CN120467240B - Contour degree detection device - Google Patents
Contour degree detection deviceInfo
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- CN120467240B CN120467240B CN202510954498.3A CN202510954498A CN120467240B CN 120467240 B CN120467240 B CN 120467240B CN 202510954498 A CN202510954498 A CN 202510954498A CN 120467240 B CN120467240 B CN 120467240B
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Abstract
本发明公开了一种轮廓度检测装置包括检测台、运动平台、升降驱动器、信号放大模组、测臂组件等，通过表面特征判定模组生成特征值，控制模组匹配检测模式，杠杆比例调节机构和信号放大模组实现机械和光学双重放大，光电探测器采集光斑位移计算轮廓度。方法包括表面特征判定、检测模式匹配、机械杠杆调节、光学系统校准等步骤，结合机器学习和动态坐标系补偿，实现高精度自适应检测。该装置解决了传统检测装置精度不足和适用性差的问题，适用于精密机械加工等领域的轮廓度检测。
The present invention discloses a contour detection device comprising a detection platform, a motion platform, a lifting actuator, a signal amplification module, and a measuring arm assembly. A surface feature determination module generates characteristic values, a control module matches the detection mode, a lever ratio adjustment mechanism and a signal amplification module achieve mechanical and optical dual amplification, and a photodetector collects light spot displacement to calculate contour. The method includes steps such as surface feature determination, detection mode matching, mechanical lever adjustment, and optical system calibration. Combined with machine learning and dynamic coordinate system compensation, high-precision adaptive detection is achieved. This device addresses the issues of insufficient accuracy and poor applicability of traditional detection devices and is suitable for contour detection in fields such as precision machining.
Description
Technical Field
The invention relates to the technical field of detection equipment, in particular to a contour degree detection device.
Background
In modern manufacturing industry, product surface profile detection is a key link for guaranteeing product quality, and is widely applied to the fields of precision machining, automobile part manufacturing, aerospace and the like. The traditional contact type measuring needle converts profile change into mechanical displacement signals through physical contact with the surface of a product and then converts the mechanical displacement signals into electric signals through a sensor for analysis, however, the technology has obvious limitations that firstly, high-precision detection is difficult to realize due to insufficient mechanical transmission clearance or sensor resolution, and secondly, when the traditional device faces products with different surface roughness or profile complexity (such as a precision mould and an aerospace component), the traditional device cannot flexibly adjust the detection precision, so that the high-precision detection requirement is not matched with the device range.
Therefore, it is necessary to provide a profile detection device to solve the above-mentioned problems in the prior art.
Disclosure of Invention
In order to achieve the above purpose, the invention provides a contour degree detection device, which comprises a detection platform and a motion platform arranged on the detection platform, wherein one side of the detection platform is provided with a lifting driver, the output end of the lifting driver is integrated with a signal amplification module, the outer side of the lifting driver is provided with a detection arm assembly and a lever proportion adjustment mechanism, and one side of the detection arm assembly, which is close to the motion platform, is provided with a detection needle;
the signal amplifying module comprises a first optical module and a second optical module;
The first optical module comprises three pairs of first concave mirrors which are longitudinally and symmetrically distributed and comprise a laser emitter;
The second optical module comprises five second concave mirrors which are arranged in a conjugated way, wherein the second concave mirrors in the middle are connected with the feedback end of the measuring arm assembly, and the two tail ends of the optical path are provided with photoelectric detectors for monitoring the positions of light spots;
The surface characteristic judging module is arranged on the detecting table and used for capturing a surface image of a product to be detected, acquiring surface characteristic data based on surface image processing, and generating a characteristic value based on the surface characteristic data, wherein the surface characteristic data comprises surface roughness, profile complexity and material hardness parameters;
The control module comprises a storage part and a processor, wherein the storage part pre-stores detection modes, and each detection mode corresponds to a specific characteristic value range and comprises lever proportion parameters, optical amplification factors and contact pressure thresholds;
The processor is used for receiving the characteristic value and matching the detection mode;
An error judging part for calculating the difference delta D between the profile tolerance predicted value and the actual measured value in real time, and triggering the self-adaptive adjustment module to recalibrate the optical module based on the difference delta D;
The machine coordinate system is established by the surface of the moving platform, the origin is positioned in the geometric center of the product, and the optical path calibration of the signal amplification module is performed based on the machine coordinate system, so that the laser transmitter and the middle second concave mirror are ensured to be initially coaxial;
the gesture detection module is integrated in the cylinder arm of the measuring arm assembly and is used for monitoring the deflection angle theta of the measuring needle in real time and transmitting the theta to the control module to correct the optical magnification;
The alarm drives the display device to pop up an alarm interface and pause the motion platform when the delta D exceeds the limit or the signal of the photoelectric detector is interrupted;
and the coordinate data output part updates the coordinate origin of the machine table coordinate system according to the displacement of the light-shielding shell of the signal amplification module when the lifting driver moves, so that the light path and the product surface are always orthogonal.
