Method and system capable of automatically achieving material surface recognition and coping

Abstract

The invention relates to a method and system capable of automatically achieving material surface recognition and coping. Space execution mechanisms which are independent and in different directions, laser sensors and other measuring elements serve as a whole to be used for recognizing the surface of a material and grinding the surface of the material, the movement range is large, and the degree of freedom in the operation process is high. According to the method, a material is put into the Z-axis executing mechanism and moves to be close to the laser sensor, the laser sensor scans the material and transmits data to the PC for calculation, data needing to be polished is obtained, and polishing of the material is achieved through the X-axis executing mechanism, the Y-axis executing mechanism and the Z-axis executing mechanism; the structure adopted by the method comprises a base, a trolley and a Y-axis executing mechanism are arranged on a rail of the base, an X-axis executing mechanism is arranged on the Y-axis executing mechanism, a laser sensor and a scanning and polishing assembly are arranged on the X-axis executing mechanism, the laser sensor is connected with a laser controller, and a system is controlled to move through a motion controller. And the laser controller and the motion controller are respectively connected with the PC.

Description

Technical Field

[0001] This invention relates to the field of grinding technology after casting or transformer casting, specifically to a method and system that can automatically identify and grind the surface of materials. Background Technology

[0002] In many fields such as machining and precision manufacturing, the surface morphology of a product is also an important factor in measuring product quality.

[0003] Currently, for industries with strict requirements on dimensions and surface smoothness, further precision machining can be achieved using machine tools and other equipment. However, for surfaces with irregular structures, or those with burrs and uneven surfaces after epoxy resin casting in a vacuum on dry-type transformers, precision machining using machine tools is not feasible due to the inherent irregularities. Currently, manual grinding is the primary method, requiring human observation and judgment during the grinding process. Manual grinding is inefficient due to dust hazards, limitations imposed by physical exertion, and low work efficiency. Furthermore, while grinding equipment exists, it utilizes robotic arms that require human input of parameters. This method, with its multi-degree-of-freedom design, also has limited operating range, restricts the size of materials being ground, and is relatively expensive, resulting in limited market application.

[0004] The patent, numbered 202510316338.6, is titled "An Intelligent Inspection and Grinding System and Method for Medium-Thick Plates with Efficient Multi-Task Collaborative Allocation." It includes a medium-thick plate defect detection system, a task allocation system, and a robotic grinding system. The defect detection system acquires the location and depth information of defects. The task allocation system receives defect information in real time and, through constraints such as dividing the steel plate working area and preventing robot collisions, uses a consensus-based greedy algorithm to allocate tasks to the robotic grinding system in real time. The robotic grinding system, based on the defect information, initiates the steel plate positioning and grinding program, and performs a re-inspection of the grinding area after grinding. Its problems are: the grinding surface is a medium-thick plate, and the grinding method uses multi-component collaborative judgment of the grinding position; if one component malfunctions, it will lead to grinding errors and scrap the workpiece. Furthermore, the use of a robotic arm for grinding has a limited grinding range, the robot is expensive, and manual parameter input is required, which can lead to input errors. Summary of the Invention

[0005] In view of the above, the present application provides a method and system for automatically identifying and grinding the surface of a material to solve the low efficiency problem in the grinding process of irregular structure surface.

[0006] To solve the problems in the prior art, the present application adopts the technical scheme of a method for automatically identifying and grinding the surface of a material, comprising the following steps: Step 1: Place the material on the Z-axis execution mechanism, reset the X-axis execution mechanism and the Y-axis execution mechanism, and rotate the material to the surface to be ground by the material rotating mechanism. Step 2: Run the Z-axis execution mechanism to make the material approach the laser sensor, the laser sensor scans the grinding surface of the material and transmits the data to the PC, the data interaction between the laser controller and the PC is used to model, analyze the concave-convex condition of the grinding surface of the material, compare and calculate with the parameter value of the expected surface, and obtain the three-dimensional data of each grinding point of the grinding surface that needs to be ground. Step 3: Control the X-axis execution mechanism and the Y-axis execution mechanism to move towards the material processing surface by the motion controller, control the two grinding heads on the X-axis execution mechanism to grind the surface to be processed of the material, scan the processed surface by the laser sensor after the grinding is completed, and compare with the parameter of the expected surface set on the PC, if they are consistent, the processing is completed, and the motion controller controls the X-axis execution mechanism, the Y-axis execution mechanism and the Z-axis execution mechanism to reset. Step 4: Rotate the material to another surface to be processed by the material rotating mechanism, repeat steps 2-3 to process the other surface of the material.

