阅读说明：本技术 一种叶片型面机器人磨抛自适应加工系统及方法 (Blade profile grinding and polishing self-adaptive machining system and method through robot ) 是由 严思杰 杨泽源 徐小虎 庞国鑫 叶松涛 于 2019-10-29 设计创作，主要内容包括：本发明公开了一种叶片型面机器人砂带磨抛自适应加工系统,包括磨抛单元,包括工业机器人(6)及设于该工业机器人(6)作业半径范围之内的磨抛机(1),力控单元,包括设于所述工业机器人(6)末端的六维力传感器(4),控制单元,包括设于所述工业机器人(6)作业范围之外的机器人控制柜(7),测量反馈单元,包括线结构光在线测量装置(10),用于测量磨抛后叶片的型面点云数据并完成CAD模型重构。本发明还公开了一种加工方法。本发明的自适应加工系统,通过机器人和线结构光在线测量装置的协同作业,实现叶片“测量-加工-监控”一体化,极大提高了叶片加工质量与效率,有效控制叶片型面加工的一致性和成品率。(The invention discloses an abrasive belt grinding and polishing self-adaptive processing system of a blade profile robot, which comprises a grinding and polishing unit, a force control unit and a control unit, wherein the grinding and polishing unit comprises an industrial robot (6) and a grinding and polishing machine (1) arranged in the working radius range of the industrial robot (6), the force control unit comprises a six-dimensional force sensor (4) arranged at the tail end of the industrial robot (6), the control unit comprises a robot control cabinet (7) arranged outside the working range of the industrial robot (6), and the measurement feedback unit comprises a linear structure light online measurement device (10) for measuring profile point cloud data of a blade after grinding and polishing and finishing CAD model reconstruction. The invention also discloses a processing method. The self-adaptive processing system realizes the integration of blade measurement, processing and monitoring through the cooperative operation of the robot and the line structured light online measuring device, greatly improves the processing quality and efficiency of the blade, and effectively controls the consistency and yield of the processing of the blade profile.)

1. A blade profile robot abrasive belt grinding and polishing self-adaptive processing system is characterized by comprising:

the grinding and polishing unit comprises an industrial robot (6) and a grinding and polishing machine (1) arranged in the working radius range of the industrial robot (6), wherein the tail end of the industrial robot (6) clamps a blade and ensures that the profile of the blade is in contact with an abrasive belt of the grinding and polishing machine (1);

the force control unit comprises a six-dimensional force sensor (4) arranged at the tail end of the industrial robot (6), and the six-dimensional force sensor (4) is used for measuring the contact force between the blade and the abrasive belt in real time;

the control unit comprises a robot control cabinet (7) which is arranged outside the working range of the industrial robot (6), and the robot control cabinet (7) controls the industrial robot (6) to grind and polish the blades according to the planned path and the selected processing parameters according to the contact force;

and the measurement feedback unit comprises a linear structured light online measurement device (10) which is used for measuring the molded surface point cloud data of the polished blade, finishing CAD model reconstruction and feeding back the measurement result to the robot control cabinet (7) so as to realize the integration of measurement, processing and control of the blade.

2. A blade profile robot belt sanding and polishing adaptive machining system according to claim 1, characterized in that the control unit comprises a central console (8), the central console (8) being used to control the measurement feedback unit, the measurement information of the six-dimensional force sensor (4), the machining information of the sanding and polishing unit.

3. The blade profile robot abrasive belt grinding and polishing adaptive machining system according to claim 1, characterized in that the measurement feedback unit comprises a probe and a bracket (9) thereof, and the probe and the bracket (9) thereof are fixedly installed on the ground for calibrating a coordinate system of the blade.

4. The blade profile robot abrasive belt grinding and polishing adaptive machining system according to claim 1, characterized in that the grinding and polishing unit comprises a pneumatic clamp (3), and the pneumatic clamp (3) is arranged at the tail end of the six-dimensional force control sensor (4).

5. A blade profile robot belt sanding adaptive machining system according to any of claims 1-4, characterized in that the machining system comprises a feed unit comprising a blade trolley (5), the blade trolley (5) being arranged within reach of the industrial robot (6).

6. A blade profile robot belt sanding and polishing adaptive machining system according to any one of claims 1-4, characterized in that the sanding and polishing machine (1) is fixedly installed on the ground for realizing rough grinding, fine grinding, air inlet and outlet edge sanding and polishing of the blade.

