Movable spliced desanding cover control system based on image processing

Abstract

The invention belongs to the technical field of industrial automation control, and relates to a movable spliced desanding cover control system based on image processing, which comprises an instruction generation module for generating an initial control instruction; the image deviation analysis module is used for generating displacement deviation information; the multi-stage regulation and control instruction generation module is used for generating a multi-stage regulation and control instruction based on the displacement deviation information and an energy-saving mark in the initial control instruction; the docking operation execution module is used for generating a component state identifier; the tightness verification module is used for generating a verification result based on the verification image and a tightness threshold value; the data feedback generation module is used for generating a feedback data packet; and the system state updating and homing module is used for controlling the mechanical lock catch and the driving device to execute homing operation according to the sealing state mark of the verification result. According to the invention, the problem that a traditional mode lacks intelligent and adaptive adjustment capability is solved.

Description

Technical Field

[0001] This invention belongs to the technical field of industrial automation control and relates to a movable splicing sand removal cover control system based on image processing. Background Technology

[0002] In modern heavy equipment manufacturing, the precise splicing and assembly of large components is a critical process. For example, equipment such as mobile sand removal hoods are typically composed of multiple modular components, and the quality of their splicing directly affects the overall performance and service life of the equipment. During assembly, it is essential to ensure that the mating surfaces between components are precisely aligned and form a tight seal to prevent leakage of the working medium or intrusion of external impurities.

[0003] Traditional component assembly methods primarily rely on manual operation or semi-automated equipment. Operators typically use hoisting equipment to guide component alignment through visual inspection and manual measurement, and then use a fixed clamping force for locking. This method heavily depends on the operator's experience and skill level, making it difficult to guarantee alignment accuracy and consistency. Furthermore, manual measurement and visual judgment are subject to subjective errors, failing to comprehensively assess the gap distribution across the entire mating surface, which can easily lead to localized inadequate sealing and potential quality issues.

[0004] The drawbacks of traditional methods are obvious in addressing the above problems. For applications requiring high sealing performance, the clamping force set based on experience alone cannot adapt to actual alignment deviations. Insufficient clamping force can lead to seal failure, while excessive clamping force can cause component damage and unnecessary energy consumption. Furthermore, traditional methods lack intelligent and adaptive adjustment capabilities. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a movable splicing sand removal cover control system based on image processing.

[0006] Image processing-based movable splicing sand removal hood control system includes:

[0007] The instruction generation module obtains task parameters from the manufacturing information management system, including the target location coordinates of the sand removal cover, the energy-saving mode identifier, and the tightness threshold, and generates initial control instructions.

[0008] The image deviation analysis module controls an industrial camera to capture dynamic images of the splicing area of ​​movable components, and generates displacement deviation information based on the dynamic images of the splicing area and the density threshold.

[0009] The multi-level control command generation module generates multi-level control commands based on displacement deviation information and energy-saving markers in the initial control commands.

[0010] The docking operation execution module is used to input multi-level control commands into multi-level control devices to drive components to dock and generate component status identifiers.

[0011] The sealing verification module is used to trigger the industrial camera to capture a second image of the stitched area after locking, and to generate a verification result based on the verification image and the tightness threshold.

[0012] The data feedback generation module integrates the locking pressure value of the component status identifier, the sealing status mark of the verification result, and the energy-saving constraint conditions of the initial control command to generate a feedback data package.

[0013] The system status update and reset module sends the energy-saving correction coefficient in the feedback data packet back to the manufacturing information management system, and controls the mechanical latch and drive device to perform the reset operation based on the sealing status mark in the verification results.

[0014] A further aspect of the present invention generates initial control commands, comprising the following steps:

[0015] Receive task parameters;

[0016] Extract the component target angle and preset height from the task parameters, map the component target angle to an angle reference value, map the preset height to a height reference value, and map the energy-saving mode identifier to an energy-saving marker;

[0017] Integrate angle reference values, height reference values, and energy-saving markings to generate initial control commands.

[0018] A further aspect of the present invention generates displacement deviation information based on the dynamic image of the stitched region and a density threshold, including the following steps:

[0019] Identify the pixel positions of component edges in the dynamic image of the spliced ​​area and calculate the actual positions;

[0020] Calculate the lateral offset and angular deviation based on the actual position and the target position coordinates of the sand removal hood;

[0021] The size of the joint gap in the dynamic image of the splicing area is measured and compared with the tightness threshold. If the size of the joint gap exceeds the tightness threshold, a true gap exceedance mark is generated.

[0022] The lateral compensation value generated by the lateral offset, the angle correction value generated by the angle deviation, and the gap over-limit mark are integrated to generate displacement deviation information.