[0007] The system for the method of automatically identifying and grinding the surface of a material comprises a base, the base is provided with a track, the track is provided with a movable trolley and a Y-axis execution mechanism that can move back and forth, the Y-axis execution mechanism is provided with an X-axis execution mechanism that is crosswise arranged therewith, the X-axis execution mechanism is provided with a scanning and grinding assembly, the movable trolley is provided with a material rotating mechanism, the X-axis execution mechanism is provided with a laser sensor, the laser sensor is connected with a laser controller, the motion of the X-axis execution mechanism, the Y-axis execution mechanism, the material rotating mechanism and the Z-axis execution mechanism is controlled by a motion controller, the laser controller and the motion controller are connected with a PC respectively, and the PC is connected with a display screen. The X-axis actuating mechanism and the Y-axis actuating mechanism are cross arranged and have the same structure, which comprises a back plate, two symmetrical slide rails arranged on the back plate, a screw rod arranged in the middle of the two slide rails, a sliding block arranged on the slide rail, and a lead screw controlled by a speed reducer to realize rotation, and a wire groove arranged on the side of the back plate perpendicular to the back plate; The scanning and polishing assembly comprises a longitudinal mounting plate arranged on the screw rod fixing seat of the X-axis actuating mechanism, a supporting rod arranged vertically on the mounting plate, a cylinder connecting seat arranged on the supporting rod close to the mounting plate end, and a plurality of polishing head assemblies arranged on the cylinder connecting seat; the mounting plate is further provided with a scanning assembly; The material rotating mechanism comprises a rotating platform driven to rotate by a rotating transmission motor, two L-shaped material baffles arranged symmetrically on the upper part of the rotating platform, and a moving trolley driven by an up-down material transmission motor.

[0008] Further, the structure of the scanning and polishing assembly comprises a cylinder, a rotating mechanism connected to the cylinder, and a polishing head connected to the end of the rotating mechanism.

[0009] Further, the Y-axis actuating mechanism is arranged on the vertical back plate which is slidingly arranged on the base.

[0010] Further, the screw rod is fixed on the vertical back plate through a screw rod support seat and a screw rod fixing seat.

[0011] Further, one end of the screw rod is provided with a shaft coupling support seat connected with the speed reducer.

[0012] Further, the supporting rod is further provided with an air pressure adjusting valve.

[0013] Further, the protective cover is slidingly arranged on the supporting rod through the sliding block three.

[0014] Further, the two ends of the cylinder connecting seat are arranged on the two sides of the supporting rod.

[0015] Further, the moving trolley is arranged on the track of the base through the sliding block four and can slide along the track; the middle part of the rotating platform is provided with a suction cup controlled by a suction cup control valve.

[0016] Compared with the prior art, the present application has the following advantages and technologies: 1) The present application integrates the independent, different direction space actuating mechanism and the laser sensor and other measuring elements as a whole, so that the movement range is larger and the operation process has higher freedom, and a full-automatic intelligent grinding system for multiple surface processing can be realized. 2) The present application obtains information through laser sensor, and carries out data analysis through PC, and obtains three-dimensional data of each polishing point of polishing surface which needs to be polished by comparison and calculation with parameter value of expected surface; without inputting certain size, three-dimensional data is converted into XYZ path information for grinding on polishing head to carry out polishing.

