CN108039579B - Rapid assembly method for special-shaped cavity radiation unit - Google Patents
Rapid assembly method for special-shaped cavity radiation unit Download PDFInfo
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- CN108039579B CN108039579B CN201711308422.5A CN201711308422A CN108039579B CN 108039579 B CN108039579 B CN 108039579B CN 201711308422 A CN201711308422 A CN 201711308422A CN 108039579 B CN108039579 B CN 108039579B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/36—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith
- H01Q1/38—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith formed by a conductive layer on an insulating support
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q21/00—Antenna arrays or systems
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Abstract
The invention discloses a quick assembly method of a radiation unit with a special-shaped cavity, which is characterized by comprising the following steps of: s1: determining radiation unit assembly characteristic elements; s2: creating a characteristic element matching template library; s3: collecting and preprocessing an assembly characteristic image; s4: identifying the assembly characteristic contour; s5: three-dimensional reconstruction of assembly characteristics; s6: grouping of radiating elements based on manufacturing accuracy; s7: solving the minimum variance of the matching and arranging scheme of the radiation units; s8: and (4) real-time prediction and control based on the assembly precision of the measured data. The rapid assembly method for the radiation unit with the special-shaped cavity greatly improves the assembly precision and consistency of the radiation unit and ensures the batch stability of the product quality; the rapid measurement of the assembly characteristics of the radiation unit and the automatic planning of the assembly scheme can be realized, and the assembly preparation period is greatly shortened; the assembling process can be automatically optimized, the extrusion of the assembling process of the radiation unit is avoided, and the processes of repeated trial assembly and disassembly are reduced.
Description
Technical Field
The invention relates to the technical field of communication, in particular to a quick assembly method of a radiation unit with a special-shaped cavity.
Background
Phased array technology has been rapidly developed in recent years, has brought a profound influence on the development of radar systems due to incomparable performance advantages, and is widely applied to various radar systems. With the development of world military technology, the requirements on tactics and technical indexes of a phased array radar system are higher and higher.
The radiation unit is a basic structural unit and a key component which form the phased array antenna, can effectively radiate or receive radio waves, has huge demand (thousands to tens of thousands) for a single radar, and has high requirements on three-dimensional assembly density and precision. However, the assembly error of the radiation unit to the predetermined installation position may cause phase distribution of current and aperture field on the unit, so as to cause antenna gain reduction, side lobe level increase, beam pointing inaccuracy, etc., that is, electrical performance of the phased array antenna is reduced.
The radiation unit is a thin-wall special-shaped cavity structure, which basically cannot be manufactured by a conventional machining method, or the radiation unit is decomposed into a plurality of structural components to be respectively machined and then connected into a unit cavity through brazing, or the radiation unit is machined by a warm extrusion forming process and other process methods. Due to the particularity of the process, the manufactured and molded radiation unit has poor precision consistency and great discreteness, and higher design precision requirements are difficult to guarantee.
The assembly difficulty of the radiation unit is mainly reflected in that: the special-shaped cavity structure has the advantages that the traditional measuring means is difficult to accurately and quickly obtain assembling parameter information (position, size and precision) during large-batch assembling, the assembling precision influence factors are numerous, the coordination difficulty is high, and the traditional means of trial assembling by depending on experience is difficult to ensure the one-time assembling power.
At present, the radiation units are mainly assembled manually, when the radiation units are assembled by a special tool, the cavity edges of adjacent radiation units are extruded mutually, repeated trial assembly and disassembly are needed, time and labor are wasted, the assembly precision and consistency are not high, and the coupling gaps among the units are not guaranteed well; the electrical performance of the antenna can not reach the expected technical index, the assembly period is long, the repetition rate is about 30 percent, and the period occupied by the difficult structure coordination is 30 percent.
Disclosure of Invention
Based on the background technology, the invention provides a rapid assembly method of a radiation unit with a special-shaped cavity, which provides an outer contour characteristic accurate dimension parameter based on a gray level difference rapid algorithm for a clamping jaw at the tail end of a manipulator in an automatic assembly process, and solves the problems of repeated disassembly and assembly, low efficiency, poor installation accuracy and consistency and the like in the mass assembly process of a radiation unit commonly used for a phased array antenna.
