Automatic control system and method for five-axis machining robot

Abstract

An automatic control system and method for a five-axis machining robot. The automatic control system for a five-axis machining robot comprises: a data acquisition module (101) for scanning a machining workpiece to generate a scanning model, generating a digital model of the machining workpiece on the basis of a numerical control code, aligning the coordinates of the digital model and the coordinates of the scanning model, and comparing the digital model with the scanning model; a data analysis module (102) for calculating a comparison difference between the scanning model and the digital model on the basis of the comparison, and generating a machining compensation parameter on the basis of the comparison difference and a machining error preset by the numerical control code; an automatic control module (103) for extracting the machining compensation parameter in real time and dynamically adding the machining compensation parameter into a machining coordinate system on the basis of the comparison difference; and a servo control module (104) for correcting servo data in real time on the basis of the dynamic change of the machining coordinate system. According to the automatic control system for a five-axis machining robot, the size of a workpiece is checked in real time to obtain correction data, thereby greatly improving the machining precision of the workpiece.

Description

Five-axis machining robot automation control system and control method Technical Field

[0001] The present application relates to the field of automation control technology, and in particular to an automation control system for a five-axis machining robot. The present application also relates to an automation control method for a five-axis machining robot. Background Art

[0002] A five-axis machining robot refers to a machining robot with five degrees of freedom. It has strong flexibility in processing workpieces and can achieve one-time molding of complex shapes.

[0003] Due to the high processing flexibility of the five-axis machining robot, the problems it brings include: the high degree of freedom reduces the structural rigidity of the props and molds during processing by the machining robot, and reduces the processing accuracy when processing the workpiece. Especially when processing workpieces with harder materials, the problem of reduced accuracy is more prominent.

[0004] Summary of the Invention

[0005] In order to solve the technical problems mentioned in the above background technology, the present application provides a five-axis machining robot automation control system and a five-axis machining robot automation control method.

[0006] The present application provides a five-axis machining robot automation control system, comprising: a data acquisition module, a data analysis module, an automatic control module and a servo control module;

[0007] The data acquisition module includes: a three-dimensional scanning unit for scanning the workpiece to generate a scanned model, a digital model generation unit for generating a digital model of the workpiece according to the numerical control code, a position correction unit for aligning the coordinates of the data model and the scanned model, and a comparison unit for comparing the digital model with the scanned model;

[0008] The data analysis module is used to calculate the contrast difference between the scanned model and the digital model, and generate a machining compensation parameter based on the contrast difference and the machining error preset in the numerical control code;

[0009] The automatic control module extracts the machining compensation parameters in real time, and dynamically adds the machining compensation parameters to the machining coordinate system based on the contrast difference;

[0010] The servo control module corrects the servo data in real time according to the dynamic changes of the processing coordinate system.

[0011] Optionally, the three-dimensional scanning unit includes: at least three laser scanners.

[0012] Optionally, the three-dimensional scanning unit has built-in three-dimensional data of the processing end. After the workpiece is scanned, the scanning model will be optimized according to the built-in three-dimensional data of the processing end.

[0013] Optionally, the contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

[0014] Optionally, the machining coordinate system includes: a system coordinate system and a workpiece coordinate system.

[0015] The present application also provides a five-axis machining robot automation control method, comprising:

[0016] Scanning the workpiece to generate a scanned model, generating a digital model of the workpiece according to the numerical control code, aligning the coordinates of the data model and the scanned model, and using a comparison unit to compare the digital model and the scanned model;

[0017] Calculating a contrast difference between the scanned model and the digital model according to the comparison, and generating a machining compensation parameter based on the contrast difference and a machining error preset in the numerical control code;

[0018] extracting the machining compensation parameters in real time, and dynamically adding the machining compensation parameters to a machining coordinate system based on the contrast difference;

[0019] According to the dynamic changes of the processing coordinate system, the servo data is corrected in real time.

[0020] Optionally, the scanner for generating the scanning model includes at least three laser scanners.

[0021] Optionally, after the workpiece is scanned, the scan model will be optimized according to the built-in three-dimensional data of the processing end.

[0022] Optionally, the contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

[0023] Optionally, the machining coordinate system includes: a system coordinate system and a workpiece coordinate system.

