Hardness detection system and method for wear-resistant profile steel roller

Abstract

The invention belongs to the technical field of roller hardness detection. The embodiment of the invention provides a hardness detection system and method for a wear-resistant profile steel roller. The generatrix of the target roller is determined based on the surface image of the target roller shot by the industrial camera, and the generatrix determination precision is improved based on the correction process of the generatrix. And controlling a mechanical arm to drive a hardness detector to detect the hardness of the bus region according to the finally determined bus. Therefore, the hardness detection efficiency of the roller can be improved.

Description

Technical Field

[0001] This application belongs to the technical field of roll hardness detection, and particularly relates to a hardness detection system and method for wear-resistant steel rolls. Background Art

[0002] Rolls can be produced based on multiple casting methods. After production, the rolls can be transported through a transportation line to improve the transportation efficiency of the rolls based on the transportation capacity of the transportation line, and at the same time, it can effectively avoid the problem of easy injury to handling personnel caused by manual handling.

[0003] After the rolls are produced, their hardness needs to be detected. Only after determining that the rolls meet the hardness standard can the rolls be put into subsequent production applications. Usually, production personnel can use a handheld hardness detector with relatively simple structure and functions to detect the surface hardness of the rolls. However, during the hardness detection process, multiple points on the rolls need to be detected to determine that the overall hardness of the rolls meets the standard. Therefore, in the scenario of large-scale production of rolls, the hardness detection efficiency of the rolls is low. Summary of the Invention

[0004] This application provides a hardness detection system and method for wear-resistant steel rolls to solve the problem of low hardness detection efficiency of rolls.

[0005] In a first aspect, this application provides a hardness detection system for wear-resistant steel rolls, which is applied to a transportation production line of wear-resistant steel rolls. The transportation production line includes a hardness detection area, and at least an industrial camera and a robotic arm are provided in the hardness detection area, and a hardness detector is provided on the robotic arm; The industrial camera is configured to: collect an image of the wear-resistant steel roll in the hardness detection area; The hardness detection system further includes a controller, and the controller is configured to: When a target roll is transported to the hardness detection area, send a first control instruction to the industrial camera to enable the industrial camera to collect a target image, and the target image is the surface image of the target roll; Receive the target image fed back by the industrial camera; Analyze the target image based on an edge detection algorithm to determine a set of generatrix endpoints of the target roll in the target image; the set of generatrix endpoints includes generatrix endpoints located at both ends of the target roll respectively; Determine a first generatrix according to the set of generatrix endpoints; Mark at least 2 correction endpoints in the first generatrix according to a preset distance; Construct a correction circle based on each correction endpoint and the radius of the target roll, and mark the center of the correction circle; Determine a second generatrix based on the center of the corrected circle; Calculate the offset rate between the first generatrix and the second generatrix; If the offset rate is less than a preset threshold, generate a second control instruction based on the first generatrix and send the second control instruction to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position; If the offset rate is greater than or equal to the preset threshold, correct the first generatrix based on the second generatrix to obtain a first corrected generatrix; generate a third control instruction based on the first corrected generatrix and send the third control instruction to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position.

[0006] In some feasible embodiments, the controller corrects the first generatrix based on the second generatrix, and is specifically configured to: Determine a first adjustment parameter based on the coordinates of the second generatrix and the coordinates of the first generatrix; Adjust the first generatrix according to the first adjustment parameter to obtain a first corrected generatrix.

[0007] In some feasible embodiments, the controller is further configured to: Determine the target offset direction of the first generatrix relative to the second generatrix based on the coordinates of the first generatrix and the coordinates of the second generatrix; Using the target offset rate and the target offset direction as the storage table headers, store the first adjustment parameter corresponding to the target offset rate and the target offset direction in the data cache table.

[0008] In some feasible embodiments, before the controller corrects the first generatrix based on the second generatrix, it is further configured to: Determine the target offset direction and the target offset rate according to the coordinates of the first generatrix and the coordinates of the second generatrix; Query the first adjustment parameter in the data cache table based on the target offset direction and the target offset rate; If the first adjustment parameter is queried, the controller corrects the first generatrix based on the second generatrix, and is specifically configured to: Correct the first generatrix based on the first adjustment parameter to reduce the offset rate between the first generatrix and the second generatrix.

[0009] In some feasible embodiments, if the first adjustment parameter is not queried, the controller is further configured to: Execute the step of determining the first adjustment parameter based on the coordinates of the second generatrix and the coordinates of the first generatrix.

[0010] In some feasible embodiments, if the first adjustment parameter is not queried, the controller is further configured to: Query a supplementary first adjustment parameter in the data cache table based on the target offset direction and the target offset rate; the error between the offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is within a preset range, and the error between the supplementary offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is less than the error between the offset rates corresponding to other first adjustment parameters in the data cache table and the target offset rate.

[0011] In some feasible embodiments, when the manipulator drives the hardness detector to reach a preset detection position, the controller is further configured to: Send a fourth control instruction to the hardness detector so that the hardness detector executes a hardness detection process based on the first bus or the first corrected bus; the fourth control instruction is an instruction generated based on the coordinates of the first bus or the first corrected bus; the fourth control instruction is used to indicate the hardness detection position of the hardness detector.