Further, the arm measuring assembly comprises a cylinder arm, wherein the cylinder arm is fixedly arranged on one side of the side face of the light-shielding shell, which faces the moving platform, and is communicated with the inside of the light-shielding shell, waist-shaped grooves are formed in two sides in the cylinder arm, and one waist-shaped groove is communicated with the outside;
the measuring rod is arranged in the cylindrical arm in a penetrating manner, a sleeve is sleeved on the rod body in a sliding manner, a rotating shaft is symmetrically arranged on the peripheral side of the sleeve in a rotating manner perpendicular to the axis of the sleeve, the rotating shaft is rotatably and slidably arranged in the kidney-shaped groove, the rotating shaft penetrating through one side of the kidney-shaped groove outside is outwards extended, the measuring needle is arranged at the bottom of the outer end of the measuring rod, and the second concave mirror is arranged at the inner end of the measuring rod;
The flexible supporting unit is vertically arranged at the bottom of the inner end of the measuring rod, and two ends of the flexible supporting unit are respectively connected with the measuring rod and the inner bottom wall of the cylinder arm;
The lever proportion adjusting mechanism is arranged outside one side of the kidney-shaped groove penetrating through the outside and is fixedly connected with the rotating shaft, and is used for adjusting the axial position of the sleeve so as to change the position of a rotating point of the measuring rod and further adjust the length proportion of the lever arm;
a window shade is arranged at one side end part of the cylinder arm, which faces the measuring needle.
Further, the lever proportion adjusting mechanism comprises a protective cover, wherein the protective cover is fixedly arranged outside one side of the kidney-shaped groove penetrating through the outside, a second telescopic rod is fixedly arranged at one end in the protective cover, a limiting sleeve is arranged at the end part of a piston rod of the second telescopic rod, and the limiting sleeve is coaxially sleeved on the rotating shaft.
Further, the lifting driver comprises a protective shell, wherein long grooves are longitudinally formed in the side face of the protective shell in a penetrating mode, and two groups of long grooves are horizontally arranged at intervals;
The screw rod is vertically arranged inside the protective shell and far away from one side of the long groove, a lifting seat is sleeved on the outer side of the screw rod, limiting shafts are arranged at two sides of the screw rod at parallel intervals, the limiting shafts penetrate through the lifting seat in a sliding mode and are fixedly connected with the inner wall of the protective shell, and one end of the screw rod penetrates through the protective shell and is connected with a driving device.
Further, the first optical module and the second optical module each include:
the L-shaped fixing plate is fixedly arranged on one side, close to the long groove, of the lifting seat, two groups of fixing seats are fixedly arranged on the side face of the L-shaped fixing plate at intervals along the extending direction of the L-shaped fixing plate, two groups of long shafts are arranged between the fixing seats at intervals, and a plurality of long plates are arranged on the long shafts in a sliding mode;
the X-shaped hinging rods are hinged to the inner side long plates along the arrangement direction of the long plates, and the end parts of the adjacent X-shaped hinging rods are sequentially hinged;
the V-shaped hinging rod is hinged to the long plate at the outermost end along the arrangement direction of the long plate and is hinged to the end part of the adjacent X-shaped hinging rod;
The vertical plates are fixedly arranged on the L-shaped fixing plates and are arranged beside the long shafts at intervals, one ends of the first telescopic rods are symmetrically and fixedly arranged on two sides of the vertical plates respectively, connecting plates are respectively arranged on the other ends of the first telescopic rods, and each connecting plate is connected with the end part of the long plate at the outermost end;
the long plate of the first optical module is towards one end of the long groove, the laser transmitter and the first concave mirror are installed at the middle most part, the long plate is fixedly connected with the long shaft and is in limit connection with the X-shaped hinging rod, the second concave mirror is installed at one end of the long plate of the second optical module towards the long groove except the middle most part and the two ends of the long plate, the long plate is fixedly connected with the long shaft at the middle most part, and the photoelectric detectors are installed at the two ends of the long plate and are used for receiving laser signals.
Further, in the first optical module, a limiting groove is formed in the side face of the long plate at the middle part, and the hinge shafts of the X-shaped hinge rods adjacent to the two middle parts extend into the limiting groove and are in sliding fit with the limiting groove.
Further, the upper end and the lower end of the light-shielding shell penetrate through the long groove through the transverse plate to be fixedly connected with the lifting seat, and the transverse plate is stuck with light-shielding filter cloth.
Further, the flexible supporting unit comprises a fixed cylinder which is fixedly sleeved at the inner end part of the measuring rod, a spring seat is arranged at the bottom of the fixed cylinder at the bottom of the cylinder arm, and a supporting spring is arranged between the spring seat and the fixed sleeve.