[0017] 3) The present application is a flexible structure with double structure interchanging, and when the system is controlled, different polishing modes of polishing surface can be switched by using different abrasive discs on two grinding heads; when polishing, electromagnetic valve is controlled by air cylinder, and according to set air pressure, contact force in polishing process is ensured, so that flatness of polishing surface is ensured and polishing head is protected.

[0018] 4) In the present application, different abrasive discs with different softness and hardness are used in polishing process to adapt to different polishing surfaces and realize edge polishing guide angle; at the same time, the pressure of air cylinder can be adjusted by air pressure adjusting valve, so that flexible adjustable polishing according to burr size and hardness in polishing process is realized.

[0019] 5) In the present application, because polishing surface is irregular and burr shape is various, X axis and Y axis moving structure is used to realize polishing of different surfaces of material by cooperating with trolley moving and rotating structure, and the structure has polishing point positioning structure of any point in a certain range on three-dimensional surface under XYZ coordinate, the structure has small limitation on size, shape and weight of material, and has wide application range. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is control block of the system of the present application.

[0021] Figure 2 It is overall structure of the system.

[0022] Figure 3 It is X axis actuating mechanism.

[0023] Figure 4 It is polishing and scanning assembly.

[0024] Figure 5 It is Y axis actuating mechanism.

[0025] Figure 6 It is material rotating mechanism.

[0026] Marking description: 1-PC, 2-display screen, 3-motion controller, 4-laser sensor, 5-laser controller, 6-grinding head 1 solenoid valve, 7-grinding head 2 solenoid valve, 8-suction cup solenoid valve, 9-network switch, 10-grinding head X-axis actuator, 11-grinding head Y-axis actuator, 12-Z-axis actuator, 13-material rotating mechanism, 14-grinding head 1 rotating mechanism, 15-grinding head 2 rotating mechanism, 16-scanning and grinding assembly, 17-base, 18-vertical back plate, 19-material to be polished.

[0027] 10-1: horizontal back plate, 10-2: slide rail one, 10-3: screw fixed seat, 10-4: slide block one, 10-5: screw support seat one, 10-6: speed reducer one, 10-7: shaft support seat one, 10-8: screw one, 10-9: wire groove one; 11-1: vertical back plate, 11-2: slide rail two, 11-3: slide block two, 11-4: screw support seat two, 11-5: screw fixed seat two, 11-6: screw two, 11-7: shaft support seat two, 11-8: speed reducer two, 11-9: wire groove two; 13-1: rotating platform, 13-2: material baffle, 13-3: vacuum chuck, 13-4: up and down material transmission motor, 13-5: moving trolley, 13-6: slide block four, 13-7: rotating transmission motor; 16-1: mounting plate, 16-2: air pressure regulating valve, 16-3: cylinder connecting seat, 16-4: cylinder, 16-5: protective cover, 16-6: rotating mechanism, 16-7: grinding head, 16-8: slide block three, 16-9: support rod. DETAILED DESCRIPTION

[0028] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be connected inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0029] The technical solutions in the embodiments of the present application will be described clearly and completely in the following with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0030] The present embodiment provides a method capable of automatically realizing material surface identification and grinding, the steps are: Step 1: Put the material on the Z-axis actuator 12, reset the X-axis actuator 10 and the Y-axis actuator 11, and rotate the material to the surface that needs to be polished by the material rotating mechanism 13; Step 2: The Z-axis actuator 12 operates to make the material approach the laser sensor 4, and the laser sensor 4 continuously scans and judges whether the distance between the material and the laser sensor 4 reaches the set range. If not, the above process continues, and if so, the Z-axis actuator 12 stops operating, the polished surface of the material is scanned, and the data is transmitted to the PC 1. The data interaction between the laser controller 5 and the PC 1 is used to build a model, analyze the concave-convex situation of the polished surface of the material, compare it with the parameter value of the expected surface, calculate the three-dimensional data of each polishing point of the polished surface, and plan the optimal path through the three-dimensional data of the polishing points. Step 3: The X-axis actuator 10, the Y-axis actuator 11, and the Z-axis actuator 12 are controlled by the motion controller 3 to move the material processing surface close to the grinding head. The Y-axis actuator 11 controls the X-axis actuator 10 to move up and down, and the grinding head 1 rotating mechanism 14 or the grinding head 2 rotating mechanism 15 rotates. The grinding head is controlled by the electromagnetic valve 6 and the electromagnetic valve 7 to move back and forth, and the material surface to be processed is polished and processed. After processing, the laser sensor 4 is controlled by the laser controller 5 to scan the processed surface and compare it with the parameter of the expected surface set on the PC 1. If they are consistent, the processing is completed. After the processing is completed, the X-axis actuator 10, the Y-axis actuator 11, and the Z-axis actuator 12 are reset by the motion controller 3. Step 4: Rotate the material to another surface that needs to be processed by the material rotating mechanism 13, and repeat steps 2-3 to process the other surface of the material.