[0012] In some feasible embodiments, before the controller generates a second control instruction based on the first bus, the controller is further configured to: Determine a second adjustment parameter based on the coordinates of the second bus and the coordinates of the first bus; the second adjustment parameter is less than the first adjustment parameter; Correct the first bus according to the second adjustment angle.

[0013] In some feasible embodiments, the controller is further configured to: Receive the hardness detection value fed back by the hardness detector; If the hardness detection value is within the range of the hardness detection standard value, generate a first piece of information for characterizing that the target roll passes the hardness detection; If the hardness detection value is outside the range of the hardness detection standard value, generate a second piece of information for characterizing that the target roll fails the hardness detection.

[0014] In a second aspect, the present application further provides a method for detecting the hardness of a wear-resistant steel roll, which can be applied to the hardness detection system of the wear-resistant steel roll in the first aspect. The method includes: When the target roll is transported to the hardness detection area, send a first control instruction to an industrial camera so that the industrial camera captures a target image, where the target image is a surface image of the target roll; the hardness detection area is an area located in a transportation production line; the transportation production line is used to transport the processed wear-resistant steel roll; at least an industrial camera and a manipulator are provided in the hardness detection area, and a hardness detector is provided on the manipulator. Receive the target image fed back by the industrial camera; Analyze the target image based on an edge detection algorithm to determine a set of busbar endpoints of the target roll in the target image; the set of busbar endpoints includes busbar endpoints located at both ends of the target roll respectively; Determine a first busbar according to the set of busbar endpoints; Mark at least two correction endpoints in the first busbar at a preset distance; Construct correction circles based on each of the correction endpoints and the radius of the target roll, and mark the centers of the correction circles; Determine a second busbar based on the centers of the correction circles; Calculate the offset rate between the first busbar and the second busbar; If the offset rate is less than a preset threshold, generate a second control instruction based on the first busbar, and send the second control instruction to the robotic arm so that the robotic arm drives the hardness detector to reach a preset detection position; If the offset rate is greater than or equal to the preset threshold, correct the first busbar based on the second busbar to obtain a first corrected busbar; and generate a third control instruction based on the first corrected busbar, and send the third control instruction to the robotic arm so that the robotic arm drives the hardness detector to reach a preset detection position.

[0015] As can be seen from the above technical content, the embodiments of the present application provide a hardness detection system and method for wear-resistant steel rolls. Determine the busbar of the target roll based on the surface image of the target roll captured by the industrial camera, and improve the accuracy of busbar determination based on the correction process of the busbar. Control the robotic arm to drive the hardness detector to detect the hardness of the busbar area according to the finally determined busbar. This can improve the hardness detection efficiency of the roll. Description of the Drawings

[0016] In order to more clearly illustrate the technical solutions of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, for those of ordinary skill in the art, other drawings can also be obtained based on these drawings without creative efforts.

[0017] Figure 1 It is a flowchart of the hardness detection of the wear-resistant steel roll provided by the embodiment of the present application. Detailed Embodiments

[0018] Embodiments will be described in detail below, and examples thereof are shown in the accompanying drawings. When the following description refers to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following examples do not represent all embodiments consistent with the present application. They are merely examples of systems and methods consistent with some aspects of the present application.

[0019] The roll in the embodiment of the present application can be a wear-resistant section steel roll processed from centrifugally compounded high-speed steel formed by three pourings. The first pouring is the outer layer pouring, and high-carbon steel can be used as the main material, and about 9% of elements such as chromium, tungsten, molybdenum, and vanadium are added to make the microstructure of the first-layer material matrix into martensite, thereby improving the wear resistance. The second pouring is the intermediate layer pouring, and high-carbon graphite steel can be used, and based on the characteristics of high-carbon graphite steel, it can prevent the outer layer alloy from penetrating into the core of the roll. The third pouring material can be high-strength ductile iron. The roll processed in this way has characteristics such as uniform outer layer hardness and wear resistance.

[0020] After the roll pouring is completed, it is necessary to detect the hardness of the roll. Usually, production personnel can use a handheld hardness detector to detect the hardness of the roll. During the detection process, in order to ensure that the hardness of the roll is qualified and to avoid problems caused by the quality of the roll in the subsequent production process in which the roll participates, it is necessary to detect the hardness at multiple points of the roll, so the workload of production personnel will increase. Especially in the scenario of large-scale production of rolls, relying solely on manual detection by production personnel will result in low efficiency of roll hardness detection.

[0021] To solve the problem of low efficiency of manual roll detection, the embodiment of the present application provides a hardness detection system for wear-resistant section steel rolls. The hardness detection system can combine with the transportation production line for transporting rolls to realize the automatic detection of roll hardness, so as to improve the efficiency of roll hardness detection and ensure the quality of roll hardness detection.