[0023] A further aspect of the present invention generates multi-level control instructions, comprising the following steps:

[0024] The first-level lateral displacement parameters are generated based on the lateral compensation values;

[0025] The second-level angle adjustment parameters are generated based on the angle correction value;

[0026] A pressure strength coefficient is generated by combining the gap over-limit mark and the energy-saving mark. When the gap over-limit mark is true, the pressure strength coefficient is increased to ensure tightness of the connection. When the energy-saving mark is true, the pressure strength coefficient is decreased to reduce energy consumption. This combination achieves a synergistic balance between safety and energy consumption.

[0027] The pressure intensity coefficient is used as the core content for locking pre-parameters;

[0028] Integrate the first-level lateral displacement parameters, the second-level angle adjustment parameters, and the locking pre-parameters to generate multi-level control commands.

[0029] A further aspect of the present invention generates a component status identifier, comprising the following steps:

[0030] Input the first-stage lateral displacement parameters into the lateral hydraulic actuator and move the component to the compensated coordinate position.

[0031] Input the second-level angle adjustment parameters into the rotary motor, and rotate the component to the corrected alignment angle;

[0032] Based on the pressure intensity coefficient in the locking pre-parameters, the pneumatic mechanism is controlled to apply an adaptive clamping force;

[0033] Activate the mechanical locking latch to fix the component, record the compensated coordinate position as the position coordinate, record the measured value of the adaptive clamping force as the locking pressure value, and generate a component status identifier.

[0034] A further aspect of the present invention generates a verification result based on a verification image and a density threshold, comprising the following steps:

[0035] Measure and verify the gap distribution at the component mating surfaces in the image;

[0036] Extract the maximum gap value from the gap distribution state;

[0037] When the maximum gap value is less than the tightness threshold, a qualified sealing status mark is generated;

[0038] When the maximum gap value is greater than or equal to the tightness threshold, an abnormal sealing status marker is generated, and the location of the maximum gap value is recorded as the abnormal location coordinates.

[0039] Integrate the sealing status markers and abnormal location coordinates to generate verification results.

[0040] A further aspect of the present invention involves generating a feedback data packet, comprising the following steps:

[0041] Obtain the actual energy consumption value during the docking operation;

[0042] Calculate the difference between the actual energy consumption value and the energy-saving constraint of the initial control command to obtain the energy consumption difference;

[0043] An energy-saving correction coefficient is generated by combining the sealing status mark with the energy consumption difference;

[0044] The system records the sealed status of the package, the energy consumption difference, and the energy-saving correction factor, and generates a feedback data packet.

[0045] A further aspect of the present invention involves controlling the mechanical latch and drive device to perform a return operation based on the sealing status mark in the verification results, including the following steps:

[0046] Update the energy-saving correction factor in the feedback data packet to the energy-saving strategy of the manufacturing information management system;

[0047] The mechanical latch is released from its locking component based on the sealing status marking;

[0048] The lateral hydraulic actuator moves the component back to the initial coordinate position defined by the task parameters;

[0049] Control the rotary motor to return the angle to zero.

[0050] A further aspect of the present invention involves activating a mechanical latch to secure the component, comprising the following steps:

[0051] Obtain pressure sensor readings from the pneumatic mechanism;

[0052] Compare the pressure sensor reading with a preset pressure range;

[0053] The mechanical latch is activated only when the pressure sensor reading falls within the preset pressure range.

[0054] A further aspect of the present invention combines the sealing status marker with the energy consumption difference to generate an energy-saving correction coefficient, including the following steps:

[0055] When the sealing status is marked as abnormal, the energy-saving correction coefficient is set to a fixed penalty value, forcibly increasing the clamping force of subsequent operations;

[0056] When the sealing condition is marked as qualified, the energy-saving correction coefficient is dynamically calculated based on the magnitude of the energy consumption difference.

[0057] In summary, the present invention has the following beneficial technical effects:

[0058] 1. By introducing high-precision industrial cameras and image processing algorithms, real-time, non-contact measurement of component position and orientation is achieved. The system can accurately calculate minute deviations in the lateral and angular directions and generate compensation commands to guide the actuators to make micron-level adjustments. Compared to traditional manual visual inspection or simple sensor positioning, this vision-based closed-loop control greatly improves the accuracy of component docking, ensuring that components reach an ideal alignment state before locking, thereby significantly improving the final splicing quality and sealing reliability.

[0059] 2. The system achieves full automation from task reception, deviation detection, dynamic control to quality verification. It automatically retrieves instructions from the manufacturing information management system and autonomously completes a series of complex alignment, clamping, and verification operations without human intervention. This highly automated working mode not only frees operators from heavy and high-precision repetitive labor but also effectively shortens the operation cycle of a single assembly, significantly improving the overall operating efficiency and capacity of the production line.