In order to achieve the purpose, the invention adopts the following technical scheme:
a quick assembly method for a radiation unit with a special-shaped cavity comprises the following steps:
s1: combing the radiation unit and assembling characteristic elements;
s2: creating a characteristic element matching template library;
s3: collecting and preprocessing an assembly characteristic image;
s4: identifying the assembly characteristic contour;
s5: three-dimensional reconstruction of assembly characteristics;
s6: grouping of radiating elements based on manufacturing accuracy;
s7: solving a matching and arranging scheme of the radiation units;
s8: and (4) real-time prediction and control based on the assembly precision of the measured data.
Specifically, the characteristic elements for assembling the radiation unit in S1 include: the geometrical feature area of the radiating element and its dimensional tolerance requirements.
Specifically, S2: and creating a characteristic element matching template library and presetting the characteristic element matching template library in the system.
Specifically, the preprocessing of the assembled feature image in S3 is to remove noise of the image by filtering, and correct and enhance the target recognition area associated with the assembled feature elements.
Specifically, the specific process of the assembly characteristic contour identification is as follows:
the outline of a radiation unit in the digital image is in a high-brightness state, pixel points of edges are extracted based on gray level difference, and after approximate position information of characteristic edges of the radiation unit is obtained, a point group meeting requirements of gray level difference and polarity change is screened in the radiation unit through an algorithm; and fitting the point groups to form lines by using a least square method, namely accurately redrawing the contour line of the radiation unit and solving the position of the center point of the radiation unit.
Specifically, the three-dimensional reconstruction of the assembly characteristics comprises the following specific processes:
and obtaining the coordinate position of the assembly characteristic of the radiation unit in a world coordinate system by using the calibration result of the industrial camera and the image coordinate after the image characteristic is extracted, calculating the edge and the central point of the edge, the bottom boss and the central point of the bottom boss and the attitude deviation angle of the radiation unit, and obtaining the spatial pose information of the assembly characteristic of the radiation unit by adopting a spatial pose matrix transformation method.
Preferably, the groups of radiating elements based on manufacturing accuracy are divided into groups with large, medium and small deviations.
Specifically, the solution of the matching and arranging scheme of the radiation units in S7 is to establish a mathematical model of "constraint satisfaction problem" and perform a minimum variance solution.
Specifically, the assembly precision real-time prediction and control specific process based on the measured data is as follows:
quantitatively describing deviation information and deviation constraint information of the geometric features in the positions and the directions aiming at different types of deviation sources in the assembling process, and realizing qualitative description of topological relation between the deviation geometric features and the associated entities; describing the direction and range of deviation transmission through qualitative information, and describing the influence of the deviation on different transmission paths through quantitative information; and after the assembly is finished, analyzing the result, judging whether the accumulated deviation meets the requirement of the assembly precision, searching and positioning key factors influencing the deviation, and if the measured value of the assembly precision does not meet the precision requirement, disassembling and adjusting the radiation unit in the assembly.
The invention has the advantages of
The rapid assembly method for the radiation unit with the special-shaped cavity greatly improves the assembly precision and consistency of the radiation unit and ensures the batch stability of the product quality; the rapid measurement of the assembly characteristics of the radiation unit and the automatic planning of the assembly scheme can be realized, and the assembly preparation period is greatly shortened; the assembling process can be automatically optimized, the extrusion of the assembling process of the radiation unit is avoided, and the processes of repeated trial assembly and disassembly are reduced.
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FIG. 1 is a flow chart of a method for rapid assembly of a radiating element;
fig. 2 illustrates a process for rapid assembly of the radiating element in accordance with a preferred embodiment of the present invention.
Detailed Description
The present invention is described in detail below by way of examples, it should be noted that the examples are only for the purpose of further illustration, and are not to be construed as limiting the scope of the present invention, and that those skilled in the art can make insubstantial modifications and adaptations to the invention in light of the above teachings. The embodiments and features of the embodiments of the present invention may be combined with each other without conflict.
A method for quickly assembling a radiation unit with a special-shaped cavity, as shown in fig. 1, comprises the following steps:
s1: determining radiation unit assembly characteristic features
The radiation unit assembly characteristic elements of the invention refer to key geometric characteristic regions (such as mounting holes, opening edge edges and the like) related to the assembly quality of a radiation unit real object and the dimensional tolerance requirements thereof, and the geometric characteristics are composed of outlines (points) and correspond to edge points of a digital image in machine vision, namely points with abrupt change of gray level.
Through the analysis of the assembly characteristic elements, the position and the geometric distribution of the key characteristic are determined, and the important information of the key characteristic of the radiation unit in the two-dimensional image mapping is more clearly shown, so that the subsequent machine vision identification and processing are facilitated.
