技术领域Technical Field
本发明属于发动机试验装置技术领域，具体涉及一种发动机试验用对正方法及系统。The invention belongs to the technical field of engine test devices, and in particular relates to an alignment method and system for engine testing.
背景技术Background Art
在发动机技术的发展过程中，试验作为其中的关键环节，对设计方案的验证及改进有着重要的意义。以液氧煤油为介质的发动机，具备可重复使用的特性。因此可以通过在发动机使用前进行鉴定试车，一方面验证发动机整体的生产加工装配质量，另一方面可以对发动机的自身固有特性进行标定。因此发动机的试验量的提升对试验周期及试验系统的可靠性提出了更高的要求。因此在发动机与试验系统的对接环节提出了需多台设备在试验工位的流转要求。为了提高工作效率及可靠性，需使用能满足现场恶劣环境的自动对接系统，以适应高密度试验的需求。常规的设备及系统适用于常规的工业环境，无法满足试验台的复杂环境。In the development of engine technology, testing, as a key link, is of great significance to the verification and improvement of design solutions. Engines using liquid oxygen and kerosene as the medium have the characteristics of reusability. Therefore, by conducting an identification test before the engine is used, on the one hand, the overall production, processing and assembly quality of the engine can be verified, and on the other hand, the inherent characteristics of the engine can be calibrated. Therefore, the increase in the amount of engine testing has put forward higher requirements on the test cycle and the reliability of the test system. Therefore, in the docking link between the engine and the test system, it is required that multiple devices be circulated in the test station. In order to improve work efficiency and reliability, an automatic docking system that can meet the harsh environment on site is required to meet the needs of high-density testing. Conventional equipment and systems are suitable for conventional industrial environments and cannot meet the complex environment of the test bench.
区别于常规使用的自动对接技术，为了实现高精度的自动对接，一般采用对接位置下部导轨或者在地面设置多个校准定位点，由于试车台环境恶劣，下部操作空间为一个可移动结构，并且试验时需将下部空间移开。因此无法采用导轨式定位点的方式，一般采用自动转运对接平台（简称AGV车）携带试验发动机至对接位置完成对接安装工作。Different from the conventional automatic docking technology, in order to achieve high-precision automatic docking, a lower guide rail is generally used at the docking position or multiple calibration points are set on the ground. Due to the harsh environment of the test bench, the lower operating space is a movable structure, and the lower space needs to be moved away during the test. Therefore, the guide rail positioning point method cannot be used. Generally, an automatic transfer docking platform (AGV for short) is used to carry the test engine to the docking position to complete the docking installation work.
然而自动转运对接平台采用麦克纳母轮的驱动方式，该方式驱动简单技术成熟，但是由于其采用的是摩擦传动，对地面的摩擦系数敏感，使用常规的自动对接方法由于每次摩擦力的变化，其自动对接过程长，不易实现高效率高精度对接。同时，自动转运对接平台带动试验发动机移动到试车台支架下方后，操作人员通过肉眼判断各安装点的位置进行人工定位，由于肉眼判断误差较大，需要多次对位置进行修正后才能完成最终的对接安装工作，因此其在定位时相对误差大、定位精度低，不易实现高精度的定位，大大降低了安装效率。However, the automatic transfer docking platform adopts the driving method of McNabb's mother wheel. This driving method is simple and mature in technology. However, since it adopts friction transmission, it is sensitive to the friction coefficient of the ground. When using the conventional automatic docking method, due to the change of friction force each time, its automatic docking process is long, and it is not easy to achieve high-efficiency and high-precision docking. At the same time, after the automatic transfer docking platform drives the test engine to move to the bottom of the test bench bracket, the operator manually locates the position of each installation point by visually judging the position. Due to the large error in visual judgment, the position needs to be corrected many times before the final docking installation work can be completed. Therefore, the relative error is large during positioning, the positioning accuracy is low, and it is not easy to achieve high-precision positioning, which greatly reduces the installation efficiency.
