A reverse design method and manufacturing system for complex curved surface parts based on multi-source data fusion

Abstract

This invention provides a reverse design method and manufacturing system for complex curved surface parts based on multi-source data fusion, comprising the following steps: setting reference marks on the part that can be jointly identified by external contour scanning and penetration scanning; acquiring external contour data and internal flow channel data of the part, and performing spatiotemporal registration with reference marks as a reference; performing calibration fusion based on the spatiotemporal registration results; performing error analysis and compensation on the contour data after calibration fusion; performing negative pressure performance simulation on the model after error analysis and compensation, and outputting the part model after comparative verification. By setting common reference marks that can be identified by both blue light scanning and industrial CT, unified spatiotemporal reference registration of internal and external structural data is achieved, thereby avoiding problems such as misalignment of internal and external structures and inconsistency of features; the ICP iterative nearest point algorithm is used to complete the fine calibration fusion of internal and external point clouds, combined with point cloud denoising, simplification and feature separation, to improve the integrity and restoration accuracy of complex curved surface and built-in flow channel models.

Description

Technical Field

[0001] This invention relates to the field of reverse engineering technology, and in particular to a reverse design method and manufacturing system for complex curved surface parts based on multi-source data fusion. Background Technology

[0002] Reverse engineering, as a core technology for the digital replication, structural optimization, and domestic substitution of industrial products, is widely used in the research and manufacturing of precision parts with complex curved surfaces and internal flow channels. Currently, for industrial parts with both complex external curved surfaces and delicate internal flow channels (such as negative pressure suction cups and fluid devices), existing reverse engineering methods mostly use single optical scanning equipment to acquire data on the external curved surfaces of the parts, which cannot penetrate the solid to obtain hidden structures such as internal flow channels and dark cavities. Although some technologies use industrial CT for internal inspection, they have not formed a collaborative acquisition system with external high-precision scanning. The internal and external data lack a unified spatiotemporal reference and common reference marker, making it difficult to achieve accurate spatial registration of internal and external point cloud data, and easily leading to problems such as misalignment of internal and external structures and inconsistencies in feature connections. Summary of the Invention

[0003] This invention provides a reverse design method and manufacturing system for complex curved surface parts based on multi-source data fusion, which solves the problems of misalignment of internal and external structures and lack of connection of features in the reverse modeling of existing technologies.

[0004] This invention provides a reverse design method for complex curved surface parts based on multi-source data fusion, comprising the following steps: S1: Set a reference mark on the part that can be recognized by both external contour scanning and penetration scanning; S2: Obtain the external contour data of the part through external contour scanning, obtain the internal flow channel data of the part through penetration scanning, and perform spatiotemporal registration of the external contour data and the internal flow channel data with reference to the reference mark. S3: Based on the spatiotemporal registration results, the iterative nearest point algorithm is used to calibrate and fuse the internal flow channel data and the external contour data; S4: Perform error analysis and compensation on the profile data after calibration and fusion; S5: Perform negative pressure performance simulation on the model after error analysis and compensation, and compare the simulation results with the reference values ​​for verification; If the verification fails, return to step S4 and iteratively adjust the error compensation parameters for the corresponding area until the reference value meets the standard; if the verification succeeds, output the part model.

[0005] Further, step S4 includes: A global scaling factor is used to compensate for the overall outline dimensions of the part model; For complex freeform surface regions in the external contour data of the part model, local elastic deformation compensation of the NURBS surface is performed based on the deviation field between the point cloud and the reconstructed surface. Based on the internal flow channel data of the part model, and the sensitivity analysis of pressure loss in the negative pressure performance simulation, adaptive radial compensation is performed on the flow channel diameter.

[0006] Furthermore, in step S2, the spatiotemporal registration includes: using the central through hole or reference hole of the complex curved surface part as an alignment feature, and achieving spatial matching between the internal flow channel data and the external contour data through geometric fitting.

[0007] Furthermore, in step S5, the negative pressure performance simulation includes: simulating the pressure distribution and flow pattern of the internal and external structures of the part, and optimizing the diameter of the internal structure air passage and the curvature of the surface.

[0008] Furthermore, in step S2, a non-contact blue light scanner is used to perform external contour scanning, and an industrial X-ray tomography scanner is used to perform penetration scanning.

[0009] Furthermore, after step S5, the following steps are also included: S6: Based on the output part model, add machining allowance and perform additive manufacturing to obtain part blank; S7: Based on the part blank, the finished part is obtained by subtractive manufacturing through a machining center.