[0022] Among them, a hardness detection area can be set in the transportation production line, that is, the process of detecting the roll hardness is executed in the hardness detection area. An industrial camera and a robotic arm can be set in the hardness detection area, and a hardness detector can be provided on the robotic arm. The hardness detection system also includes a controller that can communicate with the industrial camera, the robotic arm, and the hardness detector, and then control these components based on the controller to realize the automatic detection of roll hardness.

[0023] It can be understood that the industrial cameras can be distributed on both sides and above the transportation line to realize the omnidirectional acquisition of the surface image of the target roll. The robotic arm can be arranged according to the actual position of the transportation production line, and the degree of freedom of the robotic arm can be selected according to the detection scenario to ensure that when detecting the target roll, the robotic arm can drive the hardness detector to reach a suitable detection position.

[0024] In this way, the controller is configured during the transportation of the roll: S100: When the target roll is transported to the hardness detection area, send a first control instruction to the industrial camera to enable the industrial camera to collect a target image, where the target image is a surface image of the target roll.

[0025] S200: Receive the target image fed back by the industrial camera.

[0026] S300: Analyze the target image based on an edge detection algorithm to determine a set of generatrix endpoints of the target roll in the target image. The set of generatrix endpoints includes generatrix endpoints located at both ends of the target roll respectively.

[0027] S400: Determine a first generatrix according to the set of generatrix endpoints.

[0028] S500: Mark at least two correction endpoints in the first generatrix at a preset distance.

[0029] S600: Construct a correction circle based on each correction endpoint and the radius of the target roll, and mark the center of the correction circle.

[0030] S700: Determine a second generatrix based on the center of the correction circle.

[0031] S800: Calculate the offset rate between the first generatrix and the second generatrix.

[0032] S_{901}: If the offset rate is less than a preset threshold, generate a second control instruction based on the first generatrix and send the second control instruction to the robotic arm to enable the robotic arm to drive the hardness detector to a preset detection position.

[0033] S_{902}: If the offset rate is greater than or equal to the preset threshold, correct the first generatrix based on the second generatrix to obtain a first corrected generatrix. Then generate a third control instruction based on the first corrected generatrix and send the third control instruction to the robotic arm to enable the robotic arm to drive the hardness detector to a preset detection position.

[0034] In some embodiments, some position sensors, such as infrared, ultrasonic sensors, etc., can be arranged on the transportation production line. Then, when the target roll reaches the hardness detection area, the transportation production line can be controlled to pause transportation to execute the hardness detection process. When the controller is in the hardness detection area of the target roll, it can also send a first control instruction to the industrial camera. In this way, when the industrial camera receives the first control instruction, it can capture surface images of the target roll from multiple angles and feed back the collected surface images to the controller.

[0035] The controller can accept the surface image fed back by the industrial camera, i.e., the target image. Furthermore, the controller can determine the set of busbar endpoints of the target roll in the target image through an edge detection algorithm. Among them, the controller can adopt preprocessing processes such as noise reduction, grayscale conversion, and contrast enhancement to improve the image quality, and then determine the candidate endpoints by combining the multi-directional gradient analysis method. For example, the 8-direction Sobel operator is used to calculate the gradient magnitude and direction, which is beneficial to improving the edge continuity and thus the accuracy of the candidate endpoints. In addition, during the process of screening the candidate endpoints or endpoint positioning, the mutation boundary at the roll neck junction can be located based on the morphological features extractable from the target image, and then the endpoints for constructing the busbar of the target roll can be determined from the candidate endpoints based on the relationship between the mutation boundary and the endpoints.

[0036] Among them, the busbar can refer to the continuous line in the roll axis direction. Selecting the hardness test points on the busbar can avoid the invalid measurement area (such as the soft zone area specified in the roll hardness test standard), and at the same time, the uniformity of the hardness in the circumferential direction of the roll can be evaluated based on the standardized test point selection, thereby improving the hardness detection efficiency and detection quality.

[0037] In some embodiments, three busbars can be determined with a period of 120°. In other embodiments, four busbars can be determined with a period of 90°. When multiple busbars are selected, multiple sets of busbar endpoints need to be determined. Combining the images collected at the shooting angles of the industrial camera, the busbars on different surfaces can be determined based on the surface images of the roll collected at different angles.

[0038] It should be noted that the edge detection algorithm for determining the endpoints is not limited to the examples in the embodiments of the present application. The method for determining the endpoints in the embodiments of the present application is not limited in any way. The present application aims to determine the endpoints that can construct the busbar of the target roll based on the image of the target roll, and further determine the way of the busbar, so as to realize the marking of the hardness detection area of the target roll, thereby improving the hardness detection efficiency and effect.

[0039] Among them, the selected endpoints can be presented in the form of an endpoint group, and the endpoints can be described in the form of coordinates. It can be understood that the controller can use the roll or the prominent point in the roll as the benchmark for establishing the three-dimensional coordinate system, so as to provide a more accurate description of the endpoints based on the three-dimensional coordinates, which is beneficial to subsequent busbar positioning and hardness detector positioning.