[0060] 3. An intelligent adaptive control and optimization mechanism has been constructed. The system can not only dynamically adjust the clamping force based on real-time detection of gap exceeding limits, but also optimize energy consumption while ensuring sealing quality by combining energy-saving strategies. Furthermore, the system can generate feedback data packets and send them back to the upper-level management system, including operation results, energy consumption data, and sealing verification status. Through data analysis and learning, the system continuously optimizes the control strategies for subsequent tasks, enabling the entire assembly process to have self-improvement and intelligent evolution capabilities, thereby improving the system's robustness and economy. Attached Figure Description

[0061] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings are used to provide a further understanding of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0062] Figure 1 This discloses a schematic diagram of the framework in the embodiments of this application.

[0063] Figure 2 This discloses a flowchart of an embodiment of this application. Detailed Implementation

[0064] 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 with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0065] The following is in conjunction with the appendix Figures 1-2 A preferred description of the present invention is provided below.

[0066] See attached document Figures 1-2 This invention proposes a movable splicing sand removal cover control system based on image processing, comprising the following modules:

[0067] The instruction generation module obtains task parameters from the manufacturing information management system, including the target location coordinates of the sand removal cover, the energy-saving mode identifier, and the tightness threshold, and generates initial control instructions.

[0068] The image deviation analysis module controls an industrial camera to capture dynamic images of the splicing area of ​​movable components, and generates displacement deviation information based on the dynamic images of the splicing area and the density threshold.

[0069] The multi-level control command generation module generates multi-level control commands based on displacement deviation information and energy-saving markers in the initial control commands.

[0070] The docking operation execution module is used to input multi-level control commands into multi-level control devices to drive components to dock and generate component status identifiers.

[0071] The sealing verification module is used to trigger the industrial camera to capture a second image of the stitched area after locking, and to generate a verification result based on the verification image and the tightness threshold.

[0072] The data feedback generation module integrates the locking pressure value of the component status identifier, the sealing status mark of the verification result, and the energy-saving constraint conditions of the initial control command to generate a feedback data package.

[0073] The system status update and reset module sends the energy-saving correction coefficient in the feedback data packet back to the manufacturing information management system, and controls the mechanical latch and drive device to perform the reset operation based on the sealing status mark in the verification results.

[0074] In one embodiment of the present invention, generating initial control commands includes the following steps:

[0075] Receive task parameters from the manufacturing information management system, including the target position coordinates of the sand removal cover, the energy-saving mode identifier, and the tightness threshold; extract the component target angle, preset height, and energy-saving constraints from the task parameters; and generate initial control instructions including angle reference values, height reference values, and energy-saving markers.

[0076] Specifically, the system receives data packets of task parameters from the manufacturing information management system via its communication interface. These data packets contain the target position coordinates of the sand removal cover, the energy-saving mode identifier, and the tightness threshold. The data parsing module extracts the component target angle, preset height, and energy-saving constraints from the data packets. The component target angle is directly mapped to an angle reference value, the preset height is directly mapped to a height reference value, and the energy-saving mode identifier is directly mapped to an energy-saving marker. An initial control instruction file containing the angle reference value, height reference value, and energy-saving marker is then generated.

[0077] Based on the logic of data reception, parsing, and instruction generation, the manufacturing information management system serves as the data source. It transmits task parameters through standard industrial protocols, the data parsing module extracts specified information, and the execution logic ensures that the input task parameters are transformed into initial output control instructions through simple mapping, forming a continuous data transformation chain.

[0078] The manufacturing information management system (MIMS) issues work instructions. Task parameters include the target location coordinates of the sand removal hood, an energy-saving mode identifier, and a tightness threshold. The target location coordinates of the sand removal hood are three-dimensional spatial coordinates, determined based on actual manufacturing layout requirements. The energy-saving mode identifier is a Boolean value indicating the activation status of the energy-saving mode. The tightness threshold represents the maximum allowable gap between component mating surfaces, determined based on mechanical seal test specifications. The component target angle is an angle value extracted from the task parameters, set based on direct assignment of values ​​from the task parameters. The preset height is a height value extracted from the task parameters, set based on direct assignment of values ​​from the task parameters. Energy-saving constraints are energy consumption limit requirements extracted from the task parameters, set based on direct assignment of values ​​from the task parameters. The angle reference value is the angle reference value in the initial control instruction file, the height reference value is the height reference value in the initial control instruction file, and the energy-saving flag is the energy-saving mode flag in the initial control instruction file.

[0079] For example, the task parameters include the target position coordinates of the sand removal cover as 150 mm 200 mm 100 mm, the energy-saving mode identifier as true, and the compactness threshold as 0.05 mm; the task parameters are extracted to obtain the component target angle as 45 degrees, the preset height as 100 mm, and the energy-saving constraint as the maximum energy consumption of 80 joules; the generated initial control command includes the angle reference value of 45 degrees, the height reference value of 100 mm, and the energy-saving flag as true.

