Blade robot automatic grinding and polishing system and control method

Abstract

The invention provides a blade robot automatic grinding and polishing system and a control method, equipment mainly comprises a control system, a mechanical arm, a belt sander, an edge machining system, a tool system, a detection system and an exhaust inlet, all the systems cooperate to complete overall machining of blades, manual participation is not needed in the machining period, the equipment automatically completes linkage of all procedures, and the efficiency is improved. Machining and detection are completed at the same time, the technical requirements for size precision, surface roughness and the like of the machined blade are met, and machining is stable and high in efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of blade processing, and in particular to a blade robot automatic grinding and polishing system and a control method. Background Art

[0002] Currently, blade grinding and polishing in my country still relies on traditional manual grinding and polishing methods, which are time-consuming, have poor production capacity, and low processing precision. Manual grinding also has disadvantages such as poor controllability of processing quality and high labor intensity. These problems have led to low precision, backward production capacity, and insufficient performance in blade production in my country, seriously restricting the development of the field. Compared with traditional processing methods, the use of industrial robots combined with automatic belt sanders for blade grinding and polishing has the advantages of strong versatility, easy expansion, good flexibility, and low cost, making it an advanced form of blade processing.

[0003] In addition, achieving high surface machining accuracy and good surface integrity is not only limited by the hardware foundation of the equipment, but also faces many technical challenges: because the grinding removal and surface roughness are affected by multiple process factors and are difficult to accurately control, the blade is a typical free-form surface part, and the grinding process parameters involved in its surface grinding include workpiece surface curvature, workpiece material, grinding contact force, contact line speed, etc., in addition to some dynamic process influencing factors such as belt wear and grinding time changes. These influencing factors interact with each other, resulting in the inability to accurately control the blade surface grinding removal, and the surface error distribution is extremely uneven. Therefore, it is necessary to obtain a uniform blade surface error distribution by studying the adaptive machining path generation method and the dynamic adjustment method of machining parameters for blade grinding.

[0004] Therefore, a blade robot automatic grinding and polishing system and control method are needed to be used for grinding and polishing the entire blade surface, to produce blades with high dimensional accuracy and high performance, to reduce the labor intensity of workers, and to achieve a technical upgrade of blade grinding from "manual skills" to "automatic grinding and polishing". Summary of the Invention

[0005] In order to achieve the technical improvement of blade grinding from "manual skills" to "automatic grinding and polishing", the present invention provides a blade robot automatic grinding and polishing system and a control method.

[0006] The present invention provides a blade robot automatic grinding and polishing system, comprising a control system, a robotic arm, a sanding machine, an edge processing system, a tooling system, a detection system, and an air suction port; the robotic arm, the sanding machine, the edge processing system, and the tooling system are arranged in a ring in sequence and operate under the control of the control system, the detection system is arranged next to the tooling system, and the air suction port is arranged below the robotic arm; the control system comprises an industrial computer system, a data exchange system, a PLC control system, a force control system, and a six-axis robot control system; the robotic arm comprises a six-axis robot, a six-dimensional force sensor, and a universal clamping mechanism; the edge processing system comprises a polishing wheel and a grinding station; the tooling system comprises a blade tooling, a rack for materials to be processed, and a rack for finished products; the detection system comprises a structural optical three-dimensional scanner and a CCD digital camera.

[0007] The blade robot automatic grinding and polishing system described in the present invention is preferably arranged in pairs of polishing wheels, the two polishing wheels have different removal rates, and the distance between the polishing wheel with a high removal rate and the installation position of the robotic arm is greater than the distance between the polishing wheel with a low removal rate and the installation position of the robotic arm.

[0008] The present invention describes a blade robot automatic grinding and polishing system, which is a preferred embodiment. The blade tooling has a double workstation, which can place blades before and after processing respectively, and each system can place up to 8 blades; the positioning baseplate is connected to the tooling support structure through a positioning pin, and the blade tenon is inserted into the tooling system with the tenon facing upward. The robot's end gripper clamps the blade tenon and pulls out the blade, and sends it to the processing station; the blade positioning baseplate is customized with a special positioning interface according to different blades. When different types of blades need to be processed, replacing the blade tooling only requires replacing the positioning baseplate.

[0009] The blade robot automatic grinding and polishing system described in the present invention preferably has an independently driven belt sander and carries two belts. The motor drives the driving wheel, which is combined with the deflection adjustment wheel, tensioning wheel, and support wheel to ensure high-speed and stable operation of the belts.