[0040] After determining the busbar endpoint group, it is equivalent to determining the busbar endpoints that can be used to construct the busbar. Therefore, the first busbar can be determined based on these two busbar endpoints. The first busbar here can be described by an equation based on the three-dimensional coordinates of the busbar endpoints, so that each point position in the busbar can be described by coordinates. The controller can generate an instruction for controlling the movement of the robotic arm based on the selected test point position, so that the robotic arm drives the hardness detector to the preset position.

[0041] It can be understood that the endpoints obtained based on visual processing are easily affected by various factors such as ambient light, the reflectivity of the roll, and the shooting accuracy of the industrial camera. Therefore, the first busbar determined by the busbar endpoints can also be corrected to improve the accuracy of the first busbar, and further improve the detection accuracy of the hardness detector.

[0042] During the process of correcting the first busbar, at least 2 correction endpoints can be selected in the first busbar at a preset distance. Among them, the preset distance can represent the spacing between the correction endpoints, that is, the smaller the preset distance, the more correction endpoints. In this way, a correction circle can be constructed based on the correction endpoints.

[0043] It can be understood that the correction endpoint is a point on the constructed correction circle, and the radius of the roll is known. Therefore, the correction circle can be constructed based on the radius of the roll and the coordinates of the correction endpoints. Among them, each correction endpoint is located on the roll surface, and the closed curve formed by the intersection of the cross-sectional plane (perpendicular to the busbar tangent) where the correction endpoint is located and the roll surface is the correction circle. The center of the correction circle is equivalent to the normal projection of the correction endpoint in the cross-sectional plane.

[0044] Here, it is also necessary to add constraint conditions in combination with the busbar direction or other points associated with the correction endpoints to determine a unique correction circle for correcting the first busbar. For example, multiple points are selected in the cross-sectional plane where the correction endpoints are located, and the center of the circle is determined by combining the least squares fitting method. The formula can be referred to as follows: min a，b ∑(||Q j −( a , b )||− r ) 2 .

[0045] Among them, min represents minimizing the sum of the squares of the distances from each point to the circumference. Qj represents multiple points selected in the cross-sectional plane. (a, b) represents the optimal center of the correction circle. r represents the radius of the roll.

[0046] In this way, the center of the correction circle can be determined. Among them, the present application does not make any limitation on the method for determining the center of the correction circle. The purpose of the present application is to construct correction circles based on the selected multiple correction endpoints respectively to correct the first busbar through multiple correction circles and improve the accuracy of the first busbar.

[0047] After obtaining multiple corrected circles, that is, obtaining the center coordinates of multiple corrected circles, the second generatrix can be further determined based on the centers of the multiple corrected circles. It can be understood that the second generatrix is composed of the connecting lines of the centers of multiple corrected circles. However, the centers of these corrected circles may not be located on the same line segment. Therefore, the second generatrix can be obtained by fitting based on the centers of multiple corrected circles.

[0048] In this way, the second generatrix formed based on the center coordinates of multiple corrected circles can correct the first generatrix. Among them, the second generatrix is obtained by fitting according to the center coordinates of the corrected circles. Therefore, the second generatrix does not directly correspond to the surface of the roll. Therefore, by correcting the first generatrix with the second generatrix, a more accurate generatrix can be mapped to the surface of the roll, so that the controller can generate control instructions according to the coordinates of each point on the surface of the roll for controlling the robotic arm to drive the hardware detector to move.

[0049] It should be noted that the overall process of fitting the second generatrix based on the center coordinates of the corrected circles refers to the idea of differential operation. Therefore, the more corrected endpoints are selected in the first generatrix, the higher the accuracy of the second generatrix, but the required amount of calculation will also increase accordingly. Therefore, the specific number / spacing distance of the corrected endpoints can be determined by comprehensively considering the hardware resource conditions and the required accuracy of the second generatrix.

[0050] In some embodiments, the deviation rate between the first generatrix and the second generatrix can be calculated to determine whether the first generatrix can be directly used based on the deviation rate. Among them, the deviation rate can be confirmed based on the included angle between the first generatrix and the second generatrix. The calculation method for the included angle can be based on the existing calculation methods and will not be elaborated here.

[0051] In this way, when the deviation rate between the first generatrix and the second generatrix is less than the preset threshold, the controller can generate a second control instruction according to the first generatrix and send the second control instruction to the robotic arm. After receiving the second control instruction, the robotic arm can drive the hardness detector to reach the preset detection position. At this time, the hardness detector can reach the preset detection position under the drive of the robotic arm and detect the hardness of the test points according to the coordinates of the selected test points in the first generatrix.

[0052] This can reduce part of the amount of calculation when the accuracy of the first generatrix is acceptable, so as to reduce the occupation of hardware resources.

[0053] In another case, when the offset rate of the first busbar and the second busbar is greater than a preset threshold, the controller can correct the first busbar according to the second busbar, and then obtain a first corrected busbar. Among them, the first busbar is mainly corrected based on the angle. In this way, the controller can generate a third control instruction based on the first corrected busbar and send the third control instruction to the robotic arm. Furthermore, when the robotic arm receives the third control instruction, it can drive the hardness detector to a position corresponding to the selected test point in the first corrected busbar.