7. Blade profile robot belt sanding adaptive machining system according to claim 2, characterized in that the sanding machine (1) consists of driving wheels, tension wheels, belt and contact wheels, is connected to a central console (8) via TCP/IP protocol, and controls the start-stop time and belt speed of the sanding machine (1) via the central console (8).

8. A blade profile robot abrasive belt grinding and polishing self-adaptive processing method is characterized by comprising the following steps:

s100: completing the calibration of a blade material vehicle (5), a grinding and polishing machine (1), a line structured light online measuring device (10) and a compressor blade (2);

s200: the automatic clamping of the compressor blade (2) by the industrial robot (6) is realized, and the robot moves to the line structure light online measuring device (10) to measure and obtain the profile point cloud data of the compressor blade (2), and transmits the profile point cloud data to the central control console (8);

s300: upper computer software in a central control console (8) firstly smooths, denoises and trims point cloud data, then performs rasterization and NURBS surface fitting to complete rapid reconstruction of a CAD model, compares the actual CAD model with a theoretical CAD model, extracts a region to be machined which needs to be ground and polished, extracts a grinding and polishing track of the region to be machined from the original grinding and polishing track, and transmits the grinding and polishing track to an industrial robot (6);

s400: automatically selecting the optimal processing parameters in a process database according to the parameters of the area to be processed, continuously optimizing and updating the process database by taking the processing parameters as historical data of the process database, and clamping the compressor blade (2) by an industrial robot (6) to polish the area with processing;

s500: after the primary grinding and polishing is finished, the industrial robot (6) clamps the compressor blade (2) and moves to the measuring position again, the measuring device measures the compressor blade (2) again, and whether the compressor blade (2) is qualified is detected.

9. The blade profile robot abrasive belt grinding and polishing adaptive machining method according to claim 8, characterized by further comprising the step of performing automatic clamping track planning, measurement track planning, grinding and polishing track planning and transition path track planning on the industrial robot (6) through off-line programming.

10. The blade profile robot abrasive belt grinding and polishing adaptive machining method according to claim 8, wherein the detection in S500 comprises the following steps:

s501: if the blade is qualified, the robot executes an instruction for placing the compressor blade (2) and clamps the next compressor blade (2);

s502: otherwise, the industrial robot (6) clamps the compressor blade (2) again and processes the compressor blade again aiming at the area to be processed.

Technical Field

The invention belongs to the technical field of blade robot grinding and polishing processing, and particularly relates to a blade profile robot abrasive belt grinding and polishing self-adaptive processing system and method.

Background

The blade of the aero-engine, as an exposed bead on an industrial crown, is a typical high-precision free-form surface part, needs to bear extremely harsh working environments such as high temperature and high pressure, and the precision of the surface profile of the blade directly influences the performance of the engine. Therefore, after the blades are subjected to numerical control machining, the blades need to be polished to form high-quality molded surfaces, the main domestic blade polishing modes are manual polishing and numerical control machine tool polishing at present, the problems of high labor intensity of workers, unstable blade forming quality and the like exist in the manual polishing, and the numerical control machine tool polishing precision is higher, but the price is high and the flexibility is poor.

The grinding and polishing of the robot blade has been developed for nearly ten years, but is limited by measuring means and precision requirements, and still has the problems of high manual participation, incapability of forming effective closed-loop feedback, difficulty in measuring and detecting the profile and the like. Patent document CN105290926A intelligent blade grinding flexible manufacturing system discloses a grinding system, which realizes the automation of blade grinding, but because a numerically controlled grinder is used for grinding, the system has the problem of insufficient flexibility, the blade can not be machined by clamping once, and the cost is high.

Disclosure of Invention

Aiming at the defects or improvement requirements of the prior art, the invention provides a blade profile robot abrasive belt grinding and polishing self-adaptive processing system and method, which realize the integration of blade measurement, processing and monitoring through the cooperative operation of a robot and a linear structured light online measuring device, greatly improve the processing quality and efficiency of the blade, and effectively control the processing consistency and yield of the blade profile.