[0080] In one embodiment of the present invention, displacement deviation information is generated based on the dynamic image of the stitched region and the density threshold, including the following steps:

[0081] The system controls an industrial camera to capture dynamic images of the splicing area of ​​movable components; identifies the pixel positions of the component edges in the image, calculates the lateral offset and angular deviation between the actual position and the target position; compares the tightness threshold with the joint gap size, and generates displacement deviation information including lateral compensation value, angular correction value and gap over-limit mark.

[0082] Specifically, the control module activates an industrial camera to capture dynamic images of the splicing area of ​​the movable components. These images capture real-time visual information of the components during the splicing process. Subsequently, an image processing algorithm is applied to identify the pixel positions of the component edges in the image. Based on these pixel positions and a scaling factor, the lateral offset and angular deviation between the actual position and the target position are calculated.

[0083] The lateral offset satisfies the following formula: . This indicates the lateral offset, in millimeters. This represents the x-coordinate of the actual pixel position; Represents the x-coordinate of the target pixel position, mapped from the target position coordinates after removing the sand cover; The scaling factor, expressed in millimeters per pixel, is obtained through camera pre-calibration. A standard calibration board is used to measure the relationship between pixels and actual distances at known distances to ensure accuracy. The unit is millimeters.

[0084] The angular deviation satisfies the following formula: , This represents the angular deviation, in degrees; the angular deviation is calculated by outputting arctan in radians and multiplying by... Turn the scale over to ensure the unit is correct; and Output settings from the image processing algorithm; and Remove the target position coordinate conversion settings from the task parameters.

[0085] The measurement of the joint gap size in the image is compared with a tightness threshold to generate a displacement deviation information file containing lateral compensation values, angle correction values, and gap over-limit markers. Based on visual capture, image analysis, and threshold comparison logic, the execution flow starts with camera control, proceeds through pixel position recognition and offset calculation to threshold comparison, forming a continuous data transformation chain.

[0086] The industrial camera is an industrial-grade device used to capture optical images, specifically for dynamically photographing the component splicing area. The dynamic image of the splicing area of ​​the movable components is a video frame or image sequence data structure containing visual data of the component joining area. The pixel position of the component edge is the coordinate value attribute of the component outline edge in the image; the actual position is the coordinate value of the component in physical space, in millimeters, calculated based on pixel position and scale factor; the target position is the coordinate value of the target position excluding the sand cover, in millimeters, derived from task parameters; the lateral offset is the horizontal position difference, in millimeters; the angle deviation is the directional angle difference, in degrees; the joining gap size is the width value of the gap between the component joining surfaces, in millimeters, obtained from image measurement; the lateral compensation value is a value used for displacement correction, in millimeters; the angle correction value is a value used for angle adjustment, in degrees; the gap exceedance mark is a Boolean flag indicating whether the gap size exceeds the tightness threshold; the displacement deviation information is a data structure containing the lateral compensation value, angle correction value, and gap exceedance mark.

[0087] For example, the target position coordinates of the sand cover are x=150 mm and y=200 mm, and the tightness threshold is 0.05 mm; control the industrial camera to capture images of the splicing area, identify the pixel position of the component edge, calculate the actual position x=148 mm, the lateral offset is -2 mm, the angle deviation is +0.3 degrees; measure the joint gap size of 0.06 mm, compare with the threshold to generate a lateral compensation value of +2 mm, an angle correction value of -0.3 degrees, and mark the gap exceeding the limit as true.

[0088] In one embodiment of the present invention, generating multi-level control instructions includes the following steps:

[0089] The first-level lateral displacement parameter is generated based on the lateral compensation value, and the driver is controlled to perform X-axis displacement compensation. Subsequently, the second-level angle adjustment parameter is generated based on the angle correction value, and the rotating mechanism is controlled to perform fine adjustment within ±5°. Combining the clearance over-limit mark and the energy-saving mark in the initial control command, the locking pre-parameter containing the pressure intensity coefficient is generated. The lateral displacement parameter, angle adjustment parameter and locking pre-parameter are integrated to generate multi-level control commands.

[0090] Specifically, the control module receives a displacement deviation information file from step S2, which includes lateral compensation values, angle correction values, and clearance overrun markers. Based on the lateral compensation values, a first-level lateral displacement parameter is directly generated to control the drive to perform X-axis displacement compensation operations. Based on the angle correction values, a second-level angle adjustment parameter is directly generated to control the rotating mechanism to perform fine-tuning operations within a ±5° range. Combining the clearance overrun marker in the displacement deviation information and the energy-saving marker from the initial control command in step S1, a locking pre-parameter is generated through logical judgment. If the clearance overrun marker is true, a higher clamping force coefficient is set; if the energy-saving marker is true, the clamping force is reduced to achieve energy saving. The generated pressure strength coefficient serves as the core content of the locking pre-parameter. The first-level lateral displacement parameters, the second-level angle adjustment parameters, and the locking pre-parameter are integrated to generate a multi-level control command file.

