect the posture of the workpiece. By scanning the overall contour of the workpiece, the approximate shape and posture information of the workpiece are obtained at a relatively long distance, so as to roughly locate the grinding position. This scanning method has a large coverage range, but relatively low accuracy. It is suitable for initially determining the position and posture of the workpiece, providing a general reference for subsequent operations, and avoiding accidental situations such as collisions between the robot and the workpiece.

[0151] The proximal scan focuses on the precise measurement of the grinding points. Scanning at a position close to the workpiece can obtain higher resolution and accuracy, and precisely measure the detailed parts of the workpiece. According to these measurement data and the previously obtained overall contour data, the grinding trajectory can be planned more accurately to ensure that the grinding path closely fits the surface of the workpiece and meets the accuracy requirements of the grinding process.

[0152] Embodiment 10

[0153] This embodiment discloses a robot automated grinding control method for the longitudinal weld seam of a rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Embodiment 8 or 9, in step S4, generating the trajectory information includes the following steps:

[0154] S41, based on the point cloud data, obtain two dividing lines L1 and L2, and use the dividing lines L1 and L2 to divide the point cloud. The area between the two lines is the grinding area, and the areas outside the two lines are two planar areas. In this way, the surface of the complex rotor bracket workpiece is divided into different functional areas, clearly defining the grinding area and the non-grinding planar areas, providing a clear area range for subsequent precise grinding operations, and helping to improve the pertinence and accuracy of grinding.

[0155] S42. Perform plane segmentation and fitting on the point cloud data of the grinding area to obtain two extended intersecting planes P1 and P2, and calculate the normal vectors Normol1 and Normol2 of planes P1 and P2 respectively. Specifically: First, the Random Sample Consensus (RANSAC) algorithm can be used to fit a plane from the point cloud data of the grinding area. This algorithm calculates the plane model and evaluates the number of inliers through multiple random samplings, and finally obtains the best-fitting plane. Then, perform least squares fitting on the point cloud data that satisfies the plane model to solve the coefficients of the plane equation, thereby obtaining plane P1. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; and Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; P2. Finally, according to the coefficients of the plane equation, calculate the normal vector of the plane through vector operations. This provides a basis for subsequent calculation of the intersection line and grinding trajectory. The determination of the two intersecting planes can more accurately describe the geometric shape of the grinding area, and the normal vector is used to determine the direction of the plane, which is crucial for calculating the intersection line direction, arc center, and trajectory planning. The principle is as follows: RANSAC Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; The algorithm can effectively exclude the interference of noise and outliers through random sampling and iteration, and find the plane model that best represents the data. The least squares method obtains the optimal plane fitting parameters by minimizing the sum of the squares of the distances from the points to the plane. The normal vector is perpendicular to the plane and reflects the direction information of the plane.

[0156] S43, calculating the intersection line I of the planes P1 and P2, and obtaining the direction vector Direction of the intersection line I according to the cross product of the normal vectors Normol1 and Normol2. Specifically: first, the plane can be combined to manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; P1 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; and manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; P2 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; equations, and the parametric equations of the intersection lines are obtained by solving the equation group; then according to the definition of the vector cross product, the normal vector is calculated to manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; Normol1 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; and manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; Normol2 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; cross product. In this way, the intersection line and its direction of the two intersecting planes are determined. The intersection line I and the direction vector Direction are important bases for determining the grinding arc and grinding trajectory in the future. They define the basic direction of the grinding operation in space. The principle is: the intersection line of two planes is a set of points that simultaneously satisfy the equations of the two planes. The expression of the intersection line can be obtained by solving the simultaneous equations. The result of the vector cross product is perpendicular to the two vectors involved in the cross product, so the direction of the cross product of the normal vector is the direction of the intersection line.