[0031] The above expected surface is the surface that needs to be polished and shaped.

[0032] The PC, the laser controller, and the motion controller of the present application communicate through a network switch.

[0033] The motion controller and the laser controller of the present application are existing controllers.

[0034] The system used in the above method is, for example, Figure 1 and Figure 2As shown, it comprises base 17, vertical backboard 18, Y-axis actuator 11, X-axis actuator 10, scanning and polishing assembly 16, material rotating structure 13 and moving trolley 13-5; the moving trolley is a material Z-axis actuator, the base 17 is provided with a track, the track is provided with a moving trolley 13-5 and a Y-axis actuator 11 which can move back and forth, the Y-axis actuator 11 is arranged on the vertical backboard 18, and the vertical backboard 18 is slidingly arranged on the base 17; the Y-axis actuator 11 and the X-axis actuator 10 are cross arranged, the scanning and polishing assembly 16 is arranged on the X-axis actuator 11, the material rotating structure 13 is arranged on the moving trolley 13-5, the laser sensor 4 is arranged on the X-axis actuator 10, the laser sensor 4 is connected with the laser controller 5, the movement of the X-axis actuator 10, the Y-axis actuator 11 and the material rotating mechanism 13 is controlled by the motion controller 3, the laser controller 5 and the motion controller 3 are connected with the PC 1 respectively, the PC is connected with the display screen 2, and the display screen is used for displaying the calculated XYZ results and inputting setting parameters and the like information. As shown in the figure, Figure 3 The X-axis actuator 10 comprises a horizontal backboard 10-1, two symmetrical slide rails 10-2 are arranged on the horizontal backboard 10-1, a screw rod 10-8 is fixedly arranged in the middle of the two slide rails 10-2, the screw rod 10-8 is fixedly arranged on the horizontal backboard 10-1 through a screw rod support seat 10-5 and a screw rod fixing seat 10-3, one end of the screw rod 10-8 is provided with a shaft coupling support seat 10-7, and the shaft coupling support seat 10-7 is connected with a speed reducer 10-6; a sliding block 10-4 is arranged on the slide rail 10-2, the screw rod 10-8 is controlled to rotate through the speed reducer 10-6, and a wire groove 10-9 is arranged on the side surface of the horizontal backboard 10-1.

[0035] As shown in the figure, Figure 4 The scanning and polishing assembly 16 comprises a longitudinal mounting plate 16-1 arranged on the screw rod fixing seat 10-3 of the X-axis actuator 10, a support rod 16-9 is arranged vertically on the mounting plate 16-1, a cylinder connecting seat 16-3 is arranged on the support rod 16-9 close to the mounting plate 16-1, and a plurality of grinding head assemblies are arranged on the cylinder connecting seat 16-3 respectively; the structure of each grinding head assembly comprises that a cylinder 24 is arranged on the cylinder connecting seat 16-3, the cylinder 16-4 is connected with a rotating mechanism 16-6, a grinding head 16-7 is arranged at the front end of the rotating mechanism 16-6 and is controlled by the rotating mechanism 16-6, the rotating mechanism 16-6 and the cylinder 16-4 are arranged in a protective cover 16-5 and are protected by the protective cover; the protective cover 16-5 is slidingly arranged on the support rod 16-9 through a sliding block 16-8, and an air pressure regulating valve 16-2 is further arranged on the support rod 16-9, so as to adjust the pressure of the cylinder 16-4 and make the extension and retraction amount of the cylinder different; a scanning assembly is further arranged on the mounting plate 16-1.