[0091] The first-level lateral displacement parameter, in millimeters, is a numerical value used to drive the X-axis displacement and is directly assigned based on the lateral compensation value. The second-level angle adjustment parameter, in degrees, is a numerical value used to drive fine-tuning of the angle and is directly assigned based on the angle correction value. The pressure intensity coefficient is a factor in the locking pre-parameters representing the clamping force ratio. Based on safety experiments, it is determined that the pressure coefficient increases when the clearance exceeds the limit and decreases when saving energy. The locking pre-parameters are data structures containing the pressure intensity coefficient, and their function is to predefine locking operation parameters. The multi-level control command is a data structure integrating the lateral displacement parameter, angle adjustment parameter, and locking pre-parameters, and its function is to control multi-level actuators.

[0092] For example, the displacement deviation information from step S2 includes a lateral compensation value of +2mm, an angle correction value of -0.3°, and a clearance over-limit flag of true; the energy-saving flag from the initial control command in step S1 is true; the first-level lateral displacement parameter is +2mm, and the second-level angle adjustment parameter is -0.3°; combining the clearance over-limit flag (true) and the energy-saving flag (true), the pressure intensity coefficient is set to 1.2 to balance safety and energy saving; and multi-level control commands are integrated and generated.

[0093] In one embodiment of the present invention, generating a component status identifier includes the following steps:

[0094] The lateral displacement parameter is input into the lateral hydraulic actuator to move the component to the compensated coordinate position; the angle adjustment parameter is input into the rotary motor to rotate the component to the corrected alignment angle; according to the pressure intensity coefficient in the locking pre-parameter, the pneumatic mechanism is controlled to apply an adaptive clamping force; the mechanical locking component is activated to generate a component status identifier containing position coordinates, locking pressure value, and timestamp.

[0095] Specifically, the control module receives a multi-level control command file from step S3, which includes first-level lateral displacement parameters, second-level angle adjustment parameters, and locking pre-parameters. The first-level lateral displacement parameters are input to the lateral hydraulic actuator, which moves the movable component along the X-axis according to the parameter value, bringing the component to the compensated coordinate position. The second-level angle adjustment parameters are input to the rotary motor, which rotates the component within ±5° according to the parameter value, bringing the component to the corrected alignment angle. Based on the pressure intensity coefficient in the locking pre-parameters, the pneumatic mechanism is controlled to apply an adaptive clamping force, the magnitude of which is proportional to the pressure intensity coefficient. A live mechanical lock is used to fix the component's position. After the component is fixed, a component status identification file is generated, which includes the component's compensated coordinate position, locking pressure value, and timestamp.

[0096] Among them, the lateral hydraulic actuator is a hydraulic drive device for moving the component in the X-axis direction, and its function is to perform linear displacement; the compensated coordinate position is the three-dimensional spatial coordinate value of the component after movement, in millimeters, based on the actual position measurement after the actuator performs displacement; the rotary motor is an electric motor device for rotating the component, and its function is to perform angle adjustment; the corrected alignment angle is the angle value of the component after rotation, in degrees, based on the actual angle measurement after the motor performs rotation; the pneumatic mechanism is a pneumatic device for applying pressure, and its function is to generate clamping force; the adaptive clamping force is the force value applied to the component mating surface, in Newtons, dynamically adjusted based on the pressure intensity coefficient, and determined based on the specifications of the pneumatic mechanism and safety tests.

[0097] Mechanical locking is a mechanical device used to lock components, and its function is to fix the position of the components; the component status identifier represents a data structure containing position coordinates, locking pressure value and timestamp, and its function is to record the docking status; the position coordinates are the compensated coordinate position values, in millimeters; the locking pressure value is the actual measured value of the adaptive clamping force, in Newtons; the timestamp represents the time information of recording the completion of the operation.

[0098] For example, the multi-level control command from step S3 includes a first-level lateral displacement parameter of +2mm, a second-level angle adjustment parameter of -0.3°, and a locking pre-parameter pressure strength coefficient of 1.2; the lateral hydraulic actuator moving assembly has a compensated coordinate position of (152mm, 200mm, 100mm); the rotary motor rotating assembly has a corrected alignment angle of 44.7°; the pneumatic mechanism applies an adaptive clamping force of 600N; and the mechanical locking fixing assembly is activated.

[0099] The generated component status identifier includes position coordinates (152mm, 200mm, 100mm), locking pressure value of 600N, and timestamp 2023-10-05T14:30:00.