发明内容Summary of the invention
为了解决上述问题，本发明提供了一种发动机试验用对正方法。本发明通过AGV车转运发动机，人工以遥控器方式操作AGV车，将发动机由试验准备间转运至试车间用时约22分钟，采用自动导航方式将发动机由试验准备间转运至试车间用时约9.5分钟，效率提升超过50%。通过位姿测量单元、数据处理单元及位姿调整单元实时测量解算发动机支架法兰孔与试车台支架法兰孔相对位姿，指导转运对接平台水平运动与调姿机构运动，测量与调姿循环多次直至发动机支架与试车台支架法兰孔对齐，调姿机构垂直举升发动机，至两法兰对接面留有10mm间隙时，结束整个自动引导对接过程，对正系统将向MES系统上报对接完毕，并将主要参数（对接时间）进行上报。自动对接结束后拆下测量工装，人工安装螺钉并拧紧螺母，转运对接平台运行至指定位置，等待发动机试车试验。In order to solve the above problems, the present invention provides an alignment method for engine testing. The present invention uses an AGV vehicle to transport the engine. The AGV vehicle is manually operated by a remote control. It takes about 22 minutes to transport the engine from the test preparation room to the test workshop. It takes about 9.5 minutes to transport the engine from the test preparation room to the test workshop by automatic navigation, and the efficiency is improved by more than 50%. The relative posture of the flange hole of the engine bracket and the flange hole of the test bench bracket is measured and solved in real time by the posture measurement unit, the data processing unit and the posture adjustment unit, and the horizontal movement of the transfer docking platform and the movement of the posture adjustment mechanism are guided. The measurement and posture adjustment cycle is repeated many times until the flange hole of the engine bracket is aligned with the flange hole of the test bench bracket. The posture adjustment mechanism lifts the engine vertically until there is a 10mm gap between the two flange docking surfaces. The entire automatic guided docking process is ended, and the alignment system will report to the MES system that the docking is completed, and the main parameters (docking time) will be reported. After the automatic docking is completed, the measuring tooling is removed, the screws are manually installed and the nuts are tightened, and the transfer docking platform runs to the specified position, waiting for the engine test.
为了实现上述目的，本发明提供如下技术方案：In order to achieve the above object, the present invention provides the following technical solutions:
一种发动机试验用对正方法，对正时自动转运对接平台携带发动机支架及发动机支架上的试验发动机位于试车台支架下方，所述方法包括以下步骤：An alignment method for engine testing, wherein an automatic transfer docking platform carrying an engine bracket and a test engine on the engine bracket are located below a test bench bracket during alignment, and the method comprises the following steps:
获取发动机支架的法兰图像和试车台支架的法兰图像；Acquire a flange image of an engine bracket and a flange image of a test bench bracket;
识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，并提取多个法兰安装孔的圆心坐标值；求取发动机支架法兰安装孔的圆心坐标值与对应试车台支架法兰安装孔的圆心坐标值的差值，并将圆心坐标值的差值转换为脉冲值；Identify multiple flange mounting holes in the flange image of the engine bracket and the flange image of the test bench bracket, and extract the center coordinate values of the multiple flange mounting holes; calculate the difference between the center coordinate value of the flange mounting hole of the engine bracket and the center coordinate value of the corresponding flange mounting hole of the test bench bracket, and convert the difference in the center coordinate value into a pulse value;
根据脉冲值控制自动转运对接平台的移动方向，调节发动机支架的位置，使发动机支架的法兰与试车台支架的法兰的安装孔垂直对接。The moving direction of the automatic transfer docking platform is controlled according to the pulse value, and the position of the engine bracket is adjusted so that the flange of the engine bracket and the mounting hole of the flange of the test bench bracket are vertically docked.
优选地，通过两个双目相机分别获取发动机支架的法兰图像和试车台支架的法兰图像，两个所述双目相机分别设置在自动转运对接平台的两侧。Preferably, the flange image of the engine bracket and the flange image of the test bench bracket are respectively acquired by two binocular cameras, and the two binocular cameras are respectively arranged on both sides of the automatic transport docking platform.