[0010] The blade robot automatic grinding and polishing system described in the present invention is, as a preferred embodiment, an edge processing system that uses pneumatic direct grinding to drive the polishing wheel and has two grinding stations, so it can have two specifications of grinding wheels or perform grinding and polishing at different speeds.

[0011] The present invention describes a blade robot automatic grinding and polishing system, as a preferred embodiment, in which the detection system is mainly a visual positioning system. The robot grabs the blade to complete the detection action, and the data obtained by the detection system is compatible with the grinding and polishing programming software and the processing software. After the robot grabs the blade: a structural optical three-dimensional scanner is used to project specific visible light grating stripes onto the surface of the blade profile, and the grating interference stripes are photographed with the help of a high-resolution CCD digital camera. The actual position of the blade is determined using optical photography positioning technology, and the measurement results are used to determine the processing position before the part is processed; workpiece measurement before processing: the grating measurement principle and partition measurement method are used, supplemented by the post-processing technology of point cloud data, to obtain complete point cloud data of the blade profile, measure the actual shape of the blade before processing, match the blade digital model, and compare with the blade theoretical model to determine and analyze the distribution of the processing allowance, adjust the robot processing program, and adopt appropriate process parameters (such as contact force, speed, etc.) for different allowance parts; the detection link is entered during the processing process to control the cutting amount of the final processing link to ensure that the thickness and shape of the blade meet the size requirements; after the processing is completed, the detection link is entered to determine whether the processing is qualified.

[0012] The blade robot automatic grinding and polishing system described in the present invention is preferably equipped with a blade grinding robot software system to achieve machining trajectory planning and process parameter optimization. The software mainly consists of the following parts:

[0013] (1) Robot offline programming software system.

[0014] (2) Robot grinding online control system.

[0015] (3) Blade processing surface quality detection and analysis and adaptive process parameter adjustment system.

[0016] The system, with an industrial control computer at its core, encompasses all management and control functions, including the PLC control system, force control system, robotics system, and detection system. Information exchange with the industrial robot is achieved via Ethernet. The host computer software is developed in C++; the slave computer uses a PLC to control sequential operations, offering ease of use and high reliability. The equipment also features automatic protection and reset functions.

[0017] The present invention provides a control method for a blade robot automatic grinding and polishing system, comprising the following steps:

[0018] The control method of the blade robot automatic grinding and polishing system includes the following steps:

[0019] S1. Select the processing model in the system;

[0020] S2, loading;

[0021] S3, the system determines the workpiece model;

[0022] S4, the robot grabs the leaf;

[0023] S5. Acquire three-dimensional point cloud information of the blade to be processed through a three-dimensional camera, and obtain a blade model based on the point cloud information according to the smoothness characteristics of the blade, match the blade model with a qualified blade model, and overlap the arc surfaces to obtain a volume difference model;

[0024] S6. Splitting the volume difference model into an edge compensation model and a camber compensation model according to the number of qualified leaf surfaces;

[0025] S7, dividing the edge compensation model and the arc surface compensation model into a number of processing models with equally divided depths perpendicular to the grinding and polishing directions according to the grinding and polishing directions;

[0026] S8. Grind and polish the blade surface according to the processing model;

[0027] S9, determine whether the processed blade is qualified, if it is judged to be qualified, proceed to step S11; if it is judged to be qualified, proceed to step S10;

[0028] S10, determining whether the processed blade has machining allowance, if it is determined to be, proceeding to step S5; if not, determining that the blade is a substandard product, and placing the substandard product into a waste box;

[0029] S11. Unloading: Automatically place qualified products into the qualified product workpiece box.

[0030] The present invention adopts automated production equipment to replace the existing manual operation, avoids human production errors, greatly improves the product assembly accuracy, and effectively guarantees the quality of the processed products. No human participation is required during the processing. The equipment automatically completes the connection of each process, and processing and testing are completed at the same time, ensuring the technical requirements such as dimensional accuracy and surface roughness of the blade after processing, and the processing is stable and efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a structural schematic diagram of a blade robot automatic grinding and polishing system of the present invention.