The invention also provides a contour degree detection method, which comprises the following steps:
s101, surface characteristic judgment, namely capturing a surface image of a product to be detected through a visual sensor, extracting parameters of surface roughness, contour complexity and material hardness based on image processing, generating a characteristic value, and triggering detection parameter reset when the change rate of the characteristic value is more than 10%;
s102, detecting pattern matching, namely pre-storing a plurality of detecting patterns, wherein each pattern corresponds to a specific characteristic value range and comprises lever proportion parameters, optical amplification factors and contact pressure threshold values;
S103, mechanical lever adjustment, namely driving a second telescopic rod through a lever proportion adjusting mechanism to drive a rotating shaft to slide along a kidney-shaped groove, and adjusting the rotating fulcrum position of a measuring rod, wherein the length proportion of lever arms is changed, and the adjusting range is 2:1 to 5:1;
s104, calibrating an optical system, namely synchronously adjusting a first telescopic rod of the signal amplifying module to change the distance between concave mirrors, ensuring that the first concave mirror is conjugated with a second concave mirror, compressing the distance between the concave mirrors according to a proportion based on a characteristic value, and dynamically adjusting the optical magnification;
s105, stylus contact control, namely initially dabbing the surface of a product by 0.1N, and confirming coordinates of a contact point by a gesture detection module;
S106, double amplification detection of the profile offset, namely amplifying the displacement of the measuring needle by a mechanical lever, namely amplifying the displacement of the measuring needle by a delta S m=Δd×βm, amplifying the displacement of the measuring needle by an optical lever, namely emitting a light beam by a laser emitter, generating an optical lever effect by reflection of a multistage concave mirror, wherein the light spot displacement delta L=delta S m×βo, and amplifying the total amplification rate beta total=βm×βo;
Wherein DeltaS m is the displacement after mechanical lever amplification, deltad is the actual physical displacement of the tip of the measuring needle, beta m is the mechanical lever amplification factor, deltaL is the final displacement of the light spot on the target surface of the photoelectric detector, beta o is the optical lever amplification factor, and beta total is the total amplification factor of the system;
S107, spot displacement analysis, namely acquiring spot displacement delta L by a photoelectric detector, and converting the spot displacement delta L into actual profile offset delta S=delta L/beta total, wherein the working mode of the photoelectric detector is switched according to a characteristic value, namely a spot scanning mode is carried out when the characteristic value is <4, and an area array imaging mode is carried out when the characteristic value is > 4;
Wherein, delta S is the actual profile offset;
S108, calculating and predicting the profile degree, namely comparing the delta S with a predicted profile curve output by a machine learning model, and triggering the optical module to recalibrate if the difference delta D between a predicted value and an actually measured value is three times continuously;
S109, real-time error suppression, namely monitoring the deflection angle theta of the measuring needle by the gesture detection module, and correcting the optical magnification factor according to a formula beta o'=βo/cos theta;
S110, compensating a dynamic coordinate system, namely establishing a machine coordinate system on the surface of the moving platform, wherein an origin is positioned at the geometric center of the product, and updating the origin of coordinates according to the displacement of the light-shielding shell when the lifting driver moves, so as to ensure that the light path is orthogonal with the surface of the product.
Compared with the prior art, the invention provides a contour degree detection device, which has the following beneficial effects:
The dual-optical module structure is adopted, the first optical module consists of a laser emitter and three pairs of first concave mirrors which are longitudinally and symmetrically distributed, the second optical module comprises five second concave mirrors which are arranged in a conjugated mode, the middle second concave mirrors are connected with the feedback end of the measuring arm assembly, and photoelectric detectors are arranged at the two ends of an optical path and used for monitoring positions of light spots. The laser is reflected by the multistage concave mirror to generate an optical lever amplification effect, and the micro displacement of the measuring needle is converted into remarkable light spot displacement. For example, in the initial state, the laser transmitter transmits laser at a parallax angle of 5 degrees, the reference light spot position is obtained after the laser is reflected by the first pair of concave mirrors, the parallax angle is increased to 20 degrees after the measuring needle contacts the product, the light spot displacement is amplified after the laser is reflected by the third-stage concave mirrors, the light spot displacement is accurately collected by the photoelectric detector, and then the laser is amplified by combining with a mechanical lever, so that the total amplification rate can be up to the product of the amplification factor of the mechanical lever and the optical amplification factor, and the detection precision is greatly improved.
The lever proportion adjusting mechanism is used for realizing dynamic adjustment of mechanical magnification, and enhancing applicability of the device, wherein the lever proportion adjusting mechanism drives the rotating shaft to slide along the kidney-shaped groove by driving the second telescopic rod, and adjusts the rotating fulcrum position of the measuring rod, so that the length proportion of the lever arm is changed, and the adjusting range is 2:1 to 5:1. When facing products with different surface roughness, contour complexity and material hardness, the lever proportion can be dynamically adjusted according to the characteristic value generated by the surface characteristic judging module. For example, when the characteristic value is large (the harder the surface is to detect), the short arm proportion is increased to improve the mechanical magnification and improve the detection precision, and when the characteristic value is small, the magnification is appropriately reduced to adapt to the simpler surface.