[0157] S44, according to the structure of the area to be polished of the rotor support workpiece, preset the polishing arc radius R; take a point N on the intersection line I i , let point i = 0, so that N iis the point with the smallest value in the direction of the vector Direction in the grinding area. Specifically: First, according to the design requirements of the rotor bracket workpiece, the shape of the weld, and the characteristics of the grinding tool, the radius R of the grinding arc is determined in advance. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; then traverse the intersection line. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; I. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; find the point on the intersection line where the coordinate value in the vector Direction is the smallest as the starting point. In this way, the radius and the starting point of the grinding arc are determined. The radius of the grinding arc is preset according to the structure of the area to be ground on the workpiece and the requirements of the grinding process. The selection of the starting point provides a reference for calculating the center and trajectory of the grinding arc in the follow-up. The principle is that the setting of the radius of the grinding arc should comprehensively consider the geometric shape of the workpiece and the grinding effect to ensure that the grinding can meet the expected quality requirements. Selecting the smallest point in a specific direction on the intersection line as the starting point is to ensure the orderliness and integrity of the grinding trajectory.

[0158] S45, based on the arc radius R and the point N i Obtain the center O of the grinding arc and the grinding arc M1 i M2 i. Specifically: First, use the point_on_line to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam; the function calculates the points at specified positions on the line according to the parametric equation of the line, through the given points and direction vectors; then use geometric relationships and the known arc radius to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam; R, combine the starting point and the intersection line direction, and obtain the coordinates of the center of the circle through mathematical operations. Manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam; O. Manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam; of the coordinates; finally, with the center of the circle as the center, the radius is manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld seam; R, combine the plane manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld seam; P1, manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld seam; and manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld seam; P2, manually adjusted to a predetermined position and locked, and the robot is moved to the initial position of the weld seam; the positional relationship of to determine the starting point and end point of the grinding arc, thereby determining the entire arc. In this way, the center of the grinding arc and the arc shape are accurately determined. The center of the circle and the arc are important components of the grinding trajectory, directly affecting the accuracy and effect of grinding. The principle is: the point_on_line function is based on the parametric equation of the line, and points at any position on the line can be found through the change of parameters. When determining the center of the circle and the arc, the principles of plane geometry and spatial geometry are used. According to the known radius, starting point and plane information, the positions of the center of the circle and the arc are calculated through geometric relationships.

[0159] S46, determine the single-step grinding trajectory, that is, through point N i Make the perpendicular line V1 of the intersection line I in the plane P1 i , the perpendicular line V1 i Intersects the dividing line L1 at point Q1 i ; through point N i Make the perpendicular line V2 of the intersection line in the plane P2 i , the perpendicular line V2 i Intersects the dividing line L2 at point Q2 i ; then a complete trajectory in the first cross-sectional direction is successively the straight line Q1 i M1 i 、grinding arc M1 i M2i and line M2 i Q2 i . Specifically: First, manually adjust the rotor support workpiece to the predetermined position and lock it according to the intersection line, and move the robot to the initial position of the weld; I manually adjust the rotor support workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; and the plane manually adjusts the rotor support workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; P1, P2 manually adjust the rotor support workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; the normal vector, use the vertical property of the vector to calculate the perpendicular line of the intersection in the plane; then combine the perpendicular line equation and the split line equation to solve the intersection coordinates; finally, connect the obtained intersection and the grinding arc to form a complete single-step grinding trajectory. In this way, a complete grinding trajectory in a cross-sectional direction is determined, and the single-step grinding trajectory is the basic unit of the entire grinding trajectory. Multiple single-step trajectories can be combined to cover the entire grinding area. The principle is: in a plane, the vector dot product of two perpendicular lines is zero, and this property can be used to calculate the perpendicular line of the intersection in the plane. Solving the intersection by simultaneous equations is based on the geometric principle of the intersection of straight lines. The purpose of combining different line segments and arcs into trajectories is to achieve a continuous grinding operation from a plane area to a grinding area and then to a plane area.