[0054] In this way, by determining the second busbar, the first busbar can be greatly corrected to improve the accuracy of the first busbar, which is beneficial to ensuring the accuracy of the hardness detection position and thus ensuring the hardness detection quality.

[0055] In some embodiments, adjusting the first busbar based on the second busbar means adjusting the coordinates corresponding to the first busbar according to the coordinates corresponding to the second busbar. The steps include: Based on the coordinates of the second busbar and the coordinates of the first busbar, determine a first adjustment parameter.

[0056] According to the first adjustment parameter, adjust the offset angle of the first busbar relative to the second busbar to obtain a first corrected busbar.

[0057] During the adjustment process, it is equivalent to mapping the second busbar to the same plane as the first busbar and adjusting the first busbar according to the angle between the second busbar and the first busbar. For example, if the first busbar and the second busbar are offset by 10°, then based on the coordinates of the second busbar after being mapped to the plane where the first busbar is located. The first adjustment parameter can include parameters such as an adjustment angle and an intermediate matrix. Among them, the intermediate matrix can work together with the adjustment angle to make the first busbar and the second busbar tend to be parallel and ensure as much as possible that the points of the first busbar are located on the roll surface.

[0058] It can be understood that after correcting the first busbar, the points that do not correspond to the roll surface coordinates can be deleted to avoid interfering with the screening of test points in the hardness test, or these points can be mapped to the roll surface to facilitate the hardness test. When selecting test points, they can be selected in the corrected first busbar at a preset distance to comprehensively test the roll hardness and enhance the persuasiveness of the hardness test.

[0059] For example, 10° can be both the offset angle between the first busbar and the second busbar and can be determined as the first adjustment angle. Furthermore, the controller can correct the first busbar based on the first adjustment angle to obtain a first corrected busbar.

[0060] In some embodiments, the correction process of correcting the first busbar can be recorded to facilitate directly calling the correction result in the same scenario later, without additional operations to save the occupancy of hardware resources and improve the overall efficiency of hardness detection. The steps include: Determine the target offset direction of the first bus bar relative to the second bus bar based on the coordinates of the first bus bar and the coordinates of the second bus bar.

[0061] Using the target offset rate and the target offset direction as the storage header, store the first adjustment parameter corresponding to the target offset rate and the target offset direction in the data cache table.

[0062] It can be understood that after mapping the second bus bar to the same plane as the first bus bar, the offset rate (which can be understood as the offset angle between the first bus bar and the second bus bar) can be determined. In addition, with the second bus bar as the reference, the offset direction of the first bus bar relative to the second bus bar can also be determined. For example, an offset of 10° counterclockwise and an offset of 8° clockwise.

[0063] In this way, during a hardness test, the target offset rate and the target offset direction can be used as the storage header (storage index), and the first adjustment parameter calculated in the current hardness test can be stored in the data cache table. Among them, the data cache table can be located in a preset storage space. Then, during the hardness test, after the controller calculates the target offset rate and the target offset direction of the first bus bar and the second bus bar, it can query the data cache table. Then, when the target offset rate and the target offset direction are the same, the controller can directly call the corresponding adjustment angle in the data cache table.

[0064] In some embodiments, the adjustment angle is not necessarily the same as the target offset angle and can be slightly smaller than the target offset angle to leave a margin for adjustment and prevent the corrected first bus bar from deviating from the surface limit of the roll due to calculation.

[0065] In other embodiments, correcting the first bus bar is not limited to correcting the angle, but involves multi-dimensional transformation of multiple segments in the first bus bar. Therefore, matrix operations need to be used to correct the first bus bar. In this case, data / parameters such as matrices involved in the correction process can be stored in the data cache table, and the controller can query the data cache table according to the target offset rate and the target offset direction in subsequent hardness detection scenarios to directly obtain relevant parameters or data for correcting the first bus bar.

[0066] It can be understood that the method of caching adjustment parameters based on the data cache table can effectively improve the efficiency of hardness detection and reduce the amount of calculation. That is, before correcting the first bus bar based on the second bus bar, the controller is further configured to: Determine the target offset direction and the target offset rate according to the coordinates of the first bus bar and the coordinates of the second bus bar.

[0067] Query the first adjustment parameter in the data cache table based on the target offset direction and the target offset rate.

[0068] If the first adjustment parameter is queried, the controller corrects the first busbar based on the second busbar, and is specifically configured to: Correct the first busbar based on the first adjustment parameter to reduce the deviation rate between the first busbar and the second busbar.

[0069] In some embodiments, after determining the first busbar and the second busbar, the controller may determine the target deviation direction and the target deviation rate, and then query the first adjustment parameter in the data cache table according to the target deviation direction and the target deviation rate. For example, the first adjustment parameter can be queried in the data cache table. In this way, the controller can correct the first busbar according to the first adjustment parameter. For another example, if a matrix and related matrix parameters can be queried in the data cache table, the controller can correct the first busbar according to the matrix and the matrix parameters.

[0070] It can be understood that after the controller corrects the first busbar, the deviation rate of the first busbar relative to the second busbar will be greatly reduced, which is conducive to improving the positioning accuracy of the hardness test points.