To achieve the above object, according to one aspect of the present invention, there is provided a blade profile robot belt sanding adaptive machining system including:

the grinding and polishing unit comprises an industrial robot and a grinding and polishing machine arranged in the working radius range of the industrial robot, wherein the tail end of the industrial robot clamps the blade and ensures that the profile of the blade is in contact with an abrasive belt of the grinding and polishing machine;

the force control unit comprises a six-dimensional force sensor arranged at the tail end of the industrial robot, and the six-dimensional force sensor is used for measuring the contact force between the blade and the abrasive belt in real time;

the control unit comprises a robot control cabinet which is arranged outside the working range of the industrial robot, and the robot control cabinet controls the industrial robot to grind and polish the blade according to the contact force and the selected processing parameters;

and the measurement feedback unit comprises a linear structured light online measurement device and is used for measuring the molded surface point cloud data of the polished blade, finishing CAD model reconstruction and feeding back the measurement result to the robot control cabinet to realize the integration of measurement, processing and control of the blade.

Further, the control unit comprises a central control console, and the central control console is used for controlling the measurement feedback unit, the measurement information of the six-dimensional force sensor and the processing information of the grinding and polishing unit.

Further, the measurement feedback unit comprises a probe and a support thereof, and the probe and the support thereof are fixedly arranged on the ground and used for calibrating the coordinate system of the blade.

Further, the grinding and polishing unit comprises a pneumatic clamp, and the pneumatic clamp is arranged at the tail end of the six-dimensional force control sensor.

Further, the machining system comprises a feeding unit comprising a blade trolley, which is arranged within reach of the industrial robot.

Further, the grinding and polishing machine is fixedly arranged on the ground and used for realizing coarse grinding, fine grinding, air inlet and outlet edge grinding and polishing of the blades.

Furthermore, the grinding and polishing machine comprises a driving wheel, a tension wheel, an abrasive belt and a contact wheel, the driving wheel, the tension wheel, the abrasive belt and the contact wheel are connected to a central control operation console through a TCP/IP protocol, and the central control operation console is used for controlling the starting and stopping time and the abrasive belt speed of the grinding and polishing machine.

According to another aspect of the invention, a blade profile robot abrasive belt grinding and polishing adaptive machining method is provided, and comprises the following steps:

s100: completing the calibration of a blade material vehicle, a grinding and polishing machine, a linear structure light online measuring device and a compressor blade;

s200: the industrial robot can automatically clamp the compressor blade, move to the linear structure light online measuring device to measure and obtain the molded surface point cloud data of the compressor blade, and transmit the molded surface point cloud data to the central control console;

s300: the upper computer software in the central control console firstly carries out primary processing such as smoothing, denoising and trimming on point cloud data, then carries out rasterization and NURBS curved surface fitting to complete rapid reconstruction of a CAD model, compares the actual CAD model with a theoretical CAD model, extracts a region to be machined which needs to be ground and polished, extracts a grinding and polishing track of the region to be machined from the original grinding and polishing track, and transmits the grinding and polishing track to the industrial robot;

s400: automatically selecting the optimal processing parameters in a process database according to the parameters of the area to be processed, continuously optimizing and updating the process database by taking the processing parameters as historical data of the process database, and grinding the area to be processed by clamping the compressor blades by an industrial robot;

s500: after the primary grinding and polishing is finished, the industrial robot clamps the compressor blade and moves to the measuring position again, the measuring device measures the compressor blade again, and whether the compressor blade is qualified is detected.

Further, the method also comprises the steps of automatic clamping track planning, measurement track planning, grinding and polishing track planning and transition path track planning of the industrial robot through off-line programming.

Further, the detection in S includes the following steps:

s501: if the blade is qualified, the robot executes a command for placing the compressor blade and clamps the next compressor blade;

s502: otherwise, the industrial robot clamps the compressor blade again and processes the compressor blade again in the region to be processed.

In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:

1. the self-adaptive processing system realizes the integration of blade measurement, processing and monitoring through the cooperative operation of the robot and the line structured light online measuring device, greatly improves the processing quality and efficiency of the blade, and effectively controls the consistency and yield of the processing of the blade profile.

2. The self-adaptive processing system provided by the invention uses the robot to clamp the blades for grinding, has the characteristics of high automation degree, good flexibility and high processing efficiency, effectively improves the working environment for grinding and polishing the blades of the gas compressor, and obviously reduces the labor intensity of workers.

3. The self-adaptive processing system is suitable for flexible grinding and detection of blades of various specifications, and can well meet the processing requirements of blades of various specifications and on a large scale due to the high efficiency of grinding and detection of the system.