[0010] This invention also provides a reverse manufacturing system for complex curved surface parts, used to implement a reverse design method for complex curved surface parts based on multi-source data fusion, comprising: Data acquisition module: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel data and external contour data of parts; Model processing module: Configures drawing software for calibrating and fusing internal flow channel data and external contour data, performing error analysis and compensation, and parametric modeling; Simulation verification module: uses finite element simulation software for fluid performance verification.

[0011] This invention also provides a reverse manufacturing system for complex curved surface parts, used to implement a reverse design method for complex curved surface parts based on multi-source data fusion, comprising: Data acquisition module: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel data and external contour data of parts; Model processing module: Configures drawing software for calibrating and fusing internal flow channel data and external contour data, performing error analysis and compensation, and parametric modeling; Simulation verification module: Employs finite element simulation software for fluid performance verification; Additive manufacturing module: Uses 3D printing equipment to perform integrated molding processing based on an optimized model to manufacture part blanks; Subtractive manufacturing module: Using machining center equipment, the surface of the part blank is precision machined.

[0012] The beneficial effects of this invention are as follows: 1. By setting a common reference mark that can be recognized by both blue light scanning and industrial CT, unified spatiotemporal reference registration of internal and external structural data can be achieved, thereby avoiding the problems of misalignment of internal and external structures and inconsistency of features; 2. The ICP iterative nearest point algorithm is used to complete the fine calibration and fusion of internal and external point clouds. Combined with point cloud denoising, simplification and feature separation, the integrity and restoration accuracy of complex curved surfaces and built-in flow channel models are greatly improved.

[0013] 3. Differentiated compensation is provided for the overall contour, complex freeform surfaces, and internal flow channels in different regions, taking into account both global dimensional accuracy and local surface and flow channel performance requirements, resulting in a higher degree of matching between the model and design intent. Attached Figure Description

[0014] Figure 1 This is a flowchart illustrating the reverse engineering method according to an embodiment of the present invention.

[0015] Figure 2 This is a schematic diagram of the modules in Embodiment 1 of the present invention.

[0016] Figure 3 This is a schematic diagram of the modules in Embodiment 2 of the present invention.

[0017] Figure 4 This is a schematic diagram of the overall structure of the suction cup component in Embodiment 3 of the present invention.

[0018] Figure 5 This is a schematic diagram of the internal flow channel structure of the suction cup component in Embodiment 3 of the present invention.

[0019] Figure 6 This is a scanned image of the top outer contour of the suction cup component in Embodiment 3 of the present invention.

[0020] Figure 7 This is a scanned image of the bottom outer contour of the suction cup component in Embodiment 3 of the present invention.

[0021] Figure 8 This is an overall structural diagram of the suction cup component undergoing penetration scanning in Embodiment 3 of the present invention.

[0022] Figure 9 This is a flow channel structure diagram of the suction cup component penetrating and scanning in Embodiment 3 of the present invention.

[0023] Figure label: 101. Data acquisition module; 102. Model processing module; 103. Simulation verification module; 104. Additive manufacturing module; 105. Subtractive manufacturing module; 2. Central through hole; 3. Vent; 4. Flow channel. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0025] The terms "first" and "second" in the specification and claims of this invention may explicitly or implicitly include one or more of those features. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0027] The following is combined Figure 1 This invention describes a reverse design method for complex curved surface parts based on multi-source data fusion, comprising the following steps: S1: Set a reference mark on the part that can be recognized by both external contour scanning and penetration scanning; Specifically, optical markers that can be identified by both blue light external contour scanning and industrial CT penetration scanning are uniformly pasted on the surface of the parts that need to be reverse engineered, serving as reference marks; S2: Obtain the external contour data of the part through external contour scanning, obtain the internal flow channel 4 data of the part through penetration scanning, and perform spatiotemporal registration of the external contour data and the internal flow channel 4 data with reference to the benchmark mark. Specifically, a non-contact blue light scanner was used to acquire point cloud data of the external contour of the suction cup, and an industrial X-ray tomography scanner was used to acquire point cloud data of the internal flow channel of the suction cup. Using the pasted marker points as a reference, the internal and external data were initially registered under a unified spatiotemporal reference.

[0028] S3: Based on the spatiotemporal registration results, the iterative nearest point algorithm is used to calibrate and fuse the internal flow channel 4 data and the external contour data; Specifically, internal and external data registration is achieved through geometric fitting, and the iterative nearest point (ICP) algorithm is used to finely calibrate and fuse the internal and external point cloud data. Furthermore, the fused point cloud data is denoised and simplified, and external surface features and internal flow channel features are separated.

