A part machining allowance detection method and system based on automatic three-dimensional scanning

Abstract

The present application belongs to the technical field of analysis and detection of medium and large-sized casting blanks, and relates to a part machining allowance detection method and system based on automatic three-dimensional scanning, which comprises a robot system for omnidirectional scanning of parts, a tracker system for tracking and collecting the physical position of a scanner, a control cabinet for electrical control and power supply, a rotating support platform, and an automatic control system. The end of the robot system carries the scanner to scan the part, and the rotatable part support device cooperates with the part to scan without dead angles. The scanning data is compared with the three-dimensional model of the part to realize automatic three-dimensional scanning detection of the part and improve the detection efficiency.

Description

Technical Field

[0001] This invention belongs to the field of analysis and inspection technology for medium and large-sized casting blanks, and relates to a method and system for detecting machining allowances of parts based on automatic three-dimensional scanning. Background Technology

[0002] The 3D scanner uses a blue laser line, and its light source can directly scan objects with diffuse reflection effects on their surfaces, without the need for markers or developers. It can simultaneously scan surfaces with alternating light and dark colors in both indoor and natural light environments, and has been widely used in parts inspection. The 3D scanner is equipped with scanning software that allows for real-time display of scan data, post-processing, and export of the data. The inspection software can compare the scan data with CAD models, generating a 3D color deviation map model to reflect the errors in various parts of the entire part, and can automatically generate customized inspection reports.

[0003] Current 3D scanners employ two main scanning methods: point-to-point scanning and tracking scanning. Tracking scanning is primarily used in handheld scanning scenarios, where the scanner remains within the tracker's field of view, and scanning is performed manually. For medium to large parts, this method is time-consuming, labor-intensive, and suffers from inconsistent scanning paths. Automatic scanning is suitable for scanning the external shape of most parts. However, for internal cavities, automatic scanning is susceptible to obstruction, causing the scanner to fall outside the tracker's field of view and preventing scanning.

[0004] Therefore, how to ensure that the scanner is always within the field of view of the tracker when scanning the inner cavity of a part, and reduce the scanning blind zone, is the problem that this invention aims to solve. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method and system for detecting machining allowances of parts based on automatic three-dimensional scanning. This system is suitable for efficient and high-quality automatic three-dimensional scanning and detection of the internal cavities and wall thicknesses of medium and large-sized parts. The system uses a scanner carried at the end of a robot system to scan the parts. A rotatable part support device is used to scan the parts without blind spots. The scanned data is compared with the three-dimensional model of the parts to achieve automated three-dimensional scanning and detection of the parts, thereby improving the detection efficiency.

[0006] To achieve the above objectives, the present invention employs the following technical solutions:

[0007] A part machining allowance detection system based on automatic three-dimensional scanning includes a robot system and scanner for omnidirectional scanning of the part, a tracker system for tracking and acquiring the physical position of the scanner, a control cabinet for electrical control and power supply, a rotating support platform, and an automated control system; the robot system, tracker system, and rotating support platform are respectively connected to the control cabinet; the robot system, tracker system, rotating support platform, and control cabinet are also respectively electrically connected to the control system.

[0008] Furthermore, the robot system includes a robot base, a robot pedestal, and a robot body; the robot base is fixed to the ground to ensure stability and load-bearing capacity, and the robot body is a six-axis collaborative robotic arm, which is mounted on the robot pedestal via the robot pedestal and can be used to carry a scanner to perform omnidirectional scanning of parts.

[0009] Furthermore, the tracking system includes a guide rail bracket and a tracker; the guide rail bracket is equipped with a slide rail in the vertical direction, which can be moved up and down to meet measurement needs, thereby expanding the tracking range and adapting to scanning requirements at more angles; a connecting bracket is installed on the slide rail; the tracker is mounted on the connecting bracket by a fixing clamp, and is used to track and collect the physical position of the scanner to ensure the accuracy of scanning.

[0010] Furthermore, the rotating support platform includes a base fixed to the ground, on which a motor and a turntable are mounted for driving the platform to rotate. A mounting bracket is fixedly installed on the turntable, and a lifting mechanism, linear guide rails, a V-shaped support mechanism, a quick-clamp device, and a limiting baffle are also fixedly installed on the mounting brackets. The lifting mechanism can adjust the vertical position of the V-shaped support mechanism. The V-shaped support mechanism has two V-shaped supports, with adjustable spacing via the linear guide rails to meet the needs of cylindrical products of different heights. The quick-clamp device is used to securely clamp the product. The limiting baffle is used to limit the product's position, ensuring consistent placement each time.