[0024] The advantages of this application over the prior art are:

[0025] The present application provides a five-axis machining robot automation control system, comprising: a data acquisition module, a data analysis module, an automatic control module, and a servo control module; the data acquisition module includes: a three-dimensional scanning unit for scanning a workpiece to generate a scanned model, a digital model generation unit for generating a digital model of the workpiece according to a numerical control code, a position correction unit for aligning the coordinates of the data model and the scanned model, and a comparison unit for comparing the digital model with the scanned model; the data analysis module calculates the contrast difference between the scanned model and the digital model based on the comparison, and generates machining compensation parameters based on the contrast difference and the machining error preset in the numerical control code; the automatic control module extracts the machining compensation parameters in real time and dynamically adds the machining compensation parameters to the machining coordinate system based on the contrast difference; the servo control module corrects the servo data in real time according to the dynamic changes of the machining coordinate system. The five-axis machining robot described in the present application can significantly improve the machining accuracy of the workpiece by obtaining correction data through real-time inspection of the workpiece dimensions. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG1 is a schematic diagram of the five-axis machining robot automation control system in this application.

[0027] FIG2 is a schematic diagram of the structure of the data acquisition module in this application.

[0028] FIG3 is a flow chart of the automated control method for a five-axis machining robot in this application. DETAILED DESCRIPTION

[0029] The following contents are all examples of specific implementation processes provided for detailed description of the technical solutions to be protected by this application. However, this application can also be implemented in other ways different from the descriptions here. Those skilled in the art can adopt different technical means to implement this application under the guidance of the concept of this application. Therefore, this application is not limited to the specific embodiments below.

[0030] The present application provides a five-axis machining robot automation control system, comprising: a data acquisition module, a data analysis module, an automatic control module, and a servo control module; the data acquisition module includes: a three-dimensional scanning unit for scanning a workpiece to generate a scanned model, a digital model generation unit for generating a digital model of the workpiece according to a numerical control code, a position correction unit for aligning the coordinates of the data model and the scanned model, and a comparison unit for comparing the digital model with the scanned model; the data analysis module is used to compare and calculate the contrast difference between the scanned model and the digital model, and generate machining compensation parameters based on the contrast difference and the machining error preset in the numerical control code; the automatic control module extracts the machining compensation parameters in real time and dynamically adds the machining compensation parameters to the machining coordinate system based on the contrast difference; the servo control module corrects the servo data in real time according to the dynamic changes of the machining coordinate system. The five-axis machining robot described in the present application can significantly improve the machining accuracy of the workpiece by obtaining correction data through real-time inspection of the workpiece dimensions.

[0031] FIG1 is a schematic diagram of the five-axis machining robot automation control system in this application.

[0032] The system includes a data acquisition module 101, a data analysis module 102, an automatic control module 103 and a servo control module 104, and the four modules are connected in sequence.

[0033] Please refer to Figure 1, the data acquisition module 101 includes: a three-dimensional scanning unit 201 for scanning the processed workpiece to generate a scanned model; a digital model generation unit 202 for generating a digital model of the processed workpiece according to the CNC code; a position correction unit 203 for aligning the coordinates of the data model and the scanned model; and a comparison unit 204 for comparing the digital model and the scanned model, as shown in Figure 2.

[0034] The three-dimensional scanning unit 201 may be a laser scanner, which generates a three-dimensional shape of a workpiece through a dense point cloud.

[0035] The laser scanners include at least three, which are evenly distributed around the workpiece and rotate along with the rotation of the workpiece.

[0036] When imaging, the laser scanner uses the workpiece coordinate system as a reference to image the workpiece. Specifically, each 3D scanner first acquires the robot coordinate system and its own position in the robot coordinate system. It also acquires the position of the workpiece in the robot coordinate system and the workpiece coordinate system, and then acquires its position in the workpiece coordinate system based on coordinate transformation.

[0037] After the laser scanner completes the above settings, when processing a workpiece, it scans the workpiece according to a preset scanning interval and forms a laser point cloud three-dimensional image.

[0038] The laser scanners described in the present application are multiple, and at least three, and after completing the imaging of the laser point cloud three-dimensional image, the multiple laser point cloud three-dimensional images are merged to generate a scanning model of the workpiece.

[0039] The data acquisition module also includes a digital-to-analog generation unit 202, which reads the workpiece processing process when the three-dimensional scanning unit 201 performs scanning, and digitally models the processed workpiece according to the numerical control code based on the processing process performed during scanning to form a digital model.

[0040] The data acquisition module further includes a position correction unit 203, which acquires the scanned model and the digital model and aligns the scanned model and the digital model, specifically, aligning them according to their coordinate systems, including position alignment and rotation alignment.

[0041] The system further comprises a comparing unit 204 for comparing the aligned digital model and the scanned model.