[0029] S4: Perform error analysis and compensation on the profile data after calibration and fusion; Specifically, multi-scale error analysis is performed on the merged overall 3D model, and the error data is compensated to ensure that the compensated model matches the design intent and performance requirements at different scales, thereby completing the parametric model reconstruction.

[0030] S5: Perform negative pressure performance simulation on the model after error analysis and compensation, and compare the simulation results with the reference values ​​for verification; if the verification fails, return to step S4 and iteratively adjust the error compensation parameters of the corresponding area until the reference values ​​meet the standards; if the verification meets the standards, output the part model.

[0031] Specifically, the error-compensated part model is imported into the finite element simulation software. The finite element simulation software is used to simulate the negative pressure performance of the reconstructed model after error compensation. The simulation results such as pressure difference and flow rate are compared with the target reference values. If the negative pressure performance does not meet the standard, the process returns to step S4 to iteratively adjust the parameters until the standard is met, and then the final suction cup part model is output.

[0032] By first setting universal reference marks on the parts, and then acquiring internal and external data through two scanning methods and completing spatiotemporal registration with the marks, accurate registration of internal and external structural data is achieved, avoiding data misalignment. Next, an iterative nearest-point algorithm is used to perform data calibration and fusion, improving the integrity and accuracy of point cloud data. After error compensation, negative pressure performance simulation verification is conducted. Through closed-loop optimization of the simulation verification, it is ensured that the output model meets the performance requirements for negative pressure use.

[0033] Further, step S4 includes: A global scaling factor is used to compensate for the overall outline dimensions of the part model; For complex freeform surface regions in the external contour data of the part model, local elastic deformation compensation of the NURBS surface is performed based on the deviation field between the point cloud and the reconstructed surface. Based on the data of internal flow channel 4 in the part model, and the sensitivity analysis of pressure loss in the negative pressure performance simulation, adaptive radial compensation is performed on the diameter of flow channel 4.

[0034] Specifically, based on the different structural features of the part model, error compensation is achieved in three dimensions: global contour, external complex curved surface, and internal flow channel 4. Three methods are employed: scaling, NURBS local deformation, and radial adaptation of flow channel 4, respectively, ensuring that the error between the overall model and the original point cloud is controlled within the required range. Multi-scale compensation adapts to the accuracy requirements of different features, resulting in higher model fidelity and ensuring that the compensated model matches the design intent and performance requirements at different scales.

[0035] Furthermore, in step S2, spatiotemporal registration includes: using the central through hole or reference hole of the complex curved surface part as the alignment feature, and achieving spatial matching between the internal flow channel 4 data and the external contour data through geometric fitting.

[0036] Specifically, the central through hole or reference hole inherent in the part is selected as the alignment feature, and the spatial matching between the internal flow channel 4 and the external contour data is completed using geometric fitting. Based on the inherent features of the part, the registration accuracy is high and the stability is strong, requiring no additional auxiliary tooling and simplifying the registration process.

[0037] Furthermore, in step S5, the negative pressure performance simulation includes: simulating the pressure distribution and flow pattern of the internal and external structures of the part, and optimizing the diameter of the internal structure air passage and the curvature of the surface.

[0038] Specifically, fluid simulation is used to model the internal and external pressure and flow states of the parts, and key structural parameters such as air passage diameter and surface curvature are optimized based on the simulation results. This allows for early verification of fluid performance, preventing substandard performance after actual manufacturing, targeted structural optimization, and improved stability of the parts under negative pressure.

[0039] Furthermore, a non-contact blue light scanner was used for external contour scanning, and an industrial X-ray tomography scanner was used for penetration scanning.

[0040] Specifically, the external contour scanning uses a non-contact blue light scanner with a scanning accuracy of ≤0.025mm; the internal flow channel 4 scanning uses an industrial X-ray tomography scanner (industrial CT) with a scanning accuracy of 4μm+L / 50μm, to fully acquire internal and external structural data.

[0041] Furthermore, after step S5, the following steps are also included: S6: Based on the output part model, add machining allowance and perform additive manufacturing to obtain part blank; S7: Based on the part blank, the finished part is obtained by subtractive manufacturing through a machining center.

[0042] Specifically, after outputting the qualified model, the finished parts are manufactured based on the output qualified model. First, machining allowance is reserved on the model, and then a suction cup blank is obtained by 3D printing additive manufacturing; then, the suction cup blank is used as the object, and a machining center is used to carry out subtractive finishing to obtain a finished suction cup part that meets the requirements of size, form and position tolerance and surface roughness.