[0071] Moreover, based on the method of querying the data cache table, the correction efficiency of the first busbar can be effectively improved. And in some scenarios where it is difficult to locate the first busbar or the deviation rate is extremely large, there is no need to re-determine the first busbar. And, in the case where the roll busbar cannot be determined, the roll is usually marked as an abnormal roll and measured manually.

[0072] However, in the embodiments of the present application, a method for correcting the roll busbar according to historical data is provided. Even when the deviation rate between the first busbar and the second busbar is too large, only by combining the historical data to correct the first busbar, the determination of the first busbar of the current roll can be realized and then the hardness measurement can be realized. In this way, the historical data can be fully combined to correct the first busbar, which not only ensures the accurate positioning of the first busbar, but also ensures the correction efficiency of the first busbar, and can also provide correction data in scenarios where it is difficult to correct due to a large deviation in the positioning of the first busbar, which can greatly reduce the amount of calculation.

[0073] In some embodiments, when the controller does not query the data cache table for the target deviation direction and the target deviation rate, the step of determining the first adjustment parameter based on the coordinates of the second busbar and the coordinates of the first busbar can be executed.

[0074] It can be understood that the controller can calculate parameters such as the intermediate matrix and the adjustment angle based on the straight-line equation / coordinates corresponding to the first busbar and the second busbar, that is, determine the first adjustment parameter. In this way, when the corresponding data is not included in the data cache table, the first busbar can also be corrected by real-time calculation. And after correcting the first busbar, the calculated intermediate matrix, adjustment angle and other parameters can be stored in the data cache table according to the current target offset direction and target offset rate.

[0075] In some embodiments, when the controller fails to query the first adjustment parameter in the data cache table, it can also query the supplementary first adjustment parameter in the data cache table to improve the efficiency of hardness testing. The steps include: Query the supplementary first adjustment parameter in the data cache table based on the target offset direction and the target offset rate. The error between the offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is within a preset range, and the error between the supplementary offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is less than the error between the offset rate corresponding to other first adjustment parameters in the data cache table and the target offset rate.

[0076] It can be understood that the allowable errors of the target offset rate and the target offset direction can be set in advance. In this way, when the controller queries the data cache table, it preferentially searches for the first adjustment parameter with the same target offset rate and target offset direction. Secondly, it can search for the target offset rate and target offset direction with the smallest error according to the allowable error, and then determine the first adjustment parameter according to the search result.

[0077] In this way, the efficiency of the controller to determine the first adjustment parameter can be improved. Although the allowable error will have some influence on the accuracy of busbar correction, for example, some test points in the first busbar are not mapped to the surface of the roll after correction. However, for such problems, such test points can be filtered during the subsequent selection of hardness test points to avoid the influence of such points on hardness testing. Or, after such test points are determined as hardness test points, such test points can be further corrected to map them to the surface of the roll, so that when the hardness detector performs hardness detection, it can perform hardness testing on the position of the roll surface corresponding to the hardness test point.

[0078] In some embodiments, after the robotic arm reaches the preset position, it will feedback a signal to the controller, so that the controller can know that the robotic arm has reached the preset position. Furthermore, the controller can control the hardness detector to test the hardness of the roll based on the determined busbar and the hardness test points in the busbar. The steps include: Send a fourth control instruction to the hardness detector so that the hardness detector performs a hardness detection process based on the first bus or the first corrected bus. The fourth control instruction is an instruction generated based on the coordinates of the first bus or the first corrected bus. The fourth control instruction is used to indicate the hardness detection position of the hardness detector.

[0079] Among them, the fourth control instruction refers to the instruction sent by the controller to the hardness detector. After receiving the fourth control instruction, the hardness detector can perform a hardness test according to the coordinates of the hardness test point indicated in the fourth control instruction, and feedback the test data to the controller after the hardness test is completed.

[0080] Among them, the controller can be connected to the hardness detector through wireless connection methods such as Bluetooth and wifi to prevent the cable connection from easily affecting the movement of the hardness detector with the robotic arm and improve the safety of the hardness test process. Similarly, the controller can also receive the test data transmitted back by the hardness detector through wireless transmission methods such as Bluetooth and wifi. And further output a detection result according to the hardness detection value represented by the test data. The steps include: Receive the hardness detection value feedback by the hardness detector.

[0081] If the hardness detection value is within the hardness detection standard value range, generate the first information for characterizing that the target roll passes the hardness detection.

[0082] If the hardness detection value is outside the hardness detection standard value range, generate the second information for characterizing that the target roll fails the hardness detection.

[0083] In some embodiments, the hardness detection standard value range can be preset for the hardness of the roll. In this way, after the controller obtains the roll hardness test data feedback by the hardness detector, it can be compared with the hardness detection standard value range. If the roll hardness test data feedback by the hardness detector is within the hardness detection standard value range, the first information can be generated, and the first information can be used to prompt the production personnel that the hardness of the roll meets the standard. Otherwise, the second information can be generated, and the second information can be used to prompt the production personnel that the hardness of the roll does not meet the standard.