[0032] Reference numerals:

[0033] 1. Robotic arm; 11. Six-axis robot; 12. Six-axis force sensor; 13. Universal clamping mechanism; 2. Edge processing system; 21. Polishing wheel; 22. Grinding station; 3. Belt sander; 4. Tooling system; 41. Blade tooling; 42. Rack for materials to be processed; 5. Detection system; 51. Structural optical 3D scanner; 52. CCD digital camera. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0035] Example 1

[0036] like Figure 1 As shown, a blade robot automatic grinding and polishing system includes a control system, a robotic arm 1, a sanding machine 3, an edge processing system 2, a tooling system 4, a detection system 5, and an air suction port. The robotic arm 1, the sanding machine 2, the edge processing system 3, and the tooling system 4 are arranged in a circular pattern and operate under the control of the control system. The detection system 5 is arranged next to the tooling system 4, and the air suction port is arranged below the robotic arm 1.

[0037] The control system includes an industrial computer system, a data exchange system, a PLC control system, a force control system and a six-axis robot control system; the robotic arm 1 includes a six-axis robot 11, a six-dimensional force sensor 22 and a universal clamping mechanism 13; the edge processing system 3 includes a polishing wheel 21 and a grinding station 22; the tooling system 4 includes a blade tooling 41 and a rack for materials to be processed 42; the detection system 5 includes a structural optical three-dimensional scanner 51 and a CCD digital camera 52; and the air suction port 6 is arranged below the robotic arm 1.

[0038] The universal clamping mechanism 13 includes a universal clamping claw on the robot and a universal interface for clamping the blade; the blade tooling 41 is customized for each blade, and while clamping the blade, it can cooperate with the universal mechanical interface of the universal clamping claw to complete the mechanical clamping and positioning of the blade.

[0039] The robotic arm 1, the sanding machine 2, the edge processing system 3, the tooling system 4, the detection system 5, and the air suction port 6 are arranged in a protective cover, and the protective cover is provided with an equipment door and an observation window.

[0040] The blade tooling 41 has a double workstation, which can place the blades before and after processing respectively. Each system can place up to 8 blades; the positioning baseplate is connected to the tooling support structure through positioning pins, and the blade tenon is inserted into the tooling system with the tenon facing upwards. The robot's end gripper clamps the blade tenon and pulls out the blade and sends it to the processing station; the blade positioning baseplate is customized with a dedicated positioning interface according to different blades. When different types of blades need to be processed, replacing the blade tooling only requires replacing the positioning baseplate.

[0041] The sanding belt machine 3 is independently driven and carries two sanding belts. The motor drives the driving wheel, combined with the deflection adjustment wheel, tension wheel and support wheel, so that the sanding belts can run at high speed and stably.

[0042] The edge processing system 2 uses pneumatic direct grinding to drive the polishing wheel 21 and has two grinding stations, so it can have two specifications of grinding wheels or perform grinding and polishing at different speeds.

[0043] The polishing wheels are arranged in pairs, and the two polishing wheels have different removal rates. The distance between the polishing wheel with a high removal rate and the installation position of the robotic arm is greater than the distance between the polishing wheel with a low removal rate and the installation position of the robotic arm.

[0044] The detection system 5 is mainly a visual positioning system. The robot grabs the blade to complete the detection action. The data obtained by the detection system is compatible with the grinding and polishing programming software and processing software. After the robot grabs the blade: a structural optical three-dimensional scanner 51 is used to project specific visible light grating stripes onto the surface of the blade profile, and the grating interference stripes are photographed with the help of a high-resolution CCD digital camera 52. The actual position of the blade is determined using optical photography positioning technology, and the measurement results are used to determine the processing position before the part is processed; workpiece measurement before processing: the grating measurement principle and partition measurement method are used, supplemented by the post-processing technology of point cloud data, to obtain complete point cloud data of the blade profile, measure the actual shape of the blade before processing, match the blade digital model, and compare with the blade theoretical model to determine and analyze the distribution of processing allowances, adjust the robot processing program, and use appropriate process parameters (such as contact force, speed, etc.) for different allowance parts; the detection link is entered during the processing process to control the cutting amount of the final processing link to ensure that the thickness and shape of the blade meet the size requirements; after the processing is completed, the detection link is entered to determine whether the processing is qualified.