The self-adaptive detection mode matching is combined with machine learning to realize intelligent optimization of detection parameters, wherein a control module pre-stores a plurality of detection modes, and each mode corresponds to a specific characteristic value range and comprises lever proportion parameters, optical amplification factors and contact pressure thresholds. After the surface characteristic judging module extracts the product surface roughness, the contour complexity and the material hardness parameters to generate characteristic values, the processor automatically matches the optimal detection mode and calls the machine learning model to recommend initial parameters. For example, the system automatically increases the optical magnification and adjusts the contact pressure when the eigenvalue is >5, and triggers a detection parameter reset when the eigenvalue change rate is > 10%. The machine learning model is trained through historical data, a predicted contour curve can be output according to the characteristic value and the initial contour degree, and detection parameters are optimized after the predicted contour curve is compared with the actual measurement value. The self-adaptive mechanism realizes the intellectualization of the detection process, does not need to manually and frequently adjust parameters, reduces human errors, can quickly find an optimal detection scheme especially when facing complex curved surfaces or products with large material differences, improves the reliability and efficiency of detection, and simultaneously continuously improves the detection precision and adaptability by continuously learning historical data.
The dynamic coordinate system compensation and light path calibration mechanism ensures the stability and accuracy of the detection process, namely, a machine table coordinate system is established on the surface of the motion platform, the origin is positioned at the geometric center of the product, and when the lifting driver moves, the origin of coordinates is updated according to the displacement of the light-shielding shell, so that the light path and the surface of the product are always orthogonal. The optical path calibration of the signal amplification module is executed based on a machine coordinate system, initial coaxiality of the laser transmitter and the middle second concave mirror is ensured through a limit groove and other structures, and in the detection process, if the predicted value and the measured value are differentiated three times continuously, the optical module is triggered to recalibrate. For example, when products with different height specifications are detected, the lifting seat drives the measuring arm assembly to move, the origin of the coordinate system is dynamically updated, the light path deviation caused by position change is avoided, in the detection process, the difference between the light spot displacement and the predicted value is monitored in real time, the light path is calibrated in time, and the accuracy of the detection result is ensured.
The real-time error suppression and multiple protection design ensures the reliability of the detection process, namely, the gesture detection module monitors the deflection angle of the measuring needle in real time, corrects the optical magnification factor according to a formula, detects pressure fluctuation by the micro force sensor, reduces the speed of the moving platform when the pressure fluctuation exceeds a preset value, and the alarm pauses the moving platform and alarms when the differential overrun or the signal of the photoelectric detector is interrupted. In addition, structures such as a light shielding shell, a light shielding filter cloth, a light shielding curtain and the like isolate external stray light, and the flexible supporting unit provides stable detection pressure. For example, when the measuring needle deflects, the system immediately corrects the optical magnification according to the deflection angle to avoid detection errors caused by angle deviation, the pressure fluctuation is over-limited to slow down, the damage of the measuring needle or the abnormality of detection data caused by surface mutation is prevented, the stray light isolation design avoids the interference of ambient light on a light path, and the accurate signal acquisition of the photoelectric detector is ensured.
Drawings
FIG. 1 is a schematic diagram of the overall structure of a profile tolerance detection device;
FIG. 2 is a schematic diagram of a cross-sectional structure of a lift driver of a profile tolerance detection device;
FIG. 3 is a schematic diagram of a first optical module structure of a profile tolerance detection device;
FIG. 4 is a schematic diagram of a second optical module structure of the profile tolerance detecting device;
FIG. 5 is a schematic top cross-sectional view of a profile control device arm assembly;
FIG. 6 is a schematic view of a light path reflection structure of a profile tolerance detection device;
The device comprises a detection table, a lifting driver, a signal amplifying module, a 4-measuring arm assembly, a 5-lever proportion adjusting mechanism, a 6-moving platform, a 7-display device, an 8-protecting shell, a 9-long groove, a 10-lead screw, an 11-lifting seat, a 12-limiting shaft, a 13-L-shaped fixing plate, a 14-fixing seat, a 15-long shaft, a 16-long plate, a 17-laser emitter, a 18-first concave mirror, a 19-X-shaped hinging rod, a 20-V-shaped hinging rod, a 21-vertical plate, a 22-first telescopic rod, a 23-connecting plate, a 24-limiting groove, a 25-second concave mirror, a 26-photoelectric detector, a 27-light shielding shell, a 28-transverse plate, a 29-light shielding filter cloth, a 30-barrel arm, a 31-measuring rod, a 32-sleeve, a 33-rotating shaft, a 34-waist-shaped groove, a 35-fixing barrel, a 36-limiting sleeve, a 37-second telescopic rod, a 38-protecting cover, a 39-shielding curtain and a light shielding curtain.