[0160] S47, determine all grinding tracks, that is, preset the extension distance parameter step, and set the current point N iExtend the distance of step along the direction vector Direction of the intersection line I, then let i = i + 1. After obtaining the new point Ni, return to step S45 until the grinding trajectories on all cross-sections are obtained. Specifically: First, use vector operations to add the current point and the direction vector to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; Direction to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; multiply by the extension distance parameter to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; step to obtain the new point to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; Ni; then use the new point to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; Ni to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; as the starting point, return to the step to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; S45, repeat the calculation of the center of the grinding arc and the arc, as well as the single-step grinding trajectory, until the extension distance exceeds the maximum range of the grinding area in the direction of the intersection line. In this way, through continuous extension and repeated calculation, all grinding trajectories covering the entire grinding area are obtained, ensuring the comprehensive grinding of the longitudinal weld of the rotor bracket workpiece. The principle is: by continuously extending the starting point along the direction of the intersection line and using the previously determined calculation method to repeatedly generate single-step grinding trajectories, the entire grinding area is covered. The extension distance parameter to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; step to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; controls the density of the trajectory. Reasonably selecting the extension distance parameter to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; step to manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; can balance the grinding accuracy and efficiency.

[0161] S48. The straight-line trajectories on planes P1 and P2 are respectively retracted inward by a distance of R(t) along their respective normal directions, and the arc trajectory is retracted inward by a distance of R(t) towards the center O. The resulting lines after retraction are the trajectory information generated by the path planning unit. Specifically: First, manually adjust the rotor bracket workpiece on the plane to a predetermined position and lock it, and move the robot to the initial position of the weld seam; for the straight-line trajectory on P1, manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam; and for the straight-line trajectory on P2, manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld seam. For each point on the straight line, move it along the normal vector direction by a distance of R(t) according to the normal vector of the plane; then for the grinding arc, move each point on the arc towards the center O by a distance of R(t). Considering the radius of the grinding tool in this way, adjust the previously determined trajectory to ensure that the grinding tool can accurately cover the grinding area and avoid under-grinding or over-grinding. The principle is: The grinding tool has a certain radius. To ensure the grinding effect, the trajectory needs to be retracted inward by a distance equal to the radius of the tool. Through vector operations and geometric transformations, the points on the straight line and the arc are moved to achieve the inward retraction of the trajectory.

[0162] Example 11

[0163] This embodiment discloses a method for robot automatic grinding control of the longitudinal weld seam of a rotor bracket. As a preferred implementation manner of this embodiment, that is, based on Example 10, in step S41, the following methods are used to obtain the divided straight lines L1 and L2:

[0164] Method 1. Based on the workpiece design information

[0165] If there is an accurate three-dimensional model of the rotor bracket workpiece in advance, manually adjust the rotor bracket workpiece to the predetermined position and lock it, then move the robot to the initial position of the weld seam; manually adjust the rotor bracket workpiece to the predetermined position and lock it according to the CAD model, and move the robot to the initial position of the weld seam; the geometric information of the weld seam and its surrounding area can be extracted from it. Based on this information and combined with the range requirements of the grinding area, determine the positions of L1 and L2 on the model. For example, when the weld seam is at the intersection of two planes, two dividing lines can be drawn on the model according to the boundaries of the planes and the width of the weld seam, and then the position information of these lines is converted into the coordinate system corresponding to the point cloud data. According to the design drawing of the rotor bracket workpiece, the theoretical dimensional parameters such as the width and position of the weld seam can be obtained. With the help of these parameters, calculate the positions of L1 and L2 in the point cloud data. For example, if the center position and width of the weld seam are known, two parallel lines can be determined on both sides of the center position according to the width value as L1 and L2.