[0084] In some embodiments, when the offset rate is less than the preset threshold, in order to improve the accuracy of the first bus, the first bus can also be corrected according to the second bus. The steps include: Based on the coordinates of the second bus and the coordinates of the first bus, determine the second adjustment parameter. The second adjustment parameter is less than the first adjustment parameter.

[0085] Correct the first bus according to the second adjustment parameter.

[0086] Among them, both the second adjustment parameter and the first adjustment parameter are used to adjust the first busbar based on the second busbar. Therefore, the second adjustment parameter can also be similar to the first adjustment parameter and include parameters such as an intermediate matrix and an adjustment angle. In this way, the controller can correct the first busbar according to the second adjustment parameter, and its adjustment process and purpose are the same as or similar to those of correcting the first busbar according to the first adjustment parameter. Therefore, it will not be elaborated here.

[0087] It should be noted that the second adjustment parameter and the first adjustment parameter are only names for distinguishing the adjustment parameters in two adjustment situations, rather than limitations on the type and content of the adjustment parameters.

[0088] In addition, after calculating the second adjustment parameter, the controller can store the second adjustment parameter in another data cache table. In this way, through the setting of multiple data cache tables, the controller can first find the corresponding data cache table according to the offset direction and offset rate between the first busbar and the second busbar, and then find the appropriate adjustment parameter from the data cache table, so as to improve the acquisition efficiency of the adjustment parameter and is conducive to improving the efficiency of hardness testing.

[0089] Based on the setting of multiple data cache tables, the design of multiple-level thresholds of the offset rate can also be combined. In this way, when determining the adjustment parameter, the controller can preferentially look up the table to obtain the adjustment parameter to improve the acquisition efficiency of the adjustment parameter. In addition, in the scenario where the offset rate is too large and it is difficult to mark the busbar, the corresponding adjustment parameter can also be obtained through the design of the data cache table and the allowable error to ensure the normal operation of the hardness testing process.

[0090] The embodiment of the present application also provides a method for detecting the hardness of a wear-resistant steel rolling roll, including: When the target rolling roll is transported to the hardness detection area, send a first control instruction to the industrial camera to enable the industrial camera to collect a target image, where the target image is a surface image of the target rolling roll. The hardness detection area is an area located in the transportation production line. The transportation production line is used to transport the processed wear-resistant steel rolling rolls. At least an industrial camera and a robotic arm are provided in the hardness detection area, and a hardness detector is provided on the robotic arm.

[0091] Receive the target image fed back by the industrial camera.

[0092] Analyze the target image based on an edge detection algorithm to determine a set of busbar endpoints of the target rolling roll in the target image. The set of busbar endpoints includes busbar endpoints located at both ends of the target rolling roll respectively.

[0093] Determine a first busbar according to the set of busbar endpoints.

[0094] Mark at least two correction endpoints in the first busbar according to a preset distance.

[0095] Construct correction circles based on each of the correction endpoints and the radius of the target roll, and mark the centers of the correction circles.

[0096] Determine a second busbar based on the centers of the correction circles.

[0097] Calculate the offset rate between the first busbar and the second busbar.

[0098] If the offset rate is less than a preset threshold, generate a second control instruction based on the first busbar, and send the second control instruction to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position.

[0099] If the offset rate is greater than or equal to the preset threshold, correct the first busbar based on the second busbar to obtain a first corrected busbar. Then generate a third control instruction based on the first corrected busbar, and send the third control instruction to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position.

[0100] For the similar parts between the embodiments provided in this application, reference can be made to each other. The specific embodiments provided above are only several examples under the general concept of this application and do not constitute a limitation on the protection scope of this application. For those skilled in the art, any other embodiments extended based on the solution of this application without creative efforts fall within the protection scope of this application.

Claims

1. A hardness detection system for wear-resistant steel rolling rolls, characterized in that A transportation production line applied to wear-resistant steel rolling rolls, the transportation production line includes a hardness detection area, and at least an industrial camera and a robotic arm are provided in the hardness detection area, and a hardness detector is provided on the robotic arm; The industrial camera is configured to: collect an image of the wear-resistant steel rolling roll in the hardness detection area; The hardness detection system further includes a controller, and the controller is configured to: When the target rolling roll is transported to the hardness detection area, send a first control instruction to the industrial camera to enable the industrial camera to collect a target image, and the target image is the surface image of the target rolling roll; Receive the target image fed back by the industrial camera; Analyze the target image based on an edge detection algorithm to determine a group of busbar end points of the target rolling roll in the target image; the group of busbar end points includes busbar end points located at both ends of the target rolling roll respectively; Determine a first busbar according to the group of busbar end points; Mark at least 2 correction end points in the first busbar at a preset distance; Construct a correction circle based on each correction end point and the radius of the target rolling roll, and mark the center of the correction circle; Determine a second busbar based on the center of the correction circle; Calculate the target offset rate between the first busbar and the second busbar; If the target offset rate is less than a preset threshold, generate a second control instruction based on the first busbar and send the second control instruction to the robotic arm to enable the robotic arm to drive the hardness detector to reach a preset detection position; If the target offset rate is greater than or equal to the preset threshold, correct the first busbar based on the second busbar to obtain a first corrected busbar; and generate a third control instruction based on the first corrected busbar and send the third control instruction to the robotic arm to enable the robotic arm to drive the hardness detector to reach a preset detection position.

