Device for detecting and counting effective abrasive particles of brazed grinding wheel with orderly arranged abrasive particles

Abstract

The invention discloses an effective abrasive particle detecting and counting device for a brazed grinding wheel with orderly arranged abrasive particles. The effective abrasive particle detecting and counting device comprises a machine base, a grinding wheel clamping and driving system, a machine vision system and a control system. When the device works, the grinding wheel clamping and driving system drives the grinding wheel to be detected to rotate. The machine vision system collects images of the working surface of the grinding wheel. A target recognition program based on deep learning is deployed in the control system and used for recognizing effective abrasive particles on the working surface of the grinding wheel in the image and determining the positions of the effective abrasive particles. Furthermore, a target counting program based on a multi-target tracking algorithm and a line collision counting method is deployed in the control system and is used for counting the recognized effective abrasive particles. And a result output module in the control system finally outputs position distribution and quantity information of the effective abrasive particles on the working surface of the grinding wheel. The invention provides an effective solution for the effective abrasive particle detection and counting task of the brazed grinding wheel with orderly arranged abrasive particles.

Description

Technical Field

[0001] This invention relates to the field of grinding wheel quality inspection, and in particular to a device for effective abrasive grain detection and counting of brazed grinding wheels with orderly abrasive grain arrangement. Background Technology

[0002] Abraded grinding wheels with ordered abrasive grain arrangement are advanced superhard grinding wheels in which abrasive grains are precisely fixed to a substrate according to a set pattern through a brazing process. They have outstanding advantages such as high efficiency, high precision, and long service life, and are mainly used in the precision and ultra-precision machining of difficult-to-machine materials and hard and brittle materials in aerospace applications. In machining using brazed grinding wheels with ordered abrasive grain arrangement, the abrasive grain state on the wheel surface is crucial. Typically, the abrasive grain state includes effective abrasive grains, broken abrasive grains, and detached abrasive grains. Insufficient effective abrasive grains can lead to fluctuations in grinding force, workpiece surface burns, or out-of-tolerance dimensional accuracy. Therefore, accurate detection and counting of effective abrasive grains on the grinding wheel surface is a key step in ensuring machining quality and assessing wheel life.

[0003] Traditional abrasive grain condition detection on the surface of brazed grinding wheels with ordered abrasive grain arrangement relies primarily on manual labor. This method is not only labor-intensive and inefficient, but also highly susceptible to human error, leading to missed detections or misjudgments. While some machine vision-based detection methods exist, they mostly employ traditional image processing algorithms, resulting in limited robustness and difficulty in distinguishing effective abrasive grains in complex backgrounds. Recent research has reported the use of deep learning algorithms for abrasive grain condition detection. However, these methods are mostly applicable to static grinding wheel images, limiting their comprehensiveness. In dynamic detection scenarios involving rotating grinding wheels, while deep learning algorithms can identify effective abrasive grains, they struggle to determine whether the effective abrasive grains in different frames of an image sequence are the same, leading to duplicate counting. Furthermore, to execute subsequent grinding wheel repair and abrasive grain replanting processes, it is necessary to determine the positional information of existing effective abrasive grains on the grinding wheel's working surface. Therefore, designing a detection device that can adapt to the structure and dynamic detection conditions of brazed grinding wheels with ordered abrasive grain arrangement, and meets the requirements for accurate counting and position output of effective abrasive grains on the grinding wheel's working surface, is of great significance. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a device for effective abrasive grain detection and counting of brazed grinding wheels with orderly abrasive grain arrangement.