[0043] Example 1: The present invention also provides a reverse manufacturing system for complex curved surface parts, such as... Figure 2 As shown, a reverse design method for complex surface parts based on multi-source data fusion is used to output a part model. The system includes: Data acquisition module 101: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel 4 data and external contour data of the part, and execute step S2; Model processing module 102: Configures drawing software for calibrating and fusing internal flow channel 4 data with external contour data, performing error analysis and compensation, and parametric modeling, and executes steps S3 and S4; Simulation verification module 103: Uses finite element simulation software for fluid performance verification, and executes step S5.

[0044] Example 2: The present invention also provides a reverse manufacturing system for complex curved surface parts, such as... Figure 3 As shown, a method for reverse engineering complex surface parts based on multi-source data fusion is used to output a part model and prepare the finished part based on the output part model. The system includes: Data acquisition module 101: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel 4 data and external contour data of the part, and execute step S2; Model processing module 102: Configures drawing software for calibrating and fusing internal flow channel 4 data with external contour data, performing error analysis and compensation, and parametric modeling, and executes steps S3 and S4; Simulation verification module 103: Uses finite element simulation software for fluid performance verification, and executes step S5; Additive Manufacturing Module 104: Using 3D printing equipment, the part blank is manufactured by integrated molding based on the optimized model, and step S6 is executed. Subtractive manufacturing module 105: Using machining center equipment, the surface of the part blank is precision machined to obtain the finished part, and step S7 is executed.

[0045] To enable those skilled in the art to better understand the technical solution of this application, the following will, in conjunction with specific embodiment 3, illustrate the application of a reverse design method for complex curved surface parts based on multi-source data fusion in, such as... Figure 4 ,Figure 5 The reverse engineering process of the suction cup component shown is explained in detail.

[0046] Example 3: A reverse design method for complex curved surface parts based on multi-source data fusion, comprising the following steps: S1: Attach markers that can be recognized by both non-contact blue light scanners and industrial X-ray tomography scanners at the center through hole 2 and air hole 3 of the suction cup; S2: The suction cup's external contour is scanned using a non-contact blue light scanner in the data acquisition module 101. The scanning accuracy is controlled within 0.025mm, and the single scan area is 150-3000mm, ensuring complete capture of external curved surface features and obtaining the suction cup's external contour data, such as... Figure 6 , Figure 7 As shown. The suction cup is subjected to a penetrating scan using an industrial X-ray tomography scanner in the data acquisition module 101 to obtain structural data of the internal flow channel 4, as shown. Figure 8 , Figure 9 As shown. The CT scan accuracy is 4μm+L / 50μm, where 4μm is the fixed baseline error, L is the measured length, and L / 50μm is the error that increases linearly with length (i.e., the error increases by 1μm for every 50mm increase in length). It can clearly display the distribution of the three groups of negative pressure air inlets and outlets inside the suction cup. Through multi-angle scanning, complete three-dimensional point cloud data of the internal airways is obtained. The non-contact blue light scanner and industrial X-ray tomography scanner are imported into reverse modeling software, and the external contour data and internal flow channel data are spatiotemporally registered using the reference markers. S3: The model processing module 102 completes the registration of internal and external data through geometric fitting, and uses the Iterative Closest Point (ICP) algorithm to perform fine calibration and fusion of internal and external point cloud data. The fused point cloud data will be further denoised and simplified, and the external surface features and internal flow channel features will be separated.

[0047] S4: The model processing module 102 performs multi-scale error analysis on the merged overall 3D model and compensates for the error data. For the overall contour dimensions of the part model, a global scaling factor is used for compensation; for the complex free-form surface regions in the external contour data of the part model, NURBS surface local elastic deformation compensation is performed based on the deviation field between the point cloud and the reconstructed surface; for the internal flow channel 4 data of the part model, adaptive radial compensation is performed on the diameter of flow channel 4 based on the sensitivity analysis of pressure loss in negative pressure performance simulation. This ensures that the compensated model matches the design intent and performance requirements at different scales, completing the parametric model reconstruction.

[0048] S5: Import the model with completed error analysis and compensation into simulation verification module 103 to establish a fluid simulation model. Compare and verify the simulation results with reference values; Boundary conditions are set, including different pressure gradients at the negative pressure outlet, to simulate airflow under different operating conditions. Through simulation calculations, the pressure distribution, velocity distribution, and airflow trajectory within the suction cup are obtained, and the results are compared and verified with reference values. If the verification fails, the process returns to step S4, iteratively adjusting the error compensation parameters for the corresponding region, optimizing the internal structure air passage diameter and surface curvature, until the target is met, at which point the final suction cup part model is output. S6: Based on the output part model, selective 3D printing technology is used for integrated molding manufacturing. The material selected is titanium alloy TC4, whose chemical composition meets the requirements of grade TC4 in GB / T3620.1-2016, and whose Vickers hardness meets the set requirements. During the manufacturing process, a certain machining allowance is reserved in the modeling stage to support the integrated molding of the 3D printed part, resulting in the blank of the suction cup.