[0036] The grinding head assembly is provided with two saw blades or grinding wheels, different grinding heads can be set according to the hardness and polishing flatness requirements of the material, two grinding heads 27 are controlled by grinding head 1 electromagnetic valve 6 and grinding head 2 battery valve 7, and the two electromagnetic valves are controlled by the motion controller.

[0037] As shown in Figure 5 The Y-axis actuating mechanism 11 includes a vertical back plate 11-1, two symmetrical slide rails two 11-2 are arranged on the vertical back plate 11-1, a screw rod two 11-6 is fixedly arranged in the middle of the two slide rails two 11-2, the screw rod two 11-6 is fixedly arranged on the vertical back plate 11-1 through a screw rod support seat two 11-4 and a screw rod fixing seat two 11-5, one end of the screw rod two 11-6 is provided with a shaft coupling support seat two 11-7, the shaft coupling support seat two 11-7 is connected with a speed reducer two 11-8, a sliding block two 11-3 is arranged on the slide rail two 11-2, the screw rod two 11-6 is controlled through the speed reducer two 11-8 to realize rotation, a wire groove two 11-9 is arranged on the side surface of the vertical back plate 11-1, and the horizontal back plate 10-1 of the X-axis vertical moving structure 10 is arranged on the screw rod fixing seat two 11-5.

[0038] As shown in Figure 6 The material rotating structure 13 includes a rotating platform 13-1, the rotating platform 13-1 is driven to rotate through a rotating transmission motor 13-7, two L-shaped material baffles 13-2 are symmetrically arranged on the upper portion of the rotating platform 13-1, a moving trolley 13-5 is arranged on the track of the base 17 through a sliding block four 13-6 and can slide along the track, the moving trolley 13-5 is driven through an up-down material transmission motor 13-4, a suction disc 13-3 is arranged in the middle of the rotating platform 13-1, a material is arranged on the material baffle 13-2 and is adsorbed and fastened through the suction disc 13-3, the suction disc 13-3 is controlled through a suction disc electromagnetic valve 8, the suction disc battery valve 8 is controlled through a motion controller, the vacuum suction disc adsorbs the material to prevent the material from moving; not only suitable for small and light materials, but also different suction discs can be replaced according to the weight of the material to realize the adsorption of large and heavy materials.

[0039] In the above description, many specific details are set forth in order to provide a thorough understanding of the present application, however, the present application can also be implemented in other different ways from those described herein, therefore, the protection scope of the present application is not limited by the above disclosed specific embodiments.

[0040] The above only describes the preferred embodiments of the present application and is not used to limit the present application, for those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method for automatically identifying and grinding material surfaces, characterized in that, The steps are as follows: Step 1: Place the material on the Z-axis actuator (12), reset the X-axis actuator (10) and Y-axis actuator (11), and rotate the material to the surface that needs to be ground. Step 2: The Z-axis actuator (12) runs, causing the material to approach the laser sensor (4). The laser sensor (4) scans the grinding surface of the material and transmits the data to the PC (1). The model is built using the data interaction between the laser controller (5) and the PC (1), and the unevenness of the grinding surface of the material is analyzed. By comparing the parameter values ​​with the desired surface, the three-dimensional data of each grinding point of the grinding surface that needs to be ground is obtained. Step 3: Control the X-axis actuator (10), Y-axis actuator (11), and Z-axis actuator (12) to move towards the material processing surface through the motion controller (3), control the two grinding heads on the X-axis actuator (10) to grind the surface of the material to be processed, and control the laser sensor (4) to scan the processing surface through the laser controller (5) and compare it with the parameters of the desired surface set on the PC (1). If they match, the processing is completed. After the processing is completed, the motion controller (3) controls the X-axis actuator (10), Y-axis actuator (11), and Z-axis actuator (12) to reset. Step 4: Rotate the material to another surface that needs to be processed by the material rotation mechanism (13), and repeat steps 2-3 to process other surfaces of the material.