优选地，所述识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，并提取多个法兰安装孔的圆心坐标值，具体为：Preferably, the identifying of the multiple flange mounting holes in the flange image of the engine bracket and the flange image of the test bench bracket, and extracting the center coordinate values of the multiple flange mounting holes, is specifically:
采用霍夫圆变换算法识别发动机支架的法兰图像和试车台支架的法兰图像中的多个圆形特征，并提取多个圆心坐标。The Hough circle transform algorithm is used to identify multiple circular features in the flange image of the engine bracket and the flange image of the test bench bracket, and to extract multiple circle center coordinates.
优选地，所述发动机支架法兰安装孔和对应试车台支架法兰安装孔内均设置有标志物，所述标志物在圆心处设置有标志点，上下成对安装的两个法兰安装孔内的标志点编号相同。Preferably, markers are provided in the engine bracket flange mounting hole and the corresponding test bench bracket flange mounting hole, and the markers are provided with marking points at the center of the circle, and the marking points in the two flange mounting holes installed in pairs up and down are numbered the same.
优选地，所述求取发动机支架法兰安装孔的圆心坐标值与对应试车台支架法兰安装孔的圆心坐标值的差值，具体为：在空间坐标系，求取上下成对安装的两个标志点编号相同的法兰安装孔在x轴、y轴和z轴三个方向的轴向偏差量和旋转偏差量。Preferably, the difference between the center coordinate value of the flange mounting hole of the engine bracket and the center coordinate value of the flange mounting hole of the corresponding test bench bracket is obtained by: in the spatial coordinate system, obtaining the axial deviation and rotational deviation of the two flange mounting holes with the same marking point number installed in pairs in the upper and lower directions of the x-axis, y-axis and z-axis.
优选地，所述将圆心坐标值的差值转换为脉冲值，具体为：确定单位坐标差值对应的单位脉冲数量，单位坐标差值对应的单位脉冲数量进行换算将圆心坐标值的差值转换为相应的脉冲值。Preferably, the conversion of the center coordinate value difference into a pulse value is specifically: determining the unit pulse number corresponding to the unit coordinate difference, and converting the unit pulse number corresponding to the unit coordinate difference to convert the center coordinate value difference into a corresponding pulse value.
优选地，在对安装孔图像进行处理之前，还包括对图像依次进行去噪、图像增强的预处理。Preferably, before processing the mounting hole image, the method further includes performing pre-processing of denoising and image enhancement on the image in sequence.
优选地，还包括在每一个标志点的四周设置畸变分析标准圆，利用畸变分析标准圆不同方向的直径变化为参考，对发动机支架的法兰图像和试车台支架的法兰图像进行修正，获取修正后的图像。Preferably, it also includes setting a distortion analysis standard circle around each marking point, using the diameter change of the distortion analysis standard circle in different directions as a reference, correcting the flange image of the engine bracket and the flange image of the test bench bracket, and obtaining the corrected image.
优选地，还包括在对正过程中获取自动转运对接平台的加速度值及四周力矩，通过自动转运对接平台的加速度及四周力矩对发动机支架与试车台支架的位置进行补偿，具体为：Preferably, the method further includes obtaining the acceleration value and the surrounding moment of the automatic transport docking platform during the alignment process, and compensating the positions of the engine bracket and the test bench bracket by the acceleration and the surrounding moment of the automatic transport docking platform, specifically:
计算当前发动机支架的法兰某个安装孔的位移量与实际位移量的差值，得到过冲量；Calculate the difference between the displacement of a mounting hole of the flange of the current engine bracket and the actual displacement to obtain the overshoot;
通过加速度值结合每次对接的过冲量进行对接预修正，其计算公式为：The docking pre-correction is performed by combining the acceleration value with the overshoot of each docking. The calculation formula is:
当修正度与1的差小于0.01时，采用第n项修正系数为最终的修正系数；When the difference between the correction degree and 1 is less than 0.01, the nth correction coefficient is used as the final correction coefficient;
通过四周力矩M结合每次对接的过冲量进行对接预修正，其计算公式为：The docking pre-correction is performed by combining the surrounding moment M with the overshoot of each docking. The calculation formula is:
当修正度与1的差小于0.01时，采用第n项修正系数为最终的修正系数。When the difference between the correction degree and 1 is less than 0.01, the nth correction coefficient is used as the final correction coefficient.