S2: creating a library of feature element matching templates
According to the technical requirements of the radiation unit assembly process, feature elements to be detected are respectively created into a target identification area matching template (namely ROI), a matching template library is formed and is preset in a system, and condition input of assembly feature extraction is provided for a subsequent algorithm.
S3: assembly characteristic image acquisition and preprocessing
In the process of converting, collecting, transmitting, storing and the like, external or internal interference (namely noise) is inevitably existed in the process of acquiring the image information of the radiation unit in the industrial assembly field environment. The noise deteriorates the quality of the image, blurs the image, overwhelms the features, and makes identification and analysis of the feature elements difficult. The image preprocessing is to remove the noise of the image through filtering, correct and enhance the target identification area related to the assembly characteristic elements, and facilitate the subsequent assembly characteristic contour detection.
S4: assembly feature profile identification
The outline of the radiation unit in the digital image is in a high-brightness state, pixel points of the edge can be extracted based on gray level difference, and after approximate position information of the characteristic edge of the radiation unit is obtained, a point group meeting the requirements of gray level difference, polarity change and the like is screened in the image through an algorithm. And fitting the point groups to form lines by using a least square method, namely accurately redrawing the contour line of the radiation unit and solving the position of the center point of the radiation unit.
S5: three-dimensional reconstruction of assembly features
The three-dimensional reconstruction of the assembly characteristics of the radiation unit is to utilize the calibration result of the industrial camera and the image coordinates after the extraction of the image characteristics to obtain the coordinate position of the assembly characteristics of the radiation unit in a world coordinate system, thereby calculating parameters such as the edge of the upper edge of the radiation unit and the central point thereof, the boss at the bottom and the central point thereof, the attitude deviation angle and the like, and obtaining the spatial pose information of the assembly characteristics of the radiation unit by adopting a spatial pose matrix transformation method. Example characteristic parameter information of the radiating elements is provided for subsequent assembly.
S6: grouping of radiating elements based on manufacturing accuracy
The key assembly characteristic parameters of the radiation units, namely the measured manufacturing size of the radiation units can be rapidly acquired through the assembly characteristic contour recognition and three-dimensional reconstruction technology, and therefore the manufacturing size deviation of each radiation unit can be obtained. In general, manufacturing deviations of the radiation elements of the same manufacturing lot follow a normal distribution, and thus, grouping of the radiation elements with respect to manufacturing dimensional deviations can be achieved according to the requirement of assembly accuracy. In the actual grouping process, the grouping can be divided into groups with large deviation, medium deviation, small deviation and the like, or more finely divided according to the specific assembly precision requirement.
S7: solution for matching and arranging scheme of radiation units
The matching arrangement of the radiation units can be solved by using a Constraint Satisfaction Problem (CSP), the manufacturing deviation of each radiation unit corresponds to a variable in the CSP, the matching arrangement of the radiation units corresponds to a value range in the CSP, and the assembly precision requirement corresponds to the Constraint in the CSP, namely the center distance between the radiation unit to be assembled and an installed adjacent unit meets the precision requirement, the deviation of the center distance between all adjacent radiation units is as small as possible, or the total variance of the deviation of all the center distances is as minimum; therefore, the process of solving the optimal arrangement scheme of the radiation units is to traverse all the arrangement schemes of the radiation units, and select the arrangement sequence of the radiation units which has the minimum total variance of the center distance deviation and meets the assembly precision requirement, namely the solution of the CSP.
S8: assembly precision real-time prediction and control based on measured data
Geometric positioning/orientation deviation, operation execution deviation and the like in the assembly process can cause deviation of actual assembly quality and a solved expected value. And quantitatively describing the deviation information, deviation constraint information and the like of the geometric features in the positions and directions aiming at different types of deviation sources in the assembly process, so as to realize qualitative description of the topological relation between the deviation geometric features and the associated entities. The direction and the range of deviation transmission are described through qualitative information, and the influence of the deviation on different transmission paths is described through quantitative information. And after the assembly is finished, analyzing the result, judging whether the accumulated deviation meets the requirement of the assembly precision, searching and positioning key factors influencing the deviation, and if the measured value of the assembly precision does not meet the precision requirement, disassembling and adjusting the radiation unit in the assembly.
Fig. 2 is a process for rapid assembly of the radiating element in a preferred embodiment of the invention:
an image acquisition system is prepared and system calibration is performed to determine the conversion relationship between the three-dimensional spatial coordinate points and the corresponding points in the image. And collecting the characteristics of the edge of the opening of the radiation unit, the bottom plate, the mounting hole and the like and carrying out image preprocessing.