[0011] Furthermore, the linear guide rail has evenly spaced fixing holes and graduations on its side. The linear guide rail employs a slide rail and slider structure, allowing it to slide to different positions. The evenly spaced fixing holes and graduations on the side of the slide rail are used to confirm that the product's position remains consistent after each adjustment.

[0012] Furthermore, it also includes a robot end effector, which comprises an L-shaped link, a contouring fixture, and a scanner. The contouring fixture is connected to the robot body via the L-shaped link to ensure a secure fixation. The scanner is mounted on the contouring fixture, and the installation of the scanner using the contouring fixture ensures that the position is unique each time it is disassembled and installed. The robot end effector is also connected to the control cabinet and the control system respectively.

[0013] The core of the control system is the automation control software, which is responsible for triggering the start and stop of the scanning software (scanner), importing the data exported after post-processing into the detection software, controlling the data analysis process of the detection software, and outputting the detection report. The automation control software communicates with the PLC via TCP / IP, and the PLC communicates with the robot system and the rotating support platform via bus communication to control the actions of the robot system and the rotating support platform.

[0014] A detection method for a part machining allowance detection system based on automatic 3D scanning includes the following steps:

[0015] S1. Adjust the support platform to the appropriate position according to the part model and record the position information;

[0016] S2. Place the parts on the support platform and clamp them in place;

[0017] S3. Create a new task on the automated control system, configure the task name, program number, inspection project name and other related information, import the required files as needed, add the export path and configure the export settings, add and set the robot task, and add and set the inspection program.

[0018] S4. With the job settings, robot task settings, and detection program settings complete, select the set task number on the automated control system, press the start button, and the equipment will begin to run automatically.

[0019] S5. The robot moves to the scanning position and sends a scanning request to the PLC. The PLC sends an instruction to the automation control system. The automation control system turns on the scanner and starts scanning data. The rotating support platform rotates in coordination.

[0020] S6. After scanning is completed, the scan data is automatically imported, and the scan data is compared with the 3D model of the part to generate an inspection report;

[0021] S7. The equipment returns to its initial state, materials are manually unloaded, and the equipment awaits the next inspection.

[0022] The present invention has the following advantages:

[0023] (1) The system design of the present invention expands the scanning range of the robot system. By using the turntable system and the support platform together, the parts can be rotated 360°. With the tracker guide rail, the scanning coverage of the system is greatly expanded, realizing all-round scanning of the parts and ensuring that even parts with complex internal structures can be automatically scanned without blind spots.

[0024] (2) The present invention adopts a non-contact automated scanning method to achieve full automation of scanning and data collection and recording, thereby reducing the labor intensity of operators and improving work efficiency.

[0025] (3) The system of the present invention adopts a modular design, including a robot system, a tracking system, a robot end effector, a rotating support platform and a control cabinet, etc. This design allows the system to be quickly adjusted and upgraded according to different detection needs, improving the system's flexibility and scalability. Attached Figure Description

[0026] Figure 1 This is a diagram showing the overall system layout of the present invention;

[0027] Figure 2 This is a schematic diagram of the tracking system composition of the present invention;

[0028] Figure 3 This is a schematic diagram of the robot end effector of the present invention;

[0029] Figure 4 This is a schematic diagram of the rotating support platform of the present invention;

[0030] Figure 5 This is a flowchart of the automatic three-dimensional scanning and detection method of the present invention;

[0031] Figure 6 This is a schematic diagram of the control system logic of the present invention;

[0032] In the diagram: 1. Robot system; 2. Tracker system; 3. Robot end effector; 4. Rotary support platform; 5. Control cabinet; 6. Robot body; 7. Robot base; 8. Robot base; 9. Guide rail bracket; 10. Slide rail; 11. Tracker; 12. Fixture; 13. Connecting bracket; 14. L-shaped link; 15. Contouring fixture; 16. Scanner; 17. Base; 18. Motor; 19. Turntable; 20. Mounting bracket; 21. Lifting mechanism; 22. Linear guide rail; 23. V-shaped support mechanism; 24. Quick clamp device; 25. Limiting baffle. Detailed Implementation

[0033] The present invention will now be described in detail with reference to the accompanying drawings.

[0034] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0035] This invention provides a method and system for detecting machining allowances in parts based on automatic 3D scanning. This 3D scanning detection system addresses the requirements for accessibility of internal scanning space, scanning field of view, and scanning content for medium to large-sized parts. First, a robot carrying an end effector scanner 16 scans along a planned path. Then, a rotatable part support device adjusts the part's position in real time, ensuring the scanner 16 remains within the field of view of a tracker 11. Finally, the tracker 11 support is designed to be adjustable, allowing the position of the tracker 11 to be adjusted according to the part's characteristics, completing the 3D scanning of the part within the optimal field of view.