[0100] In one embodiment of the present invention, generating a verification result based on a verification image and a density threshold includes the following steps:

[0101] The system triggers a second capture of the verification image of the stitched area by the industrial camera. It measures the gap distribution of the component joint surfaces in the verification image. If the maximum gap value is less than the tightness threshold, it is marked as a qualified seal; otherwise, it is marked as an abnormal seal. The system generates a verification result that includes the seal status mark and the coordinates of the abnormal position.

[0102] Specifically, the industrial camera is activated by the control module to take a second picture of the locked movable component splicing area to obtain a verification image. The image processing algorithm is applied to identify the contour of the component joint surface in the verification image, and measurement points are evenly selected along the joint surface to calculate the gap width value of each point, forming a gap distribution state dataset. Then, the maximum gap value in the gap distribution state is extracted and compared with the tightness threshold. When the maximum gap value is less than the tightness threshold, the sealing state is marked as qualified. When the maximum gap value is greater than or equal to the tightness threshold, the sealing state is marked as abnormal. At the same time, the physical location corresponding to the maximum gap value is located as the abnormal location coordinates, and a verification result file containing the sealing state mark and the abnormal location coordinates is generated.

[0103] The verification image is a static image data structure of the stitched area captured twice after locking; the gap distribution state of the component joint surface is a set of multiple gap width values ​​measured along the joint surface, in millimeters, based on the image edge detection algorithm and the scaling factor conversion in step S2. The maximum gap value is the maximum value in the gap distribution state, in millimeters, set based on array extreme value calculation; the sealing status mark is a Boolean value indicating whether the sealing is qualified or abnormal; the abnormal position coordinates are the three-dimensional spatial coordinates corresponding to the maximum gap value, in millimeters, based on image position mapping and the coordinate transformation method in step S2; the verification result is a data structure containing the sealing status mark and the abnormal position coordinates.

[0104] For example, the tightness threshold from step S1 is 0.05mm, and the component from step S4 is in a locked state; at the same time, the industrial camera is triggered to capture verification images, and the gap distribution is measured to obtain data such as 0.02mm, 0.03mm, 0.04mm, and 0.07mm.

[0105] The maximum gap value is 0.07 mm; the comparison threshold marks the sealing status as abnormal, corresponding to the abnormal position coordinates (155 mm, 205 mm, 100 mm); the generated verification result includes the sealing status mark false and the abnormal position coordinates (155 mm, 205 mm, 100 mm).

[0106] In one embodiment of the present invention, generating a feedback data packet includes the following steps:

[0107] The locking pressure value of the component status identifier and the sealing status mark of the verification result are input into the manufacturing information management system; the difference between the actual energy consumption value and the energy-saving constraint in the initial control command is calculated; an energy-saving correction coefficient for optimizing the subsequent clamping force is generated; the sealing status mark, energy consumption difference and energy-saving correction coefficient are packaged and a feedback data package is generated.

[0108] Specifically, the locking pressure value from the component status identification file in step S4 and the sealing status mark from the verification result file in step S5 are read through the data interface module and input into the performance analysis unit of the manufacturing information management system; the actual energy consumption values ​​consumed by the transverse hydraulic drive, rotary motor, and pneumatic mechanism during the docking operation in step S4 are obtained from the actuator monitoring unit; energy-saving constraints are extracted from the initial control command file in step S1; and the difference between the actual energy consumption value and the energy-saving constraints is calculated to obtain the energy consumption difference, which satisfies the following formula: , This represents the energy consumption difference, expressed in joules. This represents the actual energy consumption value, expressed in joules. This represents the energy-saving constraint, expressed in joules. The actual energy consumption value is the total energy consumed during the docking operation, set based on the cumulative value measured in real time by the actuator's power sensor; the energy consumption difference is the difference between the actual energy consumption value and the energy-saving constraint; the energy-saving constraint is derived from the initial control command settings.

[0109] The energy-saving correction factor is generated from the sealing status mark and the energy consumption difference, satisfying the following formula: k is the energy-saving correction coefficient; α is the adjustment factor, with a typical value of 0.3; the energy-saving correction coefficient is a proportional factor used to optimize the subsequent clamping force, based on the mapping rule between the sealing state and the energy consumption difference.

[0110] The specific rules are as follows: when the sealing status is marked as qualified and the energy consumption difference is negative, a coefficient less than 1 is generated to reduce the subsequent clamping force; when the sealing status is marked as abnormal, a coefficient greater than 1 is generated to increase the clamping force. The sealing status mark, energy consumption difference, and energy-saving correction coefficient are packaged into a feedback data package file. The feedback data package is a data structure containing the sealing status mark, energy consumption difference, and energy-saving correction coefficient, and its function is to provide feedback on system performance.