本发明还提供一种发动机试验用对正系统，包括以下步骤：The present invention also provides an alignment system for engine testing, comprising the following steps:
位姿测量单元，设置在自动转运对接平台上，用于获取发动机支架的法兰图像和试车台支架的法兰图像；A posture measurement unit is arranged on the automatic transfer docking platform and is used to obtain a flange image of the engine bracket and a flange image of the test bench bracket;
数据处理单元，用于识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，并提取多个法兰安装孔的圆心坐标值；求取发动机支架法兰安装孔的圆心坐标值与对应试车台支架法兰安装孔的圆心坐标值的差值，并将差值转换为脉冲值；A data processing unit is used to identify multiple flange mounting holes in the flange image of the engine bracket and the flange image of the test bench bracket, and extract the center coordinate values of the multiple flange mounting holes; calculate the difference between the center coordinate value of the flange mounting hole of the engine bracket and the center coordinate value of the flange mounting hole of the corresponding test bench bracket, and convert the difference into a pulse value;
位姿调整单元，用于根据脉冲值控制自动转运对接平台的移动方向，调节发动机支架的位置，使发动机支架的法兰与试车台支架的法兰的安装孔垂直对接。The posture adjustment unit is used to control the moving direction of the automatic transfer docking platform according to the pulse value, and adjust the position of the engine bracket so that the flange of the engine bracket and the mounting hole of the flange of the test bench bracket are vertically docked.
本发明提供的发动机试验用对正方法具有以下有益效果：The engine test alignment method provided by the present invention has the following beneficial effects:
该方法首先获取发动机支架的法兰图像和试车台支架的法兰图像，并识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，并提取多个法兰安装孔的圆心坐标值，为后续的位置调整做好基础。在此基础上，求取发动机支架法兰安装孔的圆心坐标值与对应试车台支架法兰安装孔的圆心坐标值的差值，并将圆心坐标值的差值转换为脉冲值，根据脉冲值控制自动转运对接平台的移动方向，调节发动机支架的位置，使发动机支架的法兰与试车台支架的法兰的安装孔垂直对接。通过自动寻找各支架的法兰安装孔，并根据各孔的坐标差来得到能精确控制位移的脉冲量，能够实现对自动转运对接平台位置的精确调整，进而达到发动机支架的法兰与试车台支架的法兰的精准对正，大大减小了整个对正过程的误差，提高了定位精度和安装效率。The method first obtains the flange image of the engine bracket and the flange image of the test bench bracket, identifies multiple flange mounting holes in the flange image of the engine bracket and the flange image of the test bench bracket, and extracts the center coordinate values of the multiple flange mounting holes, so as to lay a good foundation for the subsequent position adjustment. On this basis, the difference between the center coordinate value of the flange mounting hole of the engine bracket and the center coordinate value of the corresponding flange mounting hole of the test bench bracket is obtained, and the difference in the center coordinate value is converted into a pulse value, and the moving direction of the automatic transfer docking platform is controlled according to the pulse value, and the position of the engine bracket is adjusted so that the flange of the engine bracket and the flange mounting hole of the test bench bracket are vertically docked. By automatically searching for the flange mounting holes of each bracket and obtaining the pulse amount that can accurately control the displacement according to the coordinate difference of each hole, the position of the automatic transfer docking platform can be accurately adjusted, so as to achieve the precise alignment of the flange of the engine bracket and the flange of the test bench bracket, which greatly reduces the error of the entire alignment process and improves the positioning accuracy and installation efficiency.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
为了更清楚地说明本发明实施例及其设计方案，下面将对本实施例所需的附图作简单地介绍。下面描述中的附图仅仅是本发明的部分实施例，对于本领域普通技术人员来说，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the embodiment of the present invention and its design scheme, the following briefly introduces the drawings required for this embodiment. The drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.