[0045] The control method of the blade robot automatic grinding and polishing system includes the following steps:

[0046] S1. Select the processing model in the system;

[0047] S2, loading;

[0048] S3, the system determines the workpiece model;

[0049] S4, the robot grabs the leaf;

[0050] S5. Acquire three-dimensional point cloud information of the blade to be processed through a three-dimensional camera, and obtain a blade model based on the point cloud information according to the smoothness characteristics of the blade, match the blade model with a qualified blade model, and overlap the arc surfaces to obtain a volume difference model;

[0051] S6. Splitting the volume difference model into an edge compensation model and a camber compensation model according to the number of qualified leaf surfaces;

[0052] S7, dividing the edge compensation model and the arc surface compensation model into a number of processing models with equally divided depths perpendicular to the grinding and polishing directions according to the grinding and polishing directions;

[0053] S8. Grind and polish the blade surface according to the processing model;

[0054] S9, determine whether the processed blade is qualified, if it is judged to be qualified, proceed to step S11; if it is judged to be qualified, proceed to step S10;

[0055] S10, determining whether the processed blade has machining allowance, if it is determined to be, proceeding to step S5; if not, determining that the blade is a substandard product, and placing the substandard product into a waste box;

[0056] S11. Unloading: Automatically place qualified products into the qualified product workpiece box.

[0057] The above description is only illustrative of the present invention and not restrictive. Those skilled in the art will understand that any modification, change or equivalent that can be made without departing from the spirit and scope defined by the claims will fall within the scope of protection of the present invention.

Claims

1. A blade robot automatic grinding and polishing system and control method, characterized by: The invention comprises a robotic arm (1), an edge processing system (2), a sanding machine (3), a tooling system (4), a detection system (5), an air suction port and a control system: the robotic arm (1), the sanding machine (2), the edge processing system (3) and the tooling system (4) are arranged in a circular pattern and run under the control of the control system (7); the detection system (5) is connected to the tooling system (4); and the air suction port is arranged below the robotic arm (1); The edge processing system (2) comprises a polishing wheel (21) and a grinding station (22), wherein the polishing wheel (21) is arranged above the grinding station (22). The polishing wheels (21) are arranged in pairs, and the two polishing wheels (21) have different removal rates. The distance between the polishing wheel (21) with a high removal rate and the installation position of the mechanical arm (1) is greater than the distance between the polishing wheel (21) with a low removal rate and the installation position of the mechanical arm (1). The control method of the blade robot automatic grinding and polishing system includes the following steps: S1. Select the processing model in the system; S2, loading; S3, the system determines the workpiece model; S4, the robot grabs the leaf; S5. Acquire three-dimensional point cloud information of the blade to be processed through a three-dimensional camera, and obtain a blade model based on the point cloud information according to the smoothness characteristics of the blade, match the blade model with a qualified blade model, and overlap the arc surfaces to obtain a volume difference model; S6. Splitting the volume difference model into an edge compensation model and a camber compensation model according to the number of qualified leaf surfaces; S7, dividing the edge compensation model and the arc surface compensation model into a number of processing models with equally divided depths perpendicular to the grinding and polishing directions according to the grinding and polishing directions; S8. Grind and polish the blade surface according to the processing model; S9, determine whether the processed blade is qualified, if it is judged to be qualified, proceed to step S11; if it is judged to be qualified, proceed to step S10; S10, determining whether the processed blade has machining allowance, if it is determined to be, proceeding to step S5; if not, determining that the blade is a substandard product, and placing the substandard product into a waste box; S11. Unloading: Automatically place qualified products into the qualified product workpiece box.

2. The control method of a blade robot automatic grinding and polishing system according to claim 1, characterized in that: The blade model and the qualified blade surface model are matched by a 3D scanner. The blade arc surface is used as the calibration data basis for registration. Through the iterative calibration algorithm, the precise matching of the measurement model is completed to obtain the workpiece coordinate system.

3. The blade robot automatic grinding and polishing system according to claim 1, characterized in that: The robotic arm (1) comprises a six-axis robot (11), a six-dimensional force sensor (12) and a universal clamping mechanism (13), wherein the six-dimensional force sensor (12) is connected to the six-axis robot (11), and the universal clamping mechanism (13) is connected to the six-dimensional force sensor (12).

4. The blade robot automatic grinding and polishing system according to claim 1, characterized in that: The detection system (5) comprises a structured optical three-dimensional scanner (51) and a CCD digital camera (52), and the structured optical three-dimensional scanner (51) is connected to the CCD digital camera (52).

5. The blade robot automatic grinding and polishing system according to claim 1, characterized in that: The mechanical arm (1), the sanding machine (2), the edge processing system (3), the tooling system (4), the detection system (5) and the air suction port (6) are arranged in a protective cover.

6. The blade robot automatic grinding and polishing system according to claim 2, characterized in that: The protective cover is provided with an equipment door and an observation window.

Images