[0042] The data analysis module 102 calculates the contrast difference between the scanned model and the digital model according to the comparison result of the comparison unit 204, and generates a machining compensation parameter based on the contrast difference and the machining error preset in the numerical control code;

[0043] Specifically, a comparison benchmark is generated based on the digital model, and a machining error value of the workpiece is added to the digital model to generate a comparison scale.

[0044] The scanned model has been aligned with the digital model in the data acquisition module. Differences in various inspection dimensions between the scanned model and a comparison scale generated based on the digital model are calculated, and machining compensation parameters are obtained based on these differences. Preferably, the scanned model is directly compared with the digital model, and machining errors are adjusted based on the comparison results to obtain machining compensation parameters.

[0045] The calculation method of the machining compensation parameters is as follows:

[0046] Wherein, A is the increase of the compensation parameter, G is the size of the scanned model, G(x) represents the function of the change of the machining error with the machining depth, and x represents the machining depth.

[0047] Then, based on the already set machining compensation parameters, the current machining compensation parameters are obtained by adding the above A.

[0048] The automatic control module 103 extracts the machining compensation parameters in real time, and dynamically adds the machining compensation parameters to the machining coordinate system based on the contrast difference;

[0049] The contrast difference is the additional difference generated by the robot when machining a part, just outside the preset error range. In this application, the machining compensation parameters are input into the robot's machining coordinate system after completing one CNC execution command and before executing the next CNC execution command during the robot's machining process. At this point, when the robot performs machining, the additional difference is compensated to complete the workpiece.

[0050] The servo control module 104 corrects the servo data in real time according to the dynamic changes of the processing coordinate system.

[0051] The servo control module is mainly used as a driving system for precisely controlling the tool when the robot processes parts. The processing compensation parameters will compensate and control the servo control module to reduce the error to a preset error range.

[0052] The present application also provides an automated control method for a five-axis machining robot. Specifically, the method monitors the error generated by the five-axis machining robot when machining a workpiece, calculates the size of the error, and performs parameter compensation on the machining robot to improve machining accuracy.

[0053] Preferably, the three-dimensional scanning unit 201 includes at least three laser scanners.

[0054] Preferably, the three-dimensional scanning unit 201 has built-in three-dimensional data of the processing end. After the workpiece is scanned, the scanning model will be optimized according to the built-in three-dimensional data of the processing end.

[0055] Preferably, the contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

[0056] Preferably, the machining coordinate system includes: a system coordinate system and a workpiece coordinate system.

[0057] FIG3 is a flow chart of the automated control method for a five-axis machining robot in this application.

[0058] As shown in FIG3 , S301 scans a workpiece to generate a scan model, generates a digital model of the workpiece according to a numerical control code, aligns the coordinates of the data model and the scan model, and compares the digital model and the scan model.

[0059] The three-dimensional scanning unit 201 may be a laser scanner, which generates a three-dimensional shape of a workpiece through a dense point cloud.

[0060] The laser scanners include at least three, which are evenly distributed around the workpiece and rotate along with the rotation of the workpiece.

[0061] When imaging, the laser scanner uses the workpiece coordinate system as a reference to image the workpiece. Specifically, each 3D scanner first acquires the robot coordinate system and its own position in the robot coordinate system. It also acquires the position of the workpiece in the robot coordinate system and the workpiece coordinate system, and then acquires its position in the workpiece coordinate system based on coordinate transformation.

[0062] After the laser scanner completes the above settings, when processing a workpiece, it scans the interval according to the preset scanning interval and forms a laser point cloud three-dimensional image.

[0063] The laser scanners described in the present application are multiple, and at least three, and after completing the imaging of the laser point cloud three-dimensional image, the multiple laser point cloud three-dimensional images are merged to generate a scanning model of the workpiece.

[0064] The data acquisition module also includes a digital-to-analog generation unit 202, which reads the workpiece processing process when the three-dimensional scanning unit 201 performs scanning, and digitally models the processed workpiece according to the numerical control code based on the processing process performed during scanning to form a digital model.

[0065] The data acquisition module further includes a comparison unit 204, which acquires the scanned model and the digital model and aligns the scanned model and the digital model, specifically, aligning them according to their coordinate systems, including position alignment and rotation alignment.

[0066] Comparison of the digital model and the scanned model showing the alignment is also included.

[0067] As shown in FIG. 3 , S302 calculates the contrast difference between the scanned model and the digital model based on the comparison, and generates machining compensation parameters based on the contrast difference and the machining error preset by the CNC code.

[0068] Specifically, a comparison benchmark is generated based on the digital model, and a machining error value of the workpiece is added to the digital model to generate a comparison scale.