[0005] The technical solution adopted in this invention is: a device for effective abrasive grain detection and counting of brazed grinding wheels with orderly abrasive grain arrangement, including a base, a grinding wheel clamping and driving system, a machine vision system and a control system; The grinding wheel clamping and driving system is mounted on the machine base and includes a servo motor, a transmission shaft system, and a grinding wheel clamp. The servo motor is mounted on one end of the transmission shaft system, and the grinding wheel clamp is mounted on the other end of the transmission shaft system. The grinding wheel clamp is used to clamp the brazed grinding wheel with orderly arranged abrasive grains to be tested. The machine vision system is mounted on a base and includes a mounting base, a light source assembly, and a camera assembly. The camera assembly is used to observe the working surface of a brazed grinding wheel with orderly abrasive grains. The depth of field within the observation field of the camera assembly covers the height of the abrasive grains on the working surface of the brazed grinding wheel with orderly abrasive grains. The camera assembly can observe the appearance and morphology of the abrasive grains. When the device is in operation, a servo motor drives a brazed grinding wheel with orderly arranged abrasive grains, clamped on a grinding wheel fixture, to rotate via a transmission shaft system. The machine vision system acquires an image of the working surface of the brazed grinding wheel with orderly arranged abrasive grains and sends it to the control system. The control system is equipped with a detection program, which includes a target recognition program for identifying effective abrasive grains on the working surface of the brazed grinding wheel with orderly arranged abrasive grains in the image and determining the position of the effective abrasive grains. The detection program also includes a target counting program for counting the identified effective abrasive grains. The detection program also includes a grinding wheel contour recognition program for determining the position of the grinding wheel contour of the brazed grinding wheel with orderly arranged abrasive grains in the image. The control system also includes a result output module for outputting the position distribution and quantity information of the effective abrasive grains on the working surface of the brazed grinding wheel with orderly arranged abrasive grains.

[0006] As a further optimization of this solution, the target recognition program is a deep learning model that can identify valid abrasive particles and fractured abrasive particles, and output the target detection box of the valid abrasive particles; the target counting program is based on a multi-target tracking algorithm and a collision line counting method. The multi-target tracking algorithm is used to assign and maintain a unique identity for each valid abrasive particle identified during the detection process, and to establish a target trajectory box for trajectory tracking to prevent duplicate counting; the collision line counting method sets at least one virtual counting line in the image, and performs a count accumulation operation when the target trajectory box of the tracked valid abrasive particle crosses the virtual counting line in the image.

[0007] As a further optimization of this solution, when the device is working, the brazed grinding wheel with orderly arranged abrasive grains rotates at least one full revolution.

[0008] As a further optimization of this solution, the device for detecting and counting effective abrasive grains of the brazed grinding wheel with orderly abrasive grain arrangement has two working modes: Real-time working mode: When the brazed grinding wheel with orderly arranged abrasive grains rotates, the detection program of the control system performs synchronous detection and counting based on the images acquired in real time by the machine vision system; Offline working mode: First, the machine vision system records and stores the image sequence of the brazing grinding wheel rotating with the abrasive grains arranged in an orderly manner. Then, the detection program of the control system calls the stored image sequence for detection and counting.

[0009] As a further optimization of this solution, the upper part of the mounting base is provided with an electric slide, and the light source assembly and camera assembly are mounted on the electric slide. The camera assembly includes an industrial camera and a lens mounted on the industrial camera. The electric slide can move back and forth along the axis of the industrial camera under the control of the control system to adapt to the detection of brazed grinding wheels with abrasive grains of different diameters arranged in an orderly manner.

[0010] As a further optimization of this solution, the industrial camera has an autofocus function.

[0011] As a further optimization of this solution, the field of view of the camera assembly covers the entire width of the working surface of the brazed grinding wheel with orderly arranged abrasive grains.

[0012] As a further optimization of this scheme, the positional distribution of effective abrasive grains on the working surface of the brazed grinding wheel with orderly abrasive grain arrangement in the image is characterized in the image coordinate system.

[0013] As a further optimization of this solution, the light source assembly includes a light source bracket and a light source mounted on the light source bracket, and the light source illuminates the working surface of the brazed grinding wheel with abrasive grains arranged in an orderly manner.

[0014] As a further optimization of this solution, the machine base is equipped with a display screen to display the position distribution and quantity information of effective abrasive grains on the working surface of the brazed grinding wheel with orderly abrasive grain arrangement.