Detailed Description
Referring to fig. 1-6, the invention provides a contour degree detection device, which comprises a detection table 1 and a motion platform 6 arranged on the detection table, wherein a lifting driver 2 and a display device 7 are respectively arranged at two sides of the detection table 1, a signal amplification module 3 is integrated at the output end of the lifting driver 2, a detection arm assembly 4 is arranged at the outer side of the detection arm assembly and is provided with a lever proportion adjusting mechanism 5, a detection needle is arranged at one side of the detection arm assembly 4 close to the motion platform 6, and the signal amplification module 3 amplifies and detects the offset of the detection needle through an optical lever amplification principle. The surface characteristic judging module is arranged on the detecting table 1 and comprises a visual sensor and an image processing unit, wherein the visual sensor captures a surface image of a product to be detected, the image processing unit extracts surface roughness, contour complexity and material hardness parameters to generate characteristic values (the larger the characteristic value is, the harder the surface is detected), the control module comprises a storage part and a processor, the storage part pre-stores detecting modes, and each mode corresponds to a specific characteristic value range and comprises lever proportion parameters, optical magnification and contact pressure threshold values. The processor is used for receiving the characteristic value and matching the optimal detection mode, controlling the lever proportion adjusting mechanism 5 to adjust the rotating point position of the measuring rod 31, changing the lever arm length proportion (for example, increasing the short arm proportion when the characteristic value is more than 5 to improve the precision), adjusting the first telescopic rod 22 of the signal amplifying module 3, synchronously changing the concave mirror distance to ensure the conjugation state of the first concave mirror 18 and the second concave mirror 25 (every time the characteristic value is increased by 1, the concave mirror distance is reduced by 2 percent), and setting the contact pressure of the measuring needle based on the characteristic value (for example, the pressure is increased by 15 percent when the characteristic value is more than 7 to overcome the surface hardness).
An error determination unit calculates a difference DeltaD between the profile predictive value and the actual measurement value in real time. And if the difference delta D exceeds the threshold value three times in succession, triggering the self-adaptive adjustment module to recalibrate the optical module.
The machine learning model is stored in the storage part and is generated by training historical profile data, the machine learning model inputs characteristic values and initial profile and outputs a predicted profile curve, and the control module compares the predicted curve with an actual measured curve to optimize detection parameters.
The machine coordinate system is set on the surface of the motion platform 6, and the origin is positioned in the geometric center of the product. The optical path calibration of the signal amplification module 3 is performed based on the machine coordinate system, ensuring that the laser transmitter 17 is initially coaxial with the central second concave mirror 25.
The gesture detection module is integrated in the cylinder arm 30 of the measuring arm assembly 4, comprises a macro camera for monitoring the deflection angle theta of the measuring needle in real time, and transmits the theta to the control module for correcting the optical magnification.
The storage part is used for recording the characteristic value, the differential value delta D and the corresponding detection parameter combination, and generating learning information for model iteration.
The alarm is used for driving the display device 7 to pop up the alarm interface and pause the motion platform 6 when the difference value delta D exceeds the limit or the signal of the photoelectric detector 26 is interrupted.
And the coordinate data output part updates the coordinate origin of the machine coordinate system according to the displacement of the light-shielding shell 27 of the signal amplifying module 3 when the lifting driver 2 moves, so as to ensure that the light path is always orthogonal with the surface of the product.
The signal amplifying module 3 comprises a first optical module and a second optical module, wherein the first optical module comprises a laser emitter 17 and three pairs of first concave mirrors 18 which are longitudinally and symmetrically distributed;
The second optical module comprises five second concave mirrors 25 which are arranged in a conjugated way, the second concave mirror 25in the middle is connected with the feedback end of the measuring arm assembly 4, photoelectric detectors 26 are arranged at the two ends of the optical path and used for monitoring the positions of light spots, the first telescopic rod 22 of the signal amplifying module 3 is adjusted, the distance between the concave mirrors is synchronously changed, and the conjugated state of the first concave mirror 18 and the second concave mirror 25 is ensured.
The first optical module and the second optical module each include:
The L-shaped fixing plate 13 is fixedly arranged on one side, close to the long groove 9, of the lifting seat 11, two groups of fixing seats 14 are fixedly arranged on the side surface of the L-shaped fixing plate 13 at intervals along the extending direction of the L-shaped fixing plate, two groups of long shafts 15 are arranged between the fixing seats 14 at intervals, and a plurality of long plates 16 are arranged on the long shafts 15 in a sliding mode;
an X-shaped hinge rod 19 hinged to each inner side of the long plate 16 along the arrangement direction of the long plate 16, and the ends of adjacent X-shaped hinge rods 19 are hinged in sequence;
A V-shaped hinge rod 20 hinged to the outermost long plate 16 along the arrangement direction of the long plate 16 and hinged to the end of the adjacent X-shaped hinge rod 19;
The vertical plates 21 are fixedly arranged on the L-shaped fixing plates 13 and are arranged beside the long shafts 15 at intervals, one ends of the first telescopic rods 22 are symmetrically and fixedly arranged on two sides of the vertical plates 21 respectively, connecting plates 23 are respectively arranged on the other ends of the first telescopic rods 22, and each connecting plate 23 is respectively connected with the end part of the long plate 16 at the outermost end;
The long plate 16 of the first optical module is provided with the laser emitter 17 and the first concave mirror 18 towards one end of the long groove 9, the long plate 16 at the middle part is fixedly connected with the long shaft 15 and is in limit connection with the X-shaped hinging rod 19, the long plate 16 of the second optical module is provided with the second concave mirror 25 towards one end of the long groove 9 except the middle part and two ends of the long plate 16, the long plate 16 at the middle part is fixedly connected with the long shaft 15, and the ends of the long plate 16 at the two ends are provided with the photoelectric detector 26 for receiving laser signals.