[0069] The scanned model has already been aligned with the digital model. Differences in various inspection dimensions are calculated between the scanned model and a comparison scale generated based on the digital model, and machining compensation parameters are obtained based on these differences. Preferably, the scanned model is directly compared with the digital model, and machining errors are increased or decreased based on the comparison results to obtain machining compensation parameters.

[0070] The calculation method of the machining compensation parameters is as follows:

[0071] Wherein, A is the increase of the compensation parameter, G is the size of the scanned model, G(x) represents the function of the change of the machining error with the machining depth, and x represents the machining depth.

[0072] Then, based on the already set machining compensation parameters, the current machining compensation parameters are obtained by adding the above A.

[0073] Please refer to Figure 3, S303 extracts the processing compensation parameters in real time, and dynamically adds the processing compensation parameters to the processing coordinate system based on the contrast difference.

[0074] The contrast difference is the additional difference generated by the robot when machining a part, just outside the preset error range. In this application, the machining compensation parameters are input into the robot's machining coordinate system after completing one CNC execution command and before executing the next CNC execution command during the robot's machining process. At this point, when the robot performs machining, the additional difference is compensated to complete the workpiece.

[0075] As shown in FIG. 3 , in S304 , the servo data is corrected in real time according to the dynamic changes of the processing coordinate system.

[0076] The servo control module is mainly used as a driving system for precisely controlling the tool when the robot processes parts. The processing compensation parameters will compensate and control the servo control module to reduce the error to a preset error range.

[0077] Preferably, the scanner for generating the scanning model comprises at least three laser scanners.

[0078] Preferably, after the workpiece is scanned, the scan model will be optimized according to the built-in three-dimensional data of the processing end.

[0079] Preferably, the contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

[0080] Preferably, the machining coordinate system includes: a system coordinate system and a workpiece coordinate system.

[0081] Although the embodiments of the present invention have been shown and described above, those skilled in the art will understand that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and purpose of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A five-axis machining robot automation control system, characterized in that: include: Data acquisition module, data analysis module, automatic control module and servo control module; The data acquisition module includes: a three-dimensional scanning unit for scanning a workpiece to generate a scanning model, a digital model generation unit for generating a digital model of the workpiece according to a numerical control code, a position correction unit for aligning the coordinates of the data model and the scanning model, and a comparison unit for comparing the digital model with the scanning model; The data analysis module is used to calculate the contrast difference between the scanned model and the digital model, and generate a machining compensation parameter based on the contrast difference and the machining error preset in the numerical control code; The automatic control module extracts the machining compensation parameters in real time, and dynamically adds the machining compensation parameters to the machining coordinate system based on the contrast difference; The servo control module corrects the servo data in real time according to the dynamic changes of the processing coordinate system.

2. The five-axis machining robot automation control system according to claim 1, characterized in that: The three-dimensional scanning unit includes at least three laser scanners.

3. The five-axis machining robot automation control system according to claim 1 or 2, characterized in that: The three-dimensional scanning unit has built-in three-dimensional data of the processing end. After the workpiece is scanned, the scanning model will optimize the scanning model according to the built-in three-dimensional data of the processing end.

4. The five-axis machining robot automation control system according to claim 1, characterized in that: The contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

5. The five-axis machining robot automation control system according to claim 1, characterized in that: The machining coordinate system includes: system coordinate system and workpiece coordinate system.

6. A five-axis machining robot automation control method, characterized in that: include: Scanning the workpiece to generate a scanned model, generating a digital model of the workpiece according to the numerical control code, aligning the coordinates of the data model and the scanned model, and using a comparison unit to compare the digital model with the scanned model; Calculating the contrast difference between the scanned model and the digital model according to the comparison, and generating a machining compensation parameter based on the contrast difference and a machining error preset in the numerical control code; extracting the machining compensation parameters in real time, and dynamically adding the machining compensation parameters to a machining coordinate system based on the contrast difference; According to the dynamic changes of the processing coordinate system, the servo data is corrected in real time.

7. The five-axis machining robot automation control method according to claim 6, characterized in that: The scanner for generating the scanning model: at least three laser scanners.

8. The five-axis machining robot automation control method according to claim 6 or 7, characterized in that: After the workpiece is scanned, the scanned model will be optimized according to the built-in processing end three-dimensional data.

9. The five-axis machining robot automation control method according to claim 6, characterized in that: The contrast difference includes: width difference, length difference, depth difference, feature position and / or surface flatness.

10. The five-axis machining robot automation control method according to claim 6, characterized in that: The machining coordinate system includes: system coordinate system and workpiece coordinate system.

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