[0015] Compared with existing technologies, the beneficial effects of this invention are: 1. It proposes a device for detecting and counting effective abrasive particles in a brazed grinding wheel with ordered abrasive particle arrangement, effectively solving the problems of high labor intensity, low efficiency, and unstable quality in traditional manual operations; 2. It realizes comprehensive detection and counting of effective abrasive particles on the entire working surface of the grinding wheel, ensuring the integrity and systematic nature of the detection process; 3. It introduces a multi-target tracking algorithm to maintain the continuity of abrasive particle identity during the dynamic detection process of grinding wheel rotation, and combined with the collision line counting method, it effectively overcomes the problem of repeated counting and missed counting caused by the inability to distinguish the same abrasive particle target in each frame of the image sequence in dynamic detection scenarios, improving the counting accuracy and robustness in complex scenarios; 4. While completing the detection and counting tasks, it can also output the position information of effective abrasive particles on the working surface of the grinding wheel in the image, providing important data support for the subsequent grinding wheel repair and abrasive particle replanting process. Attached Figure Description

[0016] Figure 1This is a front view of an effective abrasive grain detection and counting device for a brazed grinding wheel with ordered abrasive grain arrangement provided in an embodiment of the present invention; Figure 2 This is a top view of the device provided in an embodiment of the present invention; Figure 3 This is a perspective view of the device provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the working surface and target recognition effect of the brazed grinding wheel with orderly abrasive grain arrangement involved in the embodiments of the present invention; Figure 5 This is a schematic diagram of the collision counting method according to an embodiment of the present invention; Figure 6 yes Figure 5 A magnified view of part A in the diagram.

[0017] The main components shown in the diagram include: 1. Base; 1-1 Display screen; 2. Grinding wheel clamping and drive system; 2-1 Servo motor; 2-2 Transmission shaft system; 2-3 Grinding wheel fixture; 2-4 Brazed grinding wheel with orderly abrasive grain arrangement; 3. Machine vision system; 3-1 Mounting base; 3-1-1 Electric slide table; 3-2 Light source assembly; 3-2-1 Light source bracket; 3-2-2 Light source; 3-3 Camera assembly; 3-3-1 Industrial camera; 3-3-2 Lens. Detailed Implementation

[0018] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings.

[0019] like Figure 1 , Figure 2 , Figure 3 As shown in the figure, the effective abrasive grain detection and counting device for a brazed grinding wheel with orderly abrasive grain arrangement provided in this embodiment of the invention includes a base 1, a grinding wheel clamping and driving system 2, a machine vision system 3, and a control system.

[0020] The grinding wheel clamping and driving system 2 and the machine vision system 3 are mounted on the base 1; the base 1 is equipped with a display screen 1-1, which is used to display the position distribution and quantity information of the effective abrasive grains on the working surface of the brazed grinding wheel 2-4 with the abrasive grains arranged in an orderly manner.

[0021] like Figure 2 , Figure 3 As shown, the grinding wheel clamping and driving system 2 includes a servo motor 2-1, a transmission shaft system 2-2, and a grinding wheel clamp 2-3. The servo motor 2-1 is installed at one end of the transmission shaft system 2-2, and the grinding wheel clamp 2-3 is installed at the other end of the transmission shaft system 2-2. The grinding wheel clamp 2-3 is used to clamp the brazed grinding wheel 2-4 with orderly arranged abrasive grains to be tested.

[0022] like Figure 1 , Figure 3As shown, the machine vision system 3 includes a mounting base 3-1, a light source assembly 3-2, and a camera assembly 3-3. The mounting base 3-1 is equipped with an electric slide 3-1-1. The light source assembly 3-2 and the camera assembly 3-3 are mounted on the electric slide 3-1-1. The electric slide 3-1-1 can move back and forth along the axis of the industrial camera 3-3-1 under the control of the control system to adapt to the detection of brazed grinding wheels 2-4 with abrasive grains of different diameters arranged in an orderly manner.

[0023] The light source assembly 3-2 includes a light source bracket 3-2-1 and a light source 3-2-2 mounted on the light source bracket 3-2-1. The light source 3-2-2 illuminates the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains. The camera assembly 3-3 includes an industrial camera 3-3-1 and a lens 3-3-2 mounted on the industrial camera 3-3-1 for observing the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains. The industrial camera 3-3-1 has an autofocus function. The field of view of the camera assembly 3-3 covers the entire width of the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains. The depth of field within the field of view of the camera assembly 3-3 covers the height of the abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains. The camera assembly 3-3 can observe the appearance and morphology of the abrasive grains. When the device is working, the servo motor 2-1 drives the brazed grinding wheel 2-4 with abrasive grains arranged in an orderly manner, which is clamped on the grinding wheel fixture 2-3, to rotate at least one full revolution through the transmission shaft system 2-2. The machine vision system 3 collects images of the working surface of the brazed grinding wheel 2-4 with abrasive grains arranged in an orderly manner and sends them to the control system. like Figure 4 , Figure 5 , Figure 6 As shown, the control system is equipped with a detection program, which includes a target recognition program, a target counting program, and a grinding wheel contour recognition program. The control system also includes a result output module, which is used to output the position distribution and quantity information of effective abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly abrasive grain arrangement.