And then, searching and matching are carried out according to the characteristic element matching template, contour fitting is carried out based on gray level difference, so that the geometric characteristics are identified and accurately reconstructed, and the characteristic geometric parameter information of each radiation unit instance is calculated according to the calibrated conversion relation.
The radiation units are grouped according to the manufacturing precision, 8 radiation units are selected, the measured characteristic geometric parameter information of the radiation units is read respectively, the total variance of the center distance deviation is solved for each arrangement scheme in sequence, and the optimal arrangement scheme is updated in an iterative mode.
And assembling the radiation units according to the optimal arrangement scheme and detecting the precision, if the position precision of the assembled radiation units does not meet the design requirement, disassembling and replacing the radiation units which do not meet the requirement, and repeatedly performing arrangement and assembly iteration until all the adjusted radiation units meet the requirement.
It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the scope of the present invention.
Claims (8)
1. A quick assembly method for a radiation unit with a special-shaped cavity is characterized by comprising the following steps:
s1: determining radiation unit assembly characteristic elements;
s2: creating a characteristic element matching template library;
s3: collecting and preprocessing an assembly characteristic image;
s4: identifying the assembly characteristic contour;
s5: three-dimensional reconstruction of assembly characteristics;
s6: grouping of radiating elements based on manufacturing accuracy;
s7: solving a matching and arranging scheme of the radiation units;
s8: real-time prediction and control of assembly precision based on measured data;
the three-dimensional reconstruction process of the assembly characteristics comprises the following specific steps:
and obtaining the coordinate position of the assembly characteristic of the radiation unit in a world coordinate system by using the calibration result of the industrial camera and the image coordinate after the image characteristic is extracted, calculating the edge and the central point of the edge, the bottom boss and the central point of the bottom boss and the attitude deviation angle of the radiation unit, and obtaining the spatial pose information of the assembly characteristic of the radiation unit by adopting a spatial pose matrix transformation method.
2. The rapid assembly method of claim 1, wherein the radiation element assembly characteristic elements in S1 include: the geometrical feature area of the radiating element and its dimensional tolerance requirements.
3. The rapid assembly method according to claim 1, wherein a library of feature element matching templates is created in S2 and preset in the system.
4. The rapid assembly method according to claim 1, wherein the preprocessing of the assembly feature image in S3 is to remove noise of the image by filtering, and to correct and enhance the target recognition area associated with the assembly feature.
5. The rapid assembly method according to claim 1, wherein the specific process of assembly feature profile recognition is as follows:
the outline of a radiation unit in the digital image is in a high-brightness state, pixel points of edges are extracted based on gray level difference, and after approximate position information of characteristic edges of the radiation unit is obtained, a point group meeting requirements of gray level difference and polarity change is screened in the radiation unit through an algorithm; and fitting the point groups to form lines by using a least square method, namely accurately redrawing the contour line of the radiation unit and solving the position of the center point of the radiation unit.
6. The rapid assembly method according to claim 1, wherein the radiation elements grouped based on the manufacturing accuracy are classified into groups of large deviation, medium deviation, and small deviation.
7. The rapid assembly method of claim 1, wherein the solution of the matching arrangement of the radiating elements in S7 is performed by building a mathematical model of "constraint satisfaction problem" and performing a least square solution.
8. The rapid assembly method according to claim 1, wherein the assembly precision real-time prediction and control based on the measured data comprises the following specific processes:
quantitatively describing deviation information and deviation constraint information of the geometric features in the positions and the directions aiming at different types of deviation sources in the assembling process, and realizing qualitative description of topological relation between the deviation geometric features and the associated entities; describing the direction and range of deviation transmission through qualitative information, and describing the influence of the deviation on different transmission paths through quantitative information; and after the assembly is finished, analyzing the result, judging whether the accumulated deviation meets the requirement of the assembly precision, searching and positioning key factors influencing the deviation, and if the measured value of the assembly precision does not meet the precision requirement, disassembling and adjusting the radiation unit in the assembly.
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| CN112018508A (en) * | 2020-08-19 | 2020-12-01 | 上海一航凯迈光机电设备有限公司 | Intelligent arrangement and assembly method for feature numbers based on radiation units |
| CN112676815B (en) * | 2020-12-15 | 2022-03-15 | 北京无线电测量研究所 | Flexible automatic assembling production system and method for radiation unit |
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