In the first optical module, a limiting groove 24 is formed in the side surface of the long plate 16 at the middle part, and the hinge shafts of the two adjacent X-shaped hinge rods 19 at the middle part extend into the limiting groove 24 and are in sliding fit with the limiting groove 24.
In the above, the laser emitter 17 is controlled to emit laser at an initial position (the parallax angle is 5 °), the reference light spot position P1 is obtained by the photodetector 26 after being reflected by the first pair of concave mirrors, and the laser parallax angle is increased to 20 ° after the measuring needle contacts the product, and the amplified light spot position P2 is generated after being reflected by the third-stage concave mirrors. Based on a machine learning model, P1 is taken as input to predict high-precision contour offset, and the high-precision contour offset is compared with P2. If the difference exceeds the threshold, the predicted value is used to cover P2 to calibrate the optical path. When the product is replaced, the first telescopic rod 22 is driven to adjust the pitch angle of the concave mirror according to the reference P1 of the first measuring part, so that the light path is aligned with the normal line of the surface of the new product.
Based on the above description, in some embodiments, the reference spot position P1 is obtained, the coordinate data output unit translates the machine coordinate system according to the reference spot position P1 to compensate for the mechanical assembly error, the amplified spot position P2 is obtained, and the motion control unit generates the robot motion trajectory correction amount according to the obtained amplified spot position P2 to drive the motion platform 6 to adjust the product pose. The setting and changing part stores an inverse proportion curve, and when the amplification factor beta of the signal amplification module 3 is increased, the allowable contour degree error threshold value delta D max is widened according to the proportion of delta D max =5/beta mm, so that oversensitive false alarm is avoided. The storage part records the characteristic value, the beta value, the delta D value and the actual contour error E detected each time, and generates a data set for training the model after learning, and the model parameters are updated every 100 times of detection.
In the application, interaction can be performed through a user interface on the display device 7, a user manually drags the 3D model to set the origin of the machine coordinate system, and clicking the alarm icon can play back the light spot displacement map with the difference delta D exceeding the limit.
Real-time error proportion calculation the error determination part calculates the accuracy according to the formula R= (N low/Ntotal) x 100% (N low is DeltaD < threshold number of times, N total is the total detection point). When R <90%, the adaptive adjustment module is triggered to recalibrate the system.
The processor runs independently in three units, the characteristic value is calculated and matched with the mode, the light spot displacement delta L is converted into the profile delta S, and the machine learning model is predicted and compared with the real-time data.
The X-shaped hinging rod 19 and the V-shaped hinging rod 20 are linked to control the distance between the long plates 16. Every time the characteristic value is increased by 1, the angle of the hinging rod is reduced by 0.5 degrees, and the distance between concave mirrors is compressed to improve the magnification.
The photo detector 26 detects the light spot displacement Δl, and the control device calculates the actual offset Δs=Δl/β m（βm as the lever amplification ratio, and feeds back to the lever proportional adjustment mechanism 5 to optimize the value β m. The photodetector 26 is a two-dimensional position sensitive detector (2D-PSD) that can be switched to either a point scan mode (at eigenvalues H < 4) or an area array imaging mode (at eigenvalues H > 4) to accommodate surface complexity.
The limiting groove 24 is in sliding calibration, namely the hinge shaft of the middle X-shaped hinge rod 19 is embedded into the limiting groove 24, and when the second telescopic rod 37 moves, the hinge shaft slides along the groove, so that the laser emitter 17 and the middle second concave mirror 25 are ensured to be kept horizontally and coaxially constantly.
Further, the arm measurement assembly 4 comprises a cylindrical arm 30, wherein the cylindrical arm 30 is fixedly arranged on one side of the side face of the light-shielding shell 27, which faces the moving platform 6, and is communicated with the inside of the light-shielding shell 27, two sides in the cylindrical arm 30 are provided with waist-shaped grooves 34, and one side of the waist-shaped groove 34 is communicated with the outside;
The measuring rod 31 is arranged in the cylindrical arm 30 in a penetrating manner, a sleeve 32 is sleeved on the rod body of the measuring rod 31 in a sliding manner, a rotating shaft 33 is symmetrically arranged on the peripheral side of the sleeve 32 in a rotating manner perpendicular to the axis of the sleeve, the rotating shaft 33 is rotatably and slidably arranged in the kidney-shaped groove 34, the rotating shaft 33 penetrating through one side of the kidney-shaped groove 34 outside is arranged in an extending manner, the measuring needle is arranged at the bottom of the outer end of the measuring rod 31, and the second concave mirror 25 is arranged at the inner end of the measuring rod 31;
the flexible supporting unit is vertically arranged at the bottom of the inner end of the measuring rod 31, and two ends of the flexible supporting unit are respectively connected with the measuring rod 31 and the inner bottom wall of the cylinder arm 30;
the lever proportion adjusting mechanism 5 is mounted outside one side of the kidney-shaped groove 34 penetrating through the outside and is fixedly connected with the rotating shaft 33, and is used for adjusting the axial position of the sleeve 32 so as to change the rotating point position of the measuring rod 31 and further adjust the lever arm length proportion.