[0024] like Figure 4 As shown, the target recognition program is used to identify the effective abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly abrasive grain arrangement in the image, and determine the position of the effective abrasive grains; the target recognition program is a deep learning model, which can identify effective abrasive grains and broken abrasive grains, and output the target detection box of the effective abrasive grains; in the image, the position distribution of the effective abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly abrasive grain arrangement is represented in the image coordinate system; the grinding wheel contour recognition program is used to determine the position of the grinding wheel contour of the brazed grinding wheel 2-4 with orderly abrasive grain arrangement in the image; like Figure 5 , Figure 6As shown, the target counting program is used to count the identified valid abrasive particles. The target counting program is based on a multi-target tracking algorithm and a collision line counting method. The multi-target tracking algorithm is used to assign and maintain a unique identity for each valid abrasive particle identified during the detection process, and to establish a target trajectory box for trajectory tracking to prevent duplicate counting. The collision line counting method sets at least one virtual counting line in the image, and performs a count accumulation operation when the target trajectory box of the tracked valid abrasive particle crosses the virtual counting line in the image.

[0025] In practical implementation, the device has two operating modes: Real-time working mode: When the brazed grinding wheels 2-4 with orderly arranged abrasive grains rotate, the detection program of the control system performs synchronous detection and counting based on the images collected in real time by the machine vision system 3; Offline working mode: First, the machine vision system 3 records and stores the image sequence of the rotation process of the brazing grinding wheel 2-4 with orderly arrangement of abrasive grains. Then, the detection program of the control system calls the stored image sequence for detection and counting.

[0026] The working process of this invention is as follows: First, the electric slide 3-1-1 in the machine vision system 3, under the control of the control system, drives the light source assembly 3-2 and the camera assembly 3-3 to move back and forth along the axis of the industrial camera 3-3-1 to accommodate the detection of brazed grinding wheels 2-4 with orderly arranged abrasive grains of different diameters; simultaneously, the industrial camera 3-3-1 performs automatic focusing. When the device is working, the servo motor 2-1 drives the brazed grinding wheel 2-4 with orderly arranged abrasive grains, which is clamped on the grinding wheel fixture 2-3, to rotate at least one full revolution through the transmission shaft system 2-2. During this process, the machine vision system 3 acquires an image of the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains and sends it to the control system. The grinding wheel contour recognition program in the control system determines the position of the brazed grinding wheel 2-4 with orderly arranged abrasive grains in the image; the target recognition program identifies the effective abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly arranged abrasive grains in the image and determines the position of the effective abrasive grains in the image. Based on this, the multi-target tracking algorithm assigns and maintains a unique identifier for each valid abrasive grain identified during the detection process, and establishes a target trajectory bounding box for trajectory tracking to prevent duplicate counting. The collision line counting method sets at least one virtual counting line in the image, and performs a count accumulation operation when the target trajectory bounding box of the tracked valid abrasive grain completely crosses the virtual counting line in the image. Finally, the control system result output module outputs the position distribution and quantity information of the valid abrasive grains on the working surface of the brazed grinding wheel 2-4 with orderly abrasive grain arrangement on the display screen 1-1. This completes the entire detection and counting process.

[0027] The above is a description of the implementation steps of the present invention. Through the above description, those skilled in the art will be able to implement or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novelty disclosed herein.