2. The hardness detection system of the wear-resistant steel rolling roll according to claim 1, characterized in that, When the controller corrects the first busbar based on the second busbar, it is specifically configured to: Determine a first adjustment parameter based on the coordinates of the second busbar and the coordinates of the first busbar; Adjust the first busbar according to the first adjustment parameter to obtain a first corrected busbar.

3. The hardness detection system for the wear-resistant steel rolling roll according to claim 2, wherein, The controller is further configured to: Determine the target offset direction of the first busbar relative to the second busbar based on the coordinates of the first busbar and the coordinates of the second busbar; Using the target offset rate and the target offset direction as storage headers, store the first adjustment parameter corresponding to the target offset rate and the target offset direction in a data cache table.

4. The hardness detection system of the wear-resistant steel rolling roll according to claim 3, characterized in that, Before the controller corrects the first busbar based on the second busbar, it is further configured to: Determine the target offset direction and the target offset rate according to the coordinates of the first busbar and the coordinates of the second busbar; Query the first adjustment parameter in the data cache table based on the target offset direction and the target offset rate; If the first adjustment parameter is queried, when the controller corrects the first busbar based on the second busbar, it is specifically configured to: Correct the first busbar based on the first adjustment parameter to reduce the offset rate between the first busbar and the second busbar.

5. The hardness detection system for the wear-resistant steel rolling roll according to claim 4, wherein, If the first adjustment parameter is not queried, the controller is further configured to: Execute the step of determining the first adjustment parameter based on the coordinates of the second bus bar and the coordinates of the first bus bar.

6. The hardness detection system of the wear-resistant steel rolling roll according to claim 4, characterized in that, If the first adjustment parameter is not queried, the controller is further configured to: Query the supplementary first adjustment parameter in the data cache table based on the target offset direction and the target offset rate; the error between the offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is within a preset range, and the error between the supplementary offset rate corresponding to the supplementary first adjustment parameter and the target offset rate is less than the error between the offset rate corresponding to other first adjustment parameters in the data cache table and the target offset rate.

7. The hardness detection system for wear-resistant steel rolling rolls according to claim 1, characterized in that, When the manipulator drives the hardness detector to reach the preset detection position, the controller is further configured to: Send a fourth control instruction to the hardness detector, so that the hardness detector executes a hardness detection process based on the first bus bar or the first corrected bus bar; the fourth control instruction is an instruction generated based on the coordinates of the first bus bar or the first corrected bus bar; the fourth control instruction is used to indicate the hardness detection position of the hardness detector.

8. The hardness detection system of the wear-resistant steel rolling roll according to claim 1, characterized in that, Before the controller generates a second control instruction based on the first bus bar, the controller is further configured to: Determine a second adjustment parameter based on the coordinates of the second bus bar and the coordinates of the first bus bar; the second adjustment parameter is less than the first adjustment parameter; Correct the first bus bar according to the second adjustment parameter.

9. The hardness detection system for wear-resistant steel rolling rolls according to claim 1, characterized in that, The controller is further configured to: Receive the hardness detection value fed back by the hardness detector; If the hardness detection value is within the hardness detection standard value range, generate a first piece of information for characterizing that the target roll passes the hardness detection; If the hardness detection value is outside the hardness detection standard value range, generate a second piece of information for characterizing that the target roll fails the hardness detection.

10. A hardness detection method for wear-resistant steel rolling rolls, characterized in that, Applied to the hardness detection system of the wear-resistant steel roll according to any one of claims 1-9, comprising: When the target roll is transported to the hardness detection area, send a first control instruction to the industrial camera, so that the industrial camera acquires a target image, and the target image is a surface image of the target roll; the hardness detection area is an area located in the transportation production line; the transportation production line is used to transport the processed wear-resistant steel roll; at least an industrial camera and a manipulator are provided in the hardness detection area, and a hardness detector is provided on the manipulator; Receive the target image fed back by the industrial camera; Analyze the target image based on an edge detection algorithm to determine a bus bar endpoint group in the target image; the bus bar endpoint group includes bus bar endpoints located at both ends of the target roll respectively; Determine a first bus bar according to the bus bar endpoint group; Mark at least two correction endpoints in the first bus bar at a preset distance; Construct a correction circle based on each correction endpoint and the radius of the target roll, and mark the center of the correction circle; Determine a second bus bar based on the center of the correction circle; Calculate the target offset rate of the first bus bar and the second bus bar; If the target offset rate is less than a preset threshold, a second control instruction is generated based on the first bus, and the second control instruction is sent to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position; If the target offset rate is greater than or equal to the preset threshold, the first bus is corrected based on the second bus to obtain a first corrected bus; a third control instruction is generated based on the first corrected bus, and the third control instruction is sent to the robotic arm so that the robotic arm drives the hardness detector to a preset detection position.

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