Specifically, the position of the sleeve 32 is limited by the lever proportion adjusting mechanism 5, so that the sleeve is deflected around the axes of the rotating shafts 33 at two sides, meanwhile, the flexible supporting unit provides detection pressure to detect the surface profile of a product, and when the measuring arm assembly 4 is accurately adjusted, the position of the rotating point of the measuring rod 31 is adjusted by the lever proportion adjusting mechanism 5, the length proportion of the lever arm is changed, and the detection accuracy is adjusted.
In addition, by embedding a micro force sensor into the root of the probe, the probe pressure fluctuation Δf is monitored in real time. If the pressure fluctuation Δf exceeds a preset value (indicating abrupt surface change), the motion platform 6 is triggered to slow down. The image processing unit updates the characteristic value every 0.5 seconds, and when the characteristic value change rate is >10%, the lever scale adjusting mechanism 5 automatically resets the rotation shaft 33 position.
A window shade 39 is mounted to one end of the arm 30 facing the stylus.
The rotating shaft 33 is controlled by double degrees of freedom, namely, the rotating shaft 33 realizes radial rotation (+ -30 DEG) and axial sliding (the stroke is 20 mm) in the kidney-shaped groove 34. The second telescopic rod 37 precisely controls the three-dimensional pose of the rotating shaft 33 through the limiting sleeve 36.
Further, the lever ratio adjusting mechanism 5 includes:
The protection casing 38, the protection casing 38 is fixed and is established outside link up outside kidney slot 34 one side, the interior one end of protection casing 38 has set firmly second telescopic link 37, stop collar 36 is installed to the piston rod tip of second telescopic link 37, stop collar 36 coaxial sleeve is in pivot 33 is last.
It can be understood that the second telescopic rod 37 stretches and contracts to drive the limiting sleeve 36 to move, so that the rotating shaft 33 and the sleeve 32 move along the length direction of the kidney-shaped groove 34, the rotating point of the measuring rod 31 is adjusted (the measuring rod 31 corresponds to a lever, the tail end of the measuring rod 31 corresponds to a feedback end), and the detecting precision is adjusted by changing the arm length proportion of the lever.
Further, the flexible supporting unit comprises a fixed cylinder 35 fixedly sleeved at the inner end part of the measuring rod 31, a spring seat is arranged at the bottom of the fixed cylinder 35 and positioned at the bottom of the cylinder arm 30, and a supporting spring is arranged between the spring seat and the fixed sleeve.
Specifically, the stylus is provided with a detection pressure by a support spring.
In this embodiment, the lifting driver 2 includes:
the protective shell 8 is provided with long grooves 9 in a penetrating manner along the longitudinal direction on the side surface of the protective shell 8, and the long grooves 9 are horizontally distributed at intervals to form two groups;
The lead screw 10 is vertically arranged in the protecting shell 8 and far away from one side of the long groove 9, a lifting seat 11 is sleeved on the outer side of the lead screw 10 in a threaded manner, limiting shafts 12 are fixedly arranged on two sides of the lead screw 10 at intervals in parallel, the limiting shafts 12 penetrate through the lifting seat 11 in a sliding manner and are fixedly connected with the inner wall of the protecting shell 8, one end of the lead screw 10 penetrates through the protecting shell 8 and is connected with a driving device, bearings are sleeved at two ends of the lead screw 10 and fixedly connected with the protecting shell 8 through bearing seats, and the driving device is a servo motor.
Specifically, the servo motor drives the screw rod 10 to rotate, under the limiting action of the limiting shaft 12, the screw rod 10 drives the lifting seat 11 to lift, and meanwhile, the measuring arm assembly 4 is driven to move, so that products with different height specifications are detected. When in operation, the control module adjusts the parallax angle (B is the base line length and H is the characteristic value) according to the formula phi=arcsin (B/H), and when the lifting seat 11 rises by 10mm, the first telescopic rod 22 increases the phi angle by 2 degrees;
A magneto-rheological damper is arranged between the lead screw 10 and the protective shell 8, wherein the absolute value encoder is connected with the control module through a CAN bus, and a micro air pump pipeline extends to the upper part of the concave mirror.
In some embodiments, the photodetectors 26 may be mounted on the upper and lower ends of the first optical module, or may be disposed on the upper or lower ends of the first and second optical modules, where the photodetectors 26 of each module are disposed in a staggered manner, and may be set by the user according to the number of the first concave mirrors 18 and the second concave mirrors 25.
In this embodiment, the upper and lower ends of the light-shielding shell 27 pass through the elongated slot 9 and are fixedly connected with the lifting seat 11 through the transverse plate 28, the transverse plate 28 is respectively stuck with a light-shielding filter cloth 29, the light-shielding filter cloth 29 comprises black elastic cloth, the transverse plate 28 is integrated with a micro air pump, and when the attenuation of the photoelectric signal is more than 30%, 0.3MPa air flow is sprayed to clean the concave mirror.
It can be appreciated that when the lifting seat 11 of the lifting driver 2 is lifted, the light shielding shell 27 can be synchronously driven to move, and the light shielding filter cloth 29 can isolate stray light of an external environment and avoid interference to the internal optical detection module.