Claims

1. A device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement, characterized in that: It includes a base (1), a grinding wheel clamping and drive system (2), a machine vision system (3), and a control system; The grinding wheel clamping and driving system (2) is mounted on the machine base (1) and includes a servo motor (2-1), a transmission shaft system (2-2), and a grinding wheel clamp (2-3). The servo motor (2-1) is mounted on one end of the transmission shaft system (2-2), and the grinding wheel clamp (2-3) is mounted on the other end of the transmission shaft system (2-2). The grinding wheel clamp (2-3) is used to clamp the brazed grinding wheel (2-4) with orderly arranged abrasive grains to be tested. The machine vision system (3) is mounted on the base (1) and includes a mounting base (3-1), a light source assembly (3-2), and a camera assembly (3-3). The camera assembly (3-3) is used to observe the working surface of the brazed grinding wheel (2-4) with orderly abrasive grains. The depth of field of the camera assembly (3-3) covers the height of the abrasive grains on the working surface of the brazed grinding wheel (2-4) with orderly abrasive grains. The camera assembly (3-3) can observe the appearance and morphology of the abrasive grains. When the device is working, the servo motor (2-1) drives the brazed grinding wheel (2-4) with orderly abrasive grains clamped on the grinding wheel fixture (2-3) to rotate through the transmission shaft system (2-2). The machine vision system (3) acquires an image of the working surface of the brazed grinding wheel (2-4) with orderly abrasive grains and sends it to the control system. The control system is equipped with a detection program, which includes a target recognition program for identifying the effective abrasive grains on the working surface of the brazed grinding wheel (2-4) with orderly abrasive grains in the image and determining the position of the effective abrasive grains. The detection program also includes a target counting program for counting the identified effective abrasive grains. The detection program also includes a grinding wheel contour recognition program for determining the position of the grinding wheel contour of the brazed grinding wheel (2-4) with orderly abrasive grains in the image. The control system also includes a result output module for outputting the position distribution and quantity information of the effective abrasive grains on the working surface of the brazed grinding wheel (2-4) with orderly abrasive grains.

2. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The target recognition program is a deep learning model that can identify valid abrasive particles and broken abrasive particles, and output the target detection box of the valid abrasive particles. The target counting program is based on a multi-target tracking algorithm and a collision line counting method. The multi-target tracking algorithm is used to assign and maintain a unique identity for each valid abrasive particle identified during the detection process, and to establish a target trajectory box for trajectory tracking to prevent duplicate counting. The collision line counting method sets at least one virtual counting line in the image, and performs a count accumulation operation when the target trajectory box of the tracked valid abrasive particle crosses the virtual counting line in the image.

3. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: When the device is working, the brazed grinding wheel (2-4) with orderly arranged abrasive grains rotates at least one full revolution.

4. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The device has two operating modes: Real-time working mode: When the brazed grinding wheel (2-4) with orderly abrasive grains rotates, the detection program of the control system performs synchronous detection and counting based on the images collected in real time by the machine vision system (3); Offline working mode: First, the machine vision system (3) records and stores the image sequence of the rotation process of the brazing wheel (2-4) with orderly arrangement of abrasive grains. Then, the detection program of the control system calls the stored image sequence for detection and counting.

5. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The mounting base (3-1) is provided with an electric slide (3-1-1) on the upper part. The light source assembly (3-2) and the camera assembly (3-3) are mounted on the electric slide (3-1-1). The camera assembly (3-3) includes an industrial camera (3-3-1) and a lens (3-3-2) mounted on the industrial camera (3-3-1). The electric slide (3-1-1) can move back and forth along the axis of the industrial camera (3-3-1) under the control of the control system to adapt to the detection of brazed grinding wheels (2-4) with abrasive grains of different diameters arranged in an orderly manner.

6. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 5, characterized in that: The industrial camera (3-3-1) has an autofocus function.

7. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The field of view of the camera assembly (3-3) covers the entire width of the working surface of the brazed grinding wheel (2-4) with its abrasive grains arranged in an orderly manner.

8. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: In the image, the positional distribution of effective abrasive grains on the working surface of the brazed grinding wheel (2-4) with orderly abrasive grain arrangement is characterized in the image coordinate system.

9. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The light source assembly (3-2) includes a light source bracket (3-2-1) and a light source (3-2-2) mounted on the light source bracket (3-2-1). The light source (3-2-2) illuminates the working surface of the brazed grinding wheel (2-4) with abrasive grains arranged in an orderly manner.

10. The device for detecting and counting effective abrasive grains in a brazed grinding wheel with ordered abrasive grain arrangement as described in claim 1, characterized in that: The base (1) is equipped with a display screen (1-1) for displaying the position distribution and quantity information of effective abrasive grains on the working surface of the brazed grinding wheel (2-4) with orderly abrasive grain arrangement.

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