4. According to the self-adaptive processing system, the six-dimensional force control sensor is arranged at the tail end of the industrial robot, and the removal amount of materials is controlled by controlling the normal constant force contact of the blade and the grinding and polishing machine, so that the grinding and polishing uniformity and the product processing consistency are ensured.

Drawings

FIG. 1 is a schematic structural diagram of a blade profile robot abrasive belt grinding and polishing adaptive processing system according to an embodiment of the invention;

FIG. 2 is a schematic structural diagram of a polishing machine according to an embodiment of the present invention;

FIG. 3 is a schematic view of a blade material cart configuration in an embodiment of the present disclosure;

FIG. 4 is a schematic structural diagram of a robot control cabinet according to an embodiment of the present invention;

FIG. 5 is a schematic structural diagram of a console according to an embodiment of the present invention;

fig. 6 is a schematic structural diagram of a line structured light online measurement device in an embodiment of the present invention.

Fig. 7 is a flowchart of the operation of the abrasive belt grinding and polishing adaptive processing system of the blade profile robot according to the embodiment of the present invention.

In all the figures, the same reference numerals denote the same features, in particular: the device comprises a grinding and polishing machine 1, a gas compressor blade 2, a pneumatic clamp 3, a six-dimensional force control sensor 4, a blade material vehicle 5, an industrial robot 6, a robot control cabinet 7, a central control operation table 8, a probe 9, a probe support and a 10-line structured light online measuring device.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

Fig. 1 is a schematic structural diagram of a blade profile robot abrasive belt grinding and polishing adaptive processing system according to an embodiment of the invention. As shown in fig. 1, the abrasive belt grinding and polishing adaptive processing system of the blade profile robot in the embodiment of the invention comprises a grinding and polishing machine 1, a compressor blade 2, a pneumatic clamp 3, a six-dimensional force control sensor 4, a blade material vehicle 5, an industrial robot 6, a robot control cabinet 7, a central control operation table 8, a probe and a support thereof 9, and a linear structured light online measuring device 10. The grinding and polishing machine 1 is fixedly arranged on the ground and is responsible for rough grinding, fine grinding, air inlet and outlet edge grinding and polishing of the compressor blade 2. As shown in fig. 2, the polishing machine 1 is composed of a driving wheel, a tension wheel, a sanding belt and a contact wheel, and is connected to a central control console 8 through a TCP/IP protocol, and the start-stop time, the sanding belt speed and the like of the polishing machine 1 are controlled through the central control console 8. The pneumatic clamp 3 is arranged at the tail end of the six-dimensional force control sensor 4 and is mainly used for assisting the rapid clamping of the compressor blade 2. The six-dimensional force control sensor 4 is arranged at the tail end of the industrial robot 6, and constant force control and force information acquisition and feedback in the grinding and polishing process are achieved. The constant force control means that the blade is controlled to be in contact with the normal constant force of the grinding and polishing machine, so that the material removal amount is controlled, and the grinding and polishing uniformity and the product processing consistency are guaranteed.

In addition, the blade material vehicle 5 is arranged in the range which can be reached by the industrial robot 6, is mainly used for storing the blades 2 of the air compressor, and can enable the clamping of the blades to be more efficient and accurate. As shown in fig. 3, the blade material vehicle is provided with two blade storage areas, one of the two blade storage areas is used for storing the blades to be processed, and the other one is used for storing the processed blades, so that the clamping speed of the blades can be greatly increased. The industrial robot 6 is a main execution unit of the system and is responsible for driving the blades to measure, polish and the like according to a planned track.

Further, as shown in fig. 1, the robot control cabinet 7 is arranged on one side of the blade material vehicle 5 and used for generating a robot movement control instruction, as shown in fig. 4, the robot control cabinet is connected with the central control console through a TCP/IP protocol, and the industrial robot 6 can be controlled according to a path planned on line by the central control console to drive the compressor blade 2 to precisely polish according to the planned path.