[0111] For example, the sealing status is marked as false in the verification result from step S5, the locking pressure value is 600N and the actual energy consumption value is 90J in the component status identifier from step S4, and the energy-saving constraint condition is 80J from the initial control command from step S1.

[0112] The energy consumption difference of 90 minus 80 equals 10J; an energy-saving correction factor of 1.2 is generated due to abnormal sealing condition; the packaged feedback data includes the sealing condition flag false, the energy consumption difference of 10J, and the energy-saving correction factor of 1.2.

[0113] In one embodiment of the present invention, the mechanical latch and drive device are controlled to perform a return operation based on the sealing status mark in the verification result, including the following steps:

[0114] The energy-saving correction coefficient of the feedback data packet is sent back to the manufacturing information management system database to update the energy-saving strategy. Based on the sealing status mark, the mechanical lock is controlled to release the component lock. Then, the horizontal hydraulic drive is driven to move the component back to the initial coordinate position. Finally, the rotary motor angle is reset to zero and the industrial camera is turned off.

[0115] Specifically, the energy-saving correction coefficient from the feedback data packet in step S6 is transmitted to the manufacturing information management system database via the communication module. This database updates the energy-saving strategy parameters based on the energy-saving correction coefficient for subsequent task optimization. The mechanical latch is controlled to perform an unlocking operation based on the sealing status mark from the verification result in step S5. If the sealing status mark is qualified or abnormal, the latch is triggered to release the component lock. The horizontal hydraulic actuator is driven to move the movable component along the X-axis to the initial coordinate position, which is defined by the target position coordinate of the sand removal hood in the task parameters of step S1. The rotary motor is controlled to perform an angle zeroing operation to reset the component rotation angle to 0 degrees. The industrial camera is turned off to stop image acquisition, completing the system return to its original position.

[0116] For example, the feedback data packet from step S6 includes an energy-saving correction factor of 1.2, and the sealing status from step S5 is marked as false; the energy-saving correction factor of 1.2 is sent back to the manufacturing information management system database to update the strategy; the mechanical latch is controlled to release the component lock; the lateral hydraulic drive is driven to move the component back to the initial coordinate position (150mm, 200mm, 100mm), the rotary motor is controlled to return to 0° and the industrial camera is turned off.

[0117] It should be noted that the formulas described above, through the principle of dimensional consistency and mathematical standardization methods (such as normalization, dimensionless parameter conversion, or unit system unification), can translate physical quantities with different properties into unitless standard values ​​or superimposed parameters of the same dimension. This eliminates the interference of different dimensions on the computational logic, allowing the formulas to retain the original data distribution characteristics while possessing mathematical rationality and adaptability to objective laws. The descriptions are merely exemplary embodiments of the present invention and should not be construed as limiting the scope of the invention.

[0118] Each of the modules can be implemented in whole or in part through software, hardware, or a combination thereof. It supports hardware embedded in or independent of the processor in the computer device, and also supports software stored in the memory of the computer device, so that the processor can call and execute the operations corresponding to each of the above modules.

[0119] It should be noted that the human information (including but not limited to human device information and personal information) and data (including but not limited to data used for analysis, data stored and data displayed) involved in this invention are all information and data authorized by the human body or fully authorized by all parties. The collection, use and processing of related data require relevant legal standards.

[0120] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A movable splicing desanding cover control system based on image processing, characterized in that, The system comprises: An instruction generation module that obtains task parameters including sand cover target position coordinates, energy-saving mode identification, and tightness threshold value issued by a manufacturing information management system, and generates initial control instructions; An image deviation analysis module that controls an industrial camera to capture dynamic images of the splicing area of the movable assembly, and generates displacement deviation information based on the dynamic images and the tightness threshold value; A multi-level regulation instruction generation module that generates multi-level regulation instructions based on the displacement deviation information and the energy-saving mark in the initial control instructions; A docking operation execution module that inputs the multi-level regulation instructions into a multi-level regulation device to drive the assembly to dock, and generates an assembly state identifier; A sealing verification module that triggers the industrial camera to capture verification images of the locked splicing area, and generates a verification result based on the verification images and the tightness threshold value; A data feedback generation module that integrates the locking pressure value of the assembly state identifier, the sealing state mark of the verification result, and the energy-saving constraint condition of the initial control instructions to generate a feedback data packet; A system state updating and homing module that returns the energy-saving correction coefficient in the feedback data packet to the manufacturing information management system, and controls the mechanical lock and the driving device to perform a homing operation according to the sealing state mark in the verification result.