[0049] S7: Based on the part blank, the finished suction cup part is obtained by subtractive manufacturing through a machining center.

[0050] The finished suction cup parts were installed on the equipment for on-site debugging. After continuous improvements through multiple versions, the technical specification of a success rate of over 99% for normal operation was finally achieved, fully meeting the usage requirements.

[0051] Where there is no conflict, the above embodiments and features described herein can be combined with each other.

[0052] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A reverse design method for complex curved surface parts based on multi-source data fusion, characterized in that, Includes the following steps: S1: Set a reference mark on the part that can be recognized by both external contour scanning and penetration scanning; S2: Obtain the external contour data of the part through external contour scanning, obtain the internal flow channel data of the part through penetration scanning, and perform spatiotemporal registration of the external contour data and the internal flow channel data with reference to the reference mark. S3: Based on the spatiotemporal registration results, the iterative nearest point algorithm is used to calibrate and fuse the internal flow channel data and the external contour data; S4: Perform error analysis and compensation on the profile data after calibration and fusion; S5: Perform negative pressure performance simulation on the model after error analysis and compensation, and compare the simulation results with the reference values ​​for verification; If the verification fails, return to step S4 and iteratively adjust the error compensation parameters for the corresponding area until the reference value meets the standard. If the verification is successful, the part model will be output.

2. The reverse design method for complex curved surface parts based on multi-source data fusion according to claim 1, characterized in that, Step S4 includes: A global scaling factor is used to compensate for the overall outline dimensions of the part model; For complex freeform surface regions in the external contour data of the part model, local elastic deformation compensation of the NURBS surface is performed based on the deviation field between the point cloud and the reconstructed surface. Based on the internal flow channel data of the part model, and the sensitivity analysis of pressure loss in the negative pressure performance simulation, adaptive radial compensation is performed on the flow channel diameter.

3. The reverse design method for complex curved surface parts based on multi-source data fusion according to claim 1, characterized in that, In step S2, the spatiotemporal registration includes: using the central through hole or reference hole of the complex curved surface part as the alignment feature, and achieving spatial matching between the internal flow channel data and the external contour data through geometric fitting.

4. The reverse design method for complex curved surface parts based on multi-source data fusion according to claim 1, characterized in that, In step S5, the negative pressure performance simulation includes: simulating the pressure distribution and flow pattern of the internal and external structures of the part, and optimizing the diameter of the internal structure air passage and the curvature of the surface.

5. The reverse design method for complex curved surface parts based on multi-source data fusion according to claim 1, characterized in that: In step S2, a non-contact blue light scanner is used to scan the external contour, and an industrial X-ray tomography scanner is used to perform a penetration scan.

6. The reverse design method for complex curved surface parts based on multi-source data fusion according to any one of claims 1-5, characterized in that, Following step S5, the following steps are also included: S6: Based on the output part model, add machining allowance and perform additive manufacturing to obtain part blank; S7: Based on the part blank, the finished part is obtained by subtractive manufacturing through a machining center.

7. A reverse manufacturing system for complex curved surface parts, used to implement the reverse design method for complex curved surface parts based on multi-source data fusion as described in any one of claims 1-5, characterized in that, include: Data acquisition module: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel data and external contour data of parts; Model processing module: Configures drawing software for calibrating and fusing internal flow channel data and external contour data, performing error analysis and compensation, and parametric modeling; Simulation verification module: uses finite element simulation software for fluid performance verification.

8. A reverse manufacturing system for complex curved surface parts, used to implement the reverse design method for complex curved surface parts based on multi-source data fusion as described in claim 6, characterized in that, include: Data acquisition module: integrates a non-contact blue light scanner and an industrial X-ray tomography scanner to simultaneously acquire internal flow channel data and external contour data of parts; Model processing module: Configures drawing software for calibrating and fusing internal flow channel data and external contour data, performing error analysis and compensation, and parametric modeling; Simulation verification module: Employs finite element simulation software for fluid performance verification; Additive manufacturing module: Uses 3D printing equipment to perform integrated molding processing based on an optimized model to manufacture part blanks; Subtractive manufacturing module: Using machining center equipment, the surface of the part blank is precision machined.

Images