[0036] Combination Figures 1-4 As shown, a part machining allowance detection system based on automatic three-dimensional scanning includes a robot system 1, a tracking system 2, a robot end effector 3, a rotary support platform, a control cabinet 5, and an automated control system.

[0037] In this embodiment, combined with Figure 1 As shown, in the robot system 1, the robot body 6 is an existing product, fixed to the robot base 8 via the robot base 7, and used to drive the scanner 16 to scan the part to be measured. The tracking system 2 is placed on one side of the robot system 1, used to monitor the image at each acquisition position of the scanner 16 in real time and calculate the position and attitude of the scanner 16 in real time. The robot end effector 3 is installed on the end of the robot and used to perform automatic scanning. The rotating support platform 4 is installed and fixed on the ground, used to place and fix the product, and to control the rotation of the product. The robot system 1, carrying the robot end effector 3 and the rotating support platform 4, can achieve scanning of the product without blind spots. The control cabinet 5 is used for the electrical control and power supply of the entire system.

[0038] In this embodiment, combined with Figure 2 As shown, the tracking system 2 is fixedly mounted on the ground and mainly consists of a guide rail bracket 9, a slide rail 10, a tracker 11, a fixing clamp 12, and a connecting bracket 13. The slide rail 10 is vertically mounted on the guide rail bracket 9 and can move the connecting bracket 13 up and down to expand the scanning and tracking range. The tracker 11 is an existing product and is fixed to the connecting bracket 13 by the fixing clamp 12 to track the real-time position of the scanner 16.

[0039] In this embodiment, combined with Figure 3 As shown, the robot end effector 3 consists of an L-shaped link 14, a contour jig 15, and a scanner 16. The scanner 16 is an existing product and is mounted on the L-shaped link 14 via the contour jig 15 for scanning parts. The L-shaped link 14 is mounted on the robot end effector and serves to connect and transmit power.

[0040] In this embodiment, combined with Figure 4 As shown, the rotating support platform 4 consists of a base 17, a motor 18 and a turntable 19, a mounting bracket 20, a lifting mechanism 21, a linear guide rail 22, a V-shaped support mechanism 23, a quick-clamp device 24, and a limiting baffle 25. The motor 18 and turntable 19 are mounted on the base 17 for platform rotation. The mounting bracket 20 is mounted above the turntable 19, providing fixation and support. The lifting mechanism 21, linear guide rail 22, and V-shaped support mechanism 23 are fixed to the mounting bracket 20 for adjusting position and supporting the product to be measured. The quick-clamp device 24 is mounted at the rear end of the V-shaped support mechanism 23 for clamping and fixing the product. The limiting baffle 25 is mounted at the front end of the V-shaped support mechanism 23 for limiting product positioning.

[0041] Combination Figure 5 As shown, taking the automatic 3D scanning of cylindrical parts as an example, the automatic 3D scanning inspection method of the present invention is as follows:

[0042] (1) Adjust the V-shaped support mechanism 23 to the appropriate position through the linear guide rail 22 according to the part model, and adjust the lifting mechanism 21 to the appropriate position. The linear adjustment has a positioning pin hole and a pointer, and the lifting adjustment also has a pointer to ensure that the support platform is adjusted to the same position each time, and record the position information.

[0043] (2) After the position is adjusted, place the part to be scanned on the V-shaped support mechanism 23, with the front end aligned with the limit baffle 25 to ensure that the position is consistent each time, and fix it by the quick clamp device 24.

[0044] (3) Create a new task on the automated control system, configure the task name, program number, inspection project name and other related information, import the required files according to the requirements, add the export path and configure the export settings, add and set the robot task, and add and set the inspection program.

[0045] (4) Once the job settings, robot task settings, and detection program settings are complete, select the set task number on the automated control system, press the start button, and the equipment will start running automatically.

[0046] (5) Robot system 1, carrying robot end effector 3, moves to the part to perform scanning work, sends a scanning request to PLC, PLC sends an instruction to the automation control system, and the automation control system turns on scanner 16 to start scanning the part, scanning one end, the outer side and the inner side of the part. For areas that robot system 1 cannot scan, it rotates through rotating support platform 4 to perform scanning without blind spots. When working, scanner 16 is perpendicular to the surface being scanned, maintains a good scanning distance from the part, and moves at a stable speed to ensure that scanner 16 collects sufficient scanning data. Tracker 11 tracks and positions scanner 16 at the end of the robot in real time. If the position of tracker 11 is obstructed and cannot track scanner 16, resulting in the inability to measure the corresponding area, tracker 11 needs to change its position to measure. It automatically moves up and down through slide rail 10 to change its position to identify scanner 16.