2. The image processing based movable splicing desanding cover control system according to claim 1, characterized in that, Generating initial control instructions includes the following steps: Receiving task parameters; Extracting the component target angle and the preset height from the task parameters, and mapping the component target angle to an angle reference value, the preset height to a height reference value, and the energy-saving mode identification to an energy-saving mark; Integrating the angle reference value, the height reference value, and the energy-saving mark to generate initial control instructions.

3. The image processing based movable splicing desanding cover control system according to claim 1, characterized in that, Generating displacement deviation information based on the splicing area dynamic images and the tightness threshold value includes the following steps: Identifying the pixel position of the assembly edge in the splicing area dynamic image, and calculating the actual position; According to the actual position and the sand cover target position coordinates, calculating the lateral offset and the angle deviation; Measuring the joint gap size in the splicing area dynamic image, and comparing it with the tightness threshold value. If the joint gap size exceeds the tightness threshold value, a true gap overrun mark is generated; Integrating the lateral compensation value generated by the lateral offset, the angle correction value generated by the angle deviation, and the gap overrun mark to generate displacement deviation information.

4. The image processing based movable splicing desanding cover control system according to claim 1, characterized in that, Generating multi-level regulation instructions includes the following steps: Generating a first-level lateral displacement parameter according to the lateral compensation value; Generating a second-level angle adjustment parameter according to the angle correction value; Combining the gap overrun mark and the energy-saving mark to generate a pressure intensity coefficient. When the gap overrun mark is true, the pressure intensity coefficient is increased to ensure the tightness of the docking, and when the energy-saving mark is true, the pressure intensity coefficient is reduced to reduce energy consumption. This combination achieves a coordinated balance between safety and energy consumption; Taking the pressure intensity coefficient as the core content of the locking pre-parameter; Integrating the first-level lateral displacement parameter, the second-level angle adjustment parameter, and the locking pre-parameter to generate multi-level regulation instructions.

5. The image processing based movable splicing desanding cover control system according to claim 1, wherein, Generating an assembly state identifier includes the following steps: Inputting the first-level lateral displacement parameter into the lateral hydraulic drive to move the assembly to the compensated coordinate position; Inputting the second-level angle adjustment parameter into the rotary motor to rotate the assembly to the corrected alignment angle; According to the pressure intensity coefficient in the locking pre-parameter, the air pressure mechanism is controlled to apply adaptive clamping force; The mechanical lock is activated to fix the assembly, and the compensated coordinate position is recorded as the position coordinate, and the measured value of the adaptive clamping force is recorded as the locking pressure value, and the assembly state identifier is generated.

6. The image processing based movable splicing desanding cover control system according to claim 1, wherein, The verification result is generated based on the verification image and the tightness threshold, including the following steps: Measure the gap distribution state of the assembly joint surface in the verification image; Extract the maximum gap value from the gap distribution state; When the maximum gap value is less than the tightness threshold, generate a qualified sealing state mark; When the maximum gap value is greater than or equal to the tightness threshold, generate an abnormal sealing state mark, and record the position of the maximum gap value as the abnormal position coordinate; Integrate the sealing state mark and the abnormal position coordinate to generate the verification result.

7. The image processing based movable splicing desanding cover control system according to claim 1, wherein, The feedback data packet is generated, including the following steps: Obtain the actual energy consumption value during the execution of the docking operation; Calculate the difference between the actual energy consumption value and the initial control instruction energy saving constraint condition to obtain the energy consumption difference value; Combine the sealing state mark and the energy consumption difference value to generate the energy saving correction coefficient; Package the sealing state mark, energy consumption difference value and energy saving correction coefficient to generate the feedback data packet.

8. The image processing based movable splicing desanding cover control system according to claim 1, wherein, According to the sealing state mark in the verification result, the mechanical lock and the driving device are controlled to perform the homing operation, including the following steps: Update the energy saving correction coefficient in the feedback data packet to the energy saving strategy of the manufacturing information management system; Control the mechanical lock to release the assembly locking according to the sealing state mark; Drive the horizontal hydraulic drive to move the assembly back to the initial coordinate position defined by the task parameter; Control the rotary motor to perform angle zero.

9. The image processing based movable splicing desanding cover control system according to claim 1, wherein, Activate the mechanical lock to fix the assembly, including the following steps: Obtain the pressure sensor reading of the air pressure mechanism; Compare the pressure sensor reading with the preset pressure interval; Only when the pressure sensor reading falls within the preset pressure interval, the mechanical lock is activated.

10. The image processing based movable splicing desanding cover control system according to claim 1, wherein, Combine the sealing state mark and the energy consumption difference value to generate the energy saving correction coefficient, including the following steps: When the sealing state mark is abnormal, the energy saving correction coefficient is set to a fixed penalty value to forcibly enhance the clamping force of subsequent operations; When the sealing state mark is qualified, the energy saving correction coefficient is dynamically calculated according to the size of the energy consumption difference value.

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