2. The system used in the method for automatically identifying and grinding material surfaces according to claim 1, characterized in that, Includes a base (17), on which a track is provided, on which a movable trolley (13-5) and a Y-axis actuator (11) are provided, on which an X-axis actuator (10) is provided, which is arranged to cross with the Y-axis actuator (11), on which a scanning and polishing component (16) is provided, on which a material rotation mechanism (13) is provided on the movable trolley (13-5), on which a laser sensor (4) is provided on the X-axis actuator (10), and the laser sensor (4) is connected to a laser controller (5). The movement of the X-axis actuator (10), the Y-axis actuator (11), the Z-axis actuator (12), and the material rotation mechanism (13) is controlled by a motion controller (3). The laser controller (5) and the motion controller (3) are respectively connected to a PC (1), and the PC is connected to a display screen (2). The X-axis actuator (10) and Y-axis actuator (11) are arranged in a cross shape and have the same structure. The structure includes a back plate, two slide rails are symmetrically arranged on the back plate, a lead screw is fixed in the middle of the two slide rails, a slider is arranged on the slide rail, and the lead screw is controlled by a reducer to achieve rotation. A wire groove is arranged on the side perpendicular to the back plate. The scanning and grinding assembly (16) includes a longitudinal mounting plate (16-1) mounted on the lead screw fixing seat of the X-axis actuator (10). A support rod (16-9) is vertically mounted on the mounting plate (16-1). A cylinder connecting seat (16-3) is mounted on the support rod (16-9) near the end of the mounting plate (16-1). Several grinding head assemblies are mounted on the cylinder connecting seat (16-3). A scanning assembly is also mounted on the mounting plate (16-1). The material rotation mechanism (13) includes a rotating platform (13-1), which is driven to rotate by a rotary transmission motor (13-7). Two L-shaped material baffles (13-2) are symmetrically arranged on the upper part of the rotating platform (13-1). The material is placed on the material baffles (13-2). The moving trolley (13-5) is driven by an upper and lower material transmission motor (13-4).

3. The system used in the method for automatically identifying and grinding material surfaces according to claim 2, characterized in that, The structure of the scanning and polishing assembly (16) includes a cylinder (16-4), which is connected to a rotating mechanism (16-6). The end of the rotating mechanism (16-6) is connected to a grinding head (16-7), which is controlled by the rotating mechanism (16-6).

4. The system used in the method for automatically identifying and grinding material surfaces according to claim 3, characterized in that, The Y-axis actuator (11) is mounted on a vertical back plate (18), which is slidably mounted on a base (17).

5. The system used in the method for automatically identifying and grinding material surfaces according to claim 2, characterized in that, The lead screw is fixed to the vertical back plate by a lead screw support and a lead screw fixing seat.

6. The system used in the method for automatically identifying and grinding material surfaces according to claim 5, characterized in that, One end of the lead screw is provided with a coupling support seat, which is connected to the reducer.

7. The system used in the method for automatically identifying and grinding material surfaces according to claim 2, characterized in that, The support rod (16-9) is also equipped with a pneumatic regulating valve (16-2).

8. The system used in the method for automatically identifying and grinding material surfaces according to claim 7, characterized in that, The protective cover (16-5) is slidably mounted on the support rod (16-9) via slider three (16-8).

9. The system used in the method for automatically identifying and grinding material surfaces according to claim 8, characterized in that, The two ends of the cylinder connecting seat (16-3) are located on both sides of the support rod (16-9).

10. The system used in the method for automatically identifying and grinding material surfaces according to claim 2, characterized in that, The bottom of the mobile trolley (13-5) is mounted on the track of the base (17) via slider four (13-6) and can slide along the track; a suction cup (13-3) is provided in the middle of the rotating platform (13-1), and the suction cup (13-3) is controlled by the suction cup control valve (8).

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