[0166] Method 2: Based on point cloud data processing

[0167] Perform clustering analysis on the acquired point cloud data to separate the point clouds belonging to the weld area and the planar area. Clustering algorithms can include density-based DBSCAN algorithm or hierarchical clustering algorithms, etc. After clustering, determine L1 and L2 near the clustering boundary. For example, using the DBSCAN algorithm to divide the point cloud into weld clustering and planar clustering, draw lines L1 and L2 at the boundary of the two clusters to divide the grinding area and the planar area. Apply edge detection algorithms, such as curvature-based edge detection methods, to find the edge points in the point cloud data. These edge points may represent the junction positions between the weld and the plane. According to the distribution of the edge points, fit L1 and L2. For example, calculate the curvature of each point in the point cloud data, regard the points with larger curvature as edge points, and then fit these edge points by the least squares method to obtain two lines L1 and L2. Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial weld position; Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial weld position; Manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial weld position;

[0168] Method 3: Based on visual inspection and feature recognition

[0169] If the vision detection unit acquires image information during the scanning process, image recognition technology can be used to determine the manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and then move the robot to the initial position of the weld; L1 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; and manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L2. For example, use deep learning algorithms to identify and locate the welds in the image, then draw segmentation lines in the image, and then map the position information of these lines to the point cloud data. Extract specific geometric features in the point cloud data, such as corner points, line segments, etc., and determine the manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L1 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; and manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L2 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; position by feature matching. For example, extract some obvious corner point features near the weld area, and fit two segmentation lines according to the relative position relationship of these corner points.

[0170] Method 4, determined by manual interaction

[0171] The operator can observe the point cloud data and the three-dimensional model of the workpiece on the visualization interface, and manually draw the manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L1 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; and manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L2 according to experience and actual needs. Although this method has a certain degree of subjectivity, it can flexibly determine the position of the segmentation line in some complex situations. The operator can determine the manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L1 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; and manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; L2 manual adjustment of the rotor bracket workpiece to a predetermined position and locking, and move the robot to the initial position of the weld; position by inputting some parameters, such as the starting point, ending point, slope of the line, etc. The system draws the corresponding line in the point cloud data according to the input parameters.

[0172] The present technical solution preferably adopts method 2, that is, the edge detection based on point cloud data obtains the manual adjustment of the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; L1 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; and manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; L2. First, the curvature is calculated, and the rotor bracket workpiece is manually adjusted to the predetermined position and locked, and the robot is moved to the initial position of the weld; estimate_normals manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; the method calculates the normal of the point cloud, and then calculates the trace of the covariance matrix to obtain the curvature of each point. Points with larger curvatures usually represent edge points. Secondly, edge point screening is performed: a curvature threshold is set, and points with a curvature greater than the threshold are screened out as edge points. Finally, straight line fitting is performed: manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; RANSAC manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; the algorithm performs plane segmentation on the edge points to obtain the parametric equations of the two straight lines manually adjust the rotor bracket workpiece to the predetermined position and lock it, and move the robot to the initial position of the weld; L1 manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; and manually adjusts the rotor bracket workpiece to the predetermined position and locks it, and moves the robot to the initial position of the weld; L2.

[0173] Example 12

[0174] This embodiment discloses a rotor bracket longitudinal weld robot automatic grinding control method. As a preferred implementation of this embodiment, based on Embodiment 10 or 11, in step S43, the center O of the grinding arc and the grinding arc M1 are obtained. i M2 i The following steps are involved:

[0175] S451, point N1 i As the center, draw a circle with a virtual radius D. The intersection points of this circle with planes P1 and P2 are M1 and M2 respectively. i and M2 i . This provides a basis for the subsequent determination of the endpoints and center of the polished arc. By drawing a circle with a specific point as the center and a specific radius, and finding the intersection of the circle and the plane, the possible endpoints of the polished arc can be located in space. The principle is: a circle is a set of points whose distance to a fixed point (center) is equal to a fixed length (radius). A plane is a set of points that satisfy linear equations. By combining the equations of the two, the point that satisfies both the circle and the plane conditions is solved, that is, their intersection.