As shown in fig. 5, the central control console 8 is connected with the grinding and polishing machine 1, the robot control cabinet 7 and the linear structured light online measuring device 10 through a TCP/IP protocol, so as to effectively monitor the measurement information, the detection information and the processing information in the system, and realize the integration of measurement, processing and monitoring of the blade. Firstly, an industrial robot 6 is controlled to be quickly positioned at a blade material vehicle 5 according to track planning before work to clamp a compressor blade 2 and drive the blade to a linear structured light online measuring device 10 for measurement, a CAD model is quickly reconstructed according to point cloud data obtained by measurement and is matched with a theoretical model, a to-be-machined area needing grinding and polishing is extracted, a grinding and polishing track of the to-be-machined area is extracted from an original grinding and polishing track, and the grinding and polishing track is transmitted to the industrial robot 6. And then, automatically selecting the optimal processing parameters in the process database according to the parameters of the area to be processed, and continuously optimizing and updating the process database by taking the processing parameters as historical data of the process database. And finally, controlling the industrial robot 6 to drive the compressor blade 2 to polish according to the planned path and the selected processing parameters through the robot control cabinet 7, after a complete polishing program is completed, clamping the compressor blade 2 by the industrial robot 6, moving the compressor blade 2 to the measuring position again, measuring the compressor blade 2 by the measuring device again, and detecting whether the compressor blade 2 is qualified. If the blade is qualified, the industrial robot 6 executes an instruction for placing the compressor blade 2 and clamps the next compressor blade 2; otherwise, the industrial robot 6 again clamps the compressor blade 2 for further processing in the region to be processed.

Further, as shown in fig. 6, the probe and its support 9 are fixedly mounted on the ground for calibration of the workpiece coordinate system. The line structured light online measuring device 10 is fixedly arranged on the ground and is mainly used for quickly and accurately measuring the compressor blade 2.

As shown in fig. 7, another embodiment of the present invention provides a blade profile robot belt sanding and polishing adaptive processing method, including the following steps:

step 1: before the system works, firstly, the calibration of the blade material vehicle 5, the grinding and polishing machine 1, the linear structure light online measuring device 10 and the compressor blade 2 is required to be completed. Automatic clamping track planning, measuring track planning, grinding and polishing track planning and transition path track planning are completed on the industrial robot 6 through off-line programming, the industrial robot 6 is automatically clamped on the compressor blade 2 and moves to the linear structure light online measuring device 10 to measure and obtain molded surface point cloud data of the compressor blade 2.

Step 2: when the system works, the central control operation table 8 controls the industrial robot 6 to clamp the compressor blade 2 according to the track plan before working and measure the compressor blade 2, and the linear structure light online measuring device 10 transmits the point cloud number of the molded surface of the compressor blade 2 to the central control operation table 8. The upper computer software in the central control console 8 firstly carries out primary processing such as smoothing, denoising and trimming on point cloud data, then carries out rasterization and NURBS surface fitting to complete rapid reconstruction of a CAD model, compares the actual CAD model with a theoretical CAD model, extracts a region to be machined which needs to be ground and polished, extracts a grinding and polishing track of the region to be machined from the original grinding and polishing track, and transmits the grinding and polishing track to the industrial robot 6.

And step 3: and automatically selecting the optimal processing parameters in the process database according to the parameters of the area to be processed, and continuously optimizing and updating the process database by taking the processing parameters as historical data of the process database. The industrial robot 6 clamps the compressor blade 2 and polishes the area to be processed, after the primary polishing is finished, the industrial robot 6 clamps the compressor blade 2 and moves to the measuring position again, the measuring device measures the compressor blade 2 again, and whether the compressor blade 2 is qualified is detected. If the position is qualified, the robot executes an instruction for placing the compressor blade 2 and clamps the next compressor blade 2; otherwise, the industrial robot 6 again clamps the compressor blade 2 for further processing in the region to be processed. The self-adaptive machining of the grinding and polishing of the compressor blade 2 is realized, the integration of measurement, machining and monitoring is formed, the machining quality and efficiency of the blade are greatly improved, and the machining consistency and yield of the blade profile are effectively controlled.

According to the technical scheme, the robot is used for clamping the blades for grinding, the blade grinding machine has the characteristics of high automation degree, good flexibility and high processing efficiency, the working environment for grinding and polishing the blades of the air compressor is effectively improved, and the labor intensity of workers is remarkably reduced. The whole system realizes the integration of blade measurement, processing and monitoring through the cooperative operation of the robot and the line structured light online measuring device, greatly improves the processing quality and efficiency of the blade, and effectively controls the consistency and yield of the processing of the blade profile. Meanwhile, the flexible grinding and detecting system is suitable for flexible grinding and detecting of blades of various specifications, and can well meet the processing requirements of blades of various specifications and on a large scale due to the high efficiency of grinding and detecting of the system.

It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.