[0047] (6) After the part scanning is completed, the data collected by the scanner 16 is automatically saved and imported into the inspection software. The three-dimensional model of the part is imported into the inspection software. The scanning data and the three-dimensional model of the part are best fitted. After the fitting is completed, the surface features to be inspected are extracted. The inspection software automatically aligns and matches the data and extracts the corresponding measurement values. It automatically calculates the deviation between the scanning data and the three-dimensional model of the part, detects the machining allowance, and automatically generates an inspection report.

[0048] (7) After the test is completed, the system returns to the initial state, and the manual feeding begins, waiting for the next test.

[0049] This invention is not limited to the specific embodiments described above. The invention extends to any new feature or combination disclosed in this specification, as well as any new method or process step or combination disclosed herein.

Claims

1. A system for detecting a machining allowance of a part based on an automatic three-dimensional scanning, characterized in that, The system includes a robot system (1) and a scanner (16) for omnidirectional scanning of parts, a tracking system (2) for tracking and acquiring the physical position of the scanner (16), a control cabinet (5) for controlling electrical and power supply, a rotating support platform (4), and an automated control system; the robot system (1), the tracking system (2), and the rotating support platform (4) are respectively connected to the control cabinet (5); the robot system (1), the scanner (16), the tracking system (2), the rotating support platform (4), and the control cabinet (5) are also respectively electrically connected to the control system.

2. The part machining allowance detection system based on automatic three-dimensional scanning according to claim 1, characterized in that, The robot system (1) includes a robot base (8), a robot pedestal (7), and a robot body (6); the robot base (8) is fixed on the ground, and the robot body (6) is mounted on the robot base (8) through the robot pedestal (7) to carry a scanner (16) to perform omnidirectional scanning of the parts.

3. The part machining allowance detection system based on automatic three-dimensional scanning according to claim 1, characterized in that, The tracking system (2) includes a guide rail bracket (9) and a tracker (11); the guide rail bracket (9) is equipped with a slide rail (10) in the vertical direction, and a connecting bracket (13) is installed on the slide rail (10); the tracker (11) is installed on the connecting bracket (13) by a fixing clamp (12).

4. The part machining allowance detection system based on automatic three-dimensional scanning according to claim 1, characterized in that, The rotating support platform (4) includes a base (17) fixed on the ground, and a motor (18) and a turntable (19) are provided on the base (17); a mounting bracket (20) is fixedly installed on the turntable (19), and a lifting machine, a linear guide rail (22), a V-shaped support mechanism (23), a quick clamping device (24) and a limiting baffle (25) are also fixedly installed on the mounting bracket (20).

5. A part machining allowance detection system based on automatic three-dimensional scanning according to claim 4, characterized in that, The linear guide (22) has evenly spaced fixing holes on its side and is marked with a scale.

6. The part machining allowance detection system based on automatic three-dimensional scanning according to claim 1, characterized in that, It also includes a robot end effector (3), which includes an L-shaped link (14), a contouring fixture (15) and a scanner (16). The contouring fixture (15) is connected to the robot body (6) through the L-shaped link (14) to ensure a firm fixation. The scanner (16) is mounted on the contouring fixture (15). The robot end effector (3) is also connected to the control cabinet (5) and the control system respectively.

7. A detection method for a part machining allowance detection system based on automatic three-dimensional scanning, characterized in that, Includes the following steps: S1. Adjust the support platform to the appropriate position according to the part model and record the position information; S2. Place the parts on the support platform and clamp them in place; S3. Create a new task on the automated control system, configure the task name, program number, inspection project name and other related information, import the required files as needed, add the export path and configure the export settings, add and set the robot task, and add and set the inspection program. S4. With the job settings, robot task settings, and detection program settings complete, select the set task number on the automated control system, press the start button, and the equipment will begin to run automatically. S5. The robot moves to the scanning position and sends a scanning request to the PLC. The PLC sends an instruction to the automation control system. The automation control system turns on the scanner and starts scanning data. The rotating support platform rotates in coordination. S6. After scanning is completed, the scan data is automatically imported, and the scan data is compared with the 3D model of the part to generate an inspection report; S7. The equipment returns to its initial state, materials are manually unloaded, and the equipment awaits the next inspection.

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