[0176] S452, over M1 iExtend a distance of length R along the normal vector Normol1 and pass through M2 i Extend a distance of length R along the normal vector Normol2 so that the normal vector Normol1 and the normal vector Normol2 intersect at point O respectively with a length of R, that is, the center O of the grinding arc. In this way, the position of the center of the grinding arc is accurately determined. By using the normal vector of the plane and a specific extension length, the center point that meets the conditions is found according to the geometric relationship. This center will be used to construct the grinding arc subsequently. The principle is: the normal vector is perpendicular to the plane, and extending a specific length along the normal vector can determine a straight line in space. The intersection point of two straight lines is the point that satisfies the equations of both straight lines. By solving the simultaneous equations, this intersection point, that is, the center of the grinding arc, can be found.

[0177] S453, Make a circle based on the center O and the arc radius R to obtain the grinding arc M1 i M2 i ; At this time, the included angle between the normal vectors Normol1 and Normol2 is θ. The virtual radius D = R * tan(θ / 2). The principle is: a circle is a set of points whose distance to the center is equal to the radius, which is manifested as a spherical surface in three-dimensional space. By determining the set of points on the spherical surface that satisfy a specific angle range, the arc can be obtained. The calculation formula of the virtual radius is derived based on the geometric properties of an isosceles triangle and trigonometric function relationships. In an isosceles triangle, this formula can be obtained by using the half-angle formula and the relationship between the opposite side and the adjacent side. Manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld;

[0178] Example 13

[0179] This embodiment discloses a method for controlling the automatic grinding of the longitudinal weld of a rotor bracket by a robot. As a preferred implementation manner of this embodiment, that is, based on any one of Embodiments 8 to 12, the method for planning the specific motion trajectory of the robot in step S5 is: store the robot trajectory information in a text file, record each point data in a line, and record the X, Y, Z, A, B, and C values of the robot in each line. The values are separated by spaces. Use the SDK provided by the robot to convert the text file in this data format into an executable program for the robot, that is, the specific motion trajectory program; among them, X, Y, and Z represent the axis position coordinates of the robot end tool in space, and A, B, and C Manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; represent the attitude angles of the robot end tool on the X-axis, Y-axis, and Z-axis to determine the orientation of the robot end tool.

[0180] The operation steps are as follows: Obtain the trajectory information of the robot from the path planning unit. This information should include the spatial position coordinates (X, Y, Z) and the attitude angles (A, B, C) of the robot's end effector at each motion point. Store the trajectory information in a text file in the specified format, with each line recording the information of one point, and the values separated by spaces. Call the software development kit (SDK) provided by the robot manufacturer to convert the text file storing the trajectory information into a program that the robot can recognize and execute. Upload the converted program to the robot controller and start the robot to execute the specific motion trajectory.

[0181] The principle is as follows: Store the robot trajectory information in the form of a text file, using a unified format (one point per line, and the values separated by spaces), which is convenient for subsequent processing and interaction with the robot. The SDK provided by the robot manufacturer has the function of parsing a text file in a specific format and converting it into a program executable by the robot. The SDK will convert the point information in the text file into the motion instructions of each joint of the robot according to the kinematic model and control protocol of the robot. The X, Y, Z coordinates determine the position of the robot's end effector in space, while the A, B, C attitude angles describe the orientation of the tool. Through these six parameters, the position and attitude of the robot's end effector in three-dimensional space can be precisely controlled.

Claims

1. A rotor bracket longitudinal weld robot automatic grinding control system, characterized in that: include: A visual inspection unit, including a plurality of laser scanners and corresponding image acquisition devices, is used to scan the rotor support workpiece, complete the reconstruction of the surface model of the rotor support workpiece, and obtain the original image data of the surface of the rotor support workpiece; The point cloud integration unit is used to receive the original image data collected by the visual inspection unit through the data bus, and perform preprocessing including solving, coordinate change and filtering on the original image data, convert the original image data into orderly and processable point cloud data, perform gridding processing, and output to a file; a path planning unit, for receiving the proximal point cloud data from the point cloud integration unit, constructing a three-dimensional model of the rotor bracket workpiece, analyzing the geometric shape and weld position of the rotor bracket workpiece, generating environmental data, and calculating a terminal surface trajectory suitable for grinding, thereby generating trajectory information; The execution unit is used to read the trajectory information generated by the path planning unit, plan the specific motion trajectory of the robot according to the kinematic principle of the robot, and send the motion trajectory data to the robot for polishing operation; Database, used to store the operation data of the robot automatic polishing control system, as well as the intermediate data and result data generated by each functional unit; The interface main control unit is used to read the status information of each functional unit in real time and display the status information intuitively on the interface; at the same time, it provides an operation interface for operators to perform operations on the robot automated grinding control system, including parameter setting and start and stop control.

2. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: It also includes an external interface unit, which provides a production system interface and a positioner interface; the production system interface is used for information exchange and coordination with the entire production system; the positioner interface is used to establish communication and control between the robot automated polishing control system and the positioner.

3. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: The execution unit includes a grinding module and a relief grinding module, which are respectively used to automatically generate a terminal grinding trajectory and a terminal relief grinding trajectory based on three-dimensional point cloud data in combination with grinding process requirements.

4. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: It also includes a collision analysis and obstacle avoidance unit, which is used to perform operation simulation verification through simulation functions before the robot performs grinding operations to eliminate the possibility of collisions; if the simulation verification fails, it is necessary to call the path planning unit to re-plan the path, or call the execution unit to optimize the trajectory; if the simulation verification passes, the execution unit is triggered to send the motion trajectory data to the robot for grinding operations.

5. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: It also includes a self-check and status detection unit for performing system operation self-check, including robot status and position parameter monitoring, external axis status and position monitoring, and grinding pressure monitoring.

6. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: It also includes an integrated process programming unit for editing the relief grinding process steps and adjusting the relief grinding process parameters according to the process requirements.

7. A rotor bracket longitudinal weld robot automatic grinding control system as claimed in claim 1, characterized in that: It also includes a fault alarm unit for monitoring system faults during the grinding operation. When a fault occurs in the robot's automated grinding control system, the sound and light alarm unit will give a sound and light alarm reminder, and after the fault is eliminated, it will trigger the system to continue the task execution from the interruption location.

8. A method for controlling the robot-automated grinding of the longitudinal weld of a rotor support, characterized in that: The following steps are involved: S1, the rotor support workpiece is in place, the rotor support workpiece is manually adjusted to the predetermined position and locked, and the robot is moved to the initial position of the weld; S2, starting the visual inspection unit to scan the rotor support workpiece, completing the reconstruction of the surface model of the rotor support workpiece, and obtaining the original image data of the surface of the rotor support workpiece; S3, the point cloud integration unit receives the original image data collected by the visual inspection unit through the data bus, and performs preprocessing including solution, coordinate change and filtering on the original image data, converts the original image data into ordered and processable point cloud data, performs grid processing, and outputs it to a file; S4, the path planning unit receives the proximal point cloud data from the point cloud integration unit, constructs a three-dimensional model of the rotor bracket workpiece, analyzes the geometric shape and weld position of the rotor bracket workpiece, generates environmental data, and calculates a terminal surface trajectory suitable for grinding, thereby generating trajectory information; S5, the execution unit reads the trajectory information and plans the specific motion trajectory of the robot according to the kinematic principle of the robot; S6, the motion trajectory is simulated and verified by the collision analysis and obstacle avoidance unit; if the simulation verification fails, it is necessary to call the path planning unit to re-plan the path, or call the execution unit to optimize and adjust the trajectory; if the simulation verification passes, the execution unit is triggered to send the motion trajectory data to the robot for polishing operation; S7, during the grinding operation, real-time monitoring of the fault status of the monitoring system; when the robot automatic grinding control system fails and is interrupted, the sound and light alarm unit is controlled to sound and light alarm reminders, and after the fault is eliminated, the system is triggered from the interruption position to continue the task execution; S8, using the roller frame automatic position changing device to rotate the rotor support workpiece to the next weld position, repeating the above steps S1-S7 until the grinding of all welds of the current rotor support workpiece is completed.