The invention also provides a contour degree detection method, which comprises the following steps:
S101, surface characteristic judgment, namely capturing a surface image of a product to be detected through a visual sensor, extracting parameters of surface roughness, contour complexity and material hardness based on image processing, generating a characteristic value, and triggering detection parameter reset when the change rate of the characteristic value is more than 10%.
S102, detecting pattern matching, namely pre-storing a plurality of detecting patterns, wherein each pattern corresponds to a specific characteristic value range and comprises a lever proportion parameter beta m, an optical amplification factor beta o and a contact pressure threshold value, matching the optimal detecting pattern according to the characteristic values, and calling a machine learning model to recommend initial parameters.
S103, mechanical lever adjustment, namely driving a second telescopic rod 37 through a lever proportion adjusting mechanism 5 to drive a rotating shaft 33 to slide along a kidney-shaped groove 34 to adjust the rotating fulcrum position of a measuring rod 31, and changing the lever arm length proportion (beta m = long arm/short arm) in an adjusting range of 2:1 to 5:1.
S104, calibrating an optical system, namely synchronously adjusting a first telescopic rod 22 of the signal amplifying module 3, changing the distance between concave mirrors, ensuring that the first concave mirror 18 is conjugated with a second concave mirror 25, dynamically adjusting the optical magnification beta o to be 10-100, and compressing the distance between the concave mirrors in proportion based on a characteristic value (every time the characteristic value increases by 1 and the distance decreases by 2%).
S105, stylus contact control, namely initially touching the surface of a product by 0.1N, confirming the coordinates of a contact point by a gesture detection module, and increasing the pressure to a target pressure according to a characteristic value (the pressure is increased by 15% when the characteristic value is more than 7).
S106, double amplification detection of the profile offset, namely amplifying the probe displacement by a mechanical lever, namely amplifying the probe displacement by a delta S m=Δd×βm, amplifying the probe displacement by an optical lever, namely emitting a light beam by a laser emitter 17, generating an optical lever effect by reflection of a multistage concave mirror, and generating the light spot displacement delta L=delta S m×βo, wherein the total amplification rate beta total=βm×βo;
wherein Δs m is the displacement after mechanical lever amplification, Δd is the actual physical displacement of the stylus tip, β m is the mechanical lever amplification, Δl is the final displacement of the light spot on the target surface of the photodetector 26, β o is the optical lever amplification, and β total is the total system amplification.
S107, spot displacement analysis, namely acquiring spot displacement delta L by the photoelectric detector 26, and converting the spot displacement delta L into actual contour offset delta S=delta L/beta total, wherein the working mode of the photoelectric detector 26 is switched according to the characteristic value, namely performing a spot scanning mode when the characteristic value is <4, and performing an area array imaging mode when the characteristic value is > 4;
Where Δs is the actual profile offset.
S108, calculating and predicting the profile degree, namely comparing the delta S with a predicted profile curve output by a machine learning model, and triggering the recalibration of the optical module if the difference delta D between the predicted value and the actual measured value is continuously three times > a threshold value.
S109, real-time error suppression, wherein the gesture detection module monitors the deflection angle theta of the measuring needle, corrects the optical magnification according to the formula beta o'=βo/cos theta, and when the micro force sensor detects that the pressure fluctuation delta F > is preset, the motion platform 6 is decelerated by 50%.
S110, compensating a dynamic coordinate system, namely establishing a machine coordinate system on the surface of the moving platform 6, wherein an origin is positioned at the geometric center of the product, and updating the origin of the coordinate according to the displacement of the light-shielding shell 27 when the lifting driver 2 moves, so as to ensure that the light path is orthogonal with the surface of the product.
The concave mirror spacing adjustment in S104 specifically comprises that the first telescopic rod 22 drives the X-shaped hinging rod 19 and the V-shaped hinging rod 20 to synchronously deflect to drive the distance between the long plates 16 to change, and the hinging rod angle is reduced by 0.5 degrees when the characteristic value is increased by 1.
The machine learning model optimization in S108 comprises the steps of recording characteristic values, beta total, delta D and actual contour errors E, and detecting and updating model parameters every 100 times;
Error ratio r= (N low/Ntotal)×100%（Nlow is Δd < threshold number), when R <90%, system recalibration is triggered.
The dynamic coordinate system compensation in S110 specifically comprises the steps of translating a machine coordinate system through a reference light spot position P1 initially to compensate mechanical assembly errors, and generating a pose correction amount of the moving platform 6 according to an amplified light spot position P2.
The foregoing description is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art, who is within the scope of the present invention, should make equivalent substitutions or modifications according to the technical solution of the present invention and the inventive concept thereof, and should be covered by the scope of the present invention.
Claims (9)
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| WO2018148471A2 (en) * | 2017-02-08 | 2018-08-16 | Essenlix Corporation | Optics, device, and system for assaying |
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| US20240085304A1 (en) * | 2021-01-15 | 2024-03-14 | Essenlix Corporation | Imaging Based Assay Accuracy Improvement Through Guided Training |
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