9. A rotor bracket longitudinal weld robot automated grinding control method as claimed in claim 8, characterized in that: In step S2, scanning the rotor support workpiece includes a far-end scan and a near-end scan; wherein the far-end scan is to detect the posture of the rotor support workpiece and preliminarily locate the grinding point; the near-end scan is to accurately measure the grinding point.

10. A rotor bracket longitudinal weld robot automated grinding control method as claimed in claim 8, characterized in that: In step S4, generating trajectory information includes the following steps: S41, obtaining two segmentation lines L1 and L2 based on edge detection of point cloud data, and using the segmentation lines L1 and L2 to segment the point cloud, where the area between the two lines is a polishing area, and the areas outside the two lines are two plane areas; S42, performing plane segmentation and fitting on the point cloud data of the polishing area to obtain two extended intersecting planes P1 and P2, and respectively calculating the normal vectors Normol1 and Normol2 of the planes P1 and P2; S43, calculating the intersection line I of the planes P1 and P2, and obtaining the direction vector Direction of the intersection line I according to the cross product of the normal vectors Normol1 and Normol2; S44, according to the structure of the area to be polished of the rotor support workpiece, preset the polishing arc radius R; take a point N on the intersection line I i , let point i = 0, so that N i It is the smallest point in the polishing area in the direction of vector Direction; S45, based on arc radius R, joint point N i Get the center O of the polishing arc and the polishing arc M1 i M2 i ; S46, determine the single-step grinding trajectory, that is, passing point N i Draw a perpendicular line V1 to the intersection line I in plane P1 i , vertical line V1 i Intersects with the dividing line L1 at point Q1 i ; Pass point N i Draw a perpendicular line V2 on the intersection line in the plane P2 i , vertical line V2 i Intersects with the dividing line L2 at point Q2 i ; Then a complete trajectory in the first cross-sectional direction is the straight line Q1 i M1 i , grinding arc M1 i M2 i and line M2 i Q2 i ; S47, determine all grinding tracks, that is, preset the extension distance parameter step, and set the current point N i Extend the direction vector Direction along the intersection line I by the distance of step, then set i=i+1, obtain the new point Ni and return to step S45 until the grinding tracks on all cross sections are obtained; S48, the straight line trajectories on the planes P1 and P2 are retracted inward by a distance R(t) along their respective normal directions, and the arc trajectory is retracted inward by a distance R(t) toward the center O of the circle. The lines obtained after the retraction are the trajectory information generated by the path planning unit.

11. A rotor bracket longitudinal weld robot automated grinding control method as claimed in claim 10, characterized in that: In step S43, the center O of the polished arc and the polished arc M1 are obtained. i M2 i The following steps are involved: S451, point N i As the center, draw a circle with a virtual radius D. The intersection points of this circle with planes P1 and P2 are M1 and M2 respectively. i and M2 i ; S452, over M1 i Extend along the normal vector Normol1 for a distance of R, passing through M2 i Extend the normal vector Normol2 by a distance of R, so that the normal vector Normol1 and the normal vector Normol2 intersect at point O with a length of R, i.e., the center point O of the polishing arc; S453, make a circle based on the center O and the arc radius R to obtain the polished arc M1 i M2 i ; At this time, the angle between the normal vectors Normol1 and Normol2 is θ virtual radius D = R*tan(θ / 2).

12. A rotor bracket longitudinal weld robot automated grinding control method as claimed in claim 10, characterized in that: In step S5, the method for planning the specific motion trajectory of the robot is as follows: storing the robot trajectory information in a text file, recording one line for each point data, each line recording the X, Y, Z, A, B and C values ​​of the robot, and separating the values ​​by spaces, and using the SDK provided by the robot to convert the text file in the data format into a robot executable program, that is, a specific motion trajectory program; wherein X, Y and Z represent the axis position coordinates of the robot end tool in space, A, B and C manually adjust the rotor bracket workpiece to a predetermined position and lock it, and move the robot to the initial position of the weld; represents the attitude angle of the robot end tool on the X-axis, Y-axis and Z-axis to determine the orientation of the robot end tool.

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