图1为本发明实施例1的发动机试验用对正系统的结构示意图；FIG1 is a schematic structural diagram of an engine test alignment system according to Embodiment 1 of the present invention;
图2为自动转运对接平台与发动机支架的对接示意图；FIG2 is a schematic diagram of the docking between the automatic transfer docking platform and the engine bracket;
图3为测量工装结构图；Figure 3 is a structural diagram of the measuring tool;
图4为位姿测量单元安装示意图；Fig. 4 is a schematic diagram of the installation of the posture measurement unit;
图5为发动机试验用对正方法的控制界面图；FIG5 is a control interface diagram of an alignment method for engine testing;
图6为对接系统坐标系分布示意图。FIG6 is a schematic diagram of the coordinate system distribution of the docking system.
附图标记说明：Description of reference numerals:
自动转运对接平台1、发动机支架2、发动机3、试车台支架4、发动机支架法兰安装孔5、试车台支架法兰安装孔6、双目相机7、标志点8、引导对接控制面板9、相机保护支架10、监视相机11、发动机支架法兰测量工装12、试车台支架法兰测量工装13。Automatic transfer docking platform 1, engine bracket 2, engine 3, test bench bracket 4, engine bracket flange mounting hole 5, test bench bracket flange mounting hole 6, binocular camera 7, marking point 8, guide docking control panel 9, camera protection bracket 10, monitoring camera 11, engine bracket flange measuring tool 12, test bench bracket flange measuring tool 13.
具体实施方式DETAILED DESCRIPTION
为了使本领域技术人员更好的理解本发明的技术方案并能予以实施，下面结合附图和具体实施例对本发明进行详细说明。以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。In order to enable those skilled in the art to better understand the technical solution of the present invention and implement it, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and cannot be used to limit the scope of protection of the present invention.
在本发明的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明的技术方案和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the technical solutions of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.
此外，术语“第一”、“第二”等仅用于描述目的，而不能理解为指示或暗示相对重要性。在本发明的描述中，需要说明的是，除非另有明确的规定或限定，术语“相连”、“连接”应作广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体式连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以是通过中间媒介间接相连。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上，在此不再详述。In addition, the terms "first", "second", etc. are used for descriptive purposes only and are not to be understood as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless otherwise clearly specified or limited, the terms "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. In the description of the present invention, unless otherwise specified, "plurality" means two or more, which will not be described in detail here.
实施例1Example 1
在发动机安装完毕以后需进行发动机试验，现场为高温强振动环境，因此对于定位靶标，测量位置的设备的设置提出了相应的要求，这些设备必须在使用后撤离，或者本身的安装位置或自身结构可以适应高温强振动环境。本发明的一体化集成定位系统将能够自动对正转运对接平台，并通过设计结合角度畸变的定位标志点实现了小空间可快速布置的定位及标志点设计，可以很好地适应试验台现场复杂环境，大幅提升了对现场环境的适应性及定位精度，缩短了对接时间。After the engine is installed, it is necessary to conduct an engine test. The site is a high temperature and strong vibration environment. Therefore, corresponding requirements are put forward for the setting of the positioning target and the equipment for measuring the position. These devices must be evacuated after use, or their own installation position or structure can adapt to the high temperature and strong vibration environment. The integrated positioning system of the present invention will be able to automatically align the transport docking platform, and through the design of the positioning mark points combined with the angle distortion, the positioning and mark point design that can be quickly arranged in a small space is realized. It can adapt well to the complex environment of the test bench site, greatly improve the adaptability to the site environment and positioning accuracy, and shorten the docking time.
具体地，本发明首先提供了一种发动机试验用对正系统，如图1至图4所示，当发动机运输至试车台支架下部后开启自动对接系统，自动对接如图3所示的系统优化后的测量工装，包括发动机支架法兰测量工装12和试车台支架法兰测量工装13，具体如图1所示，该对正系统在现有发动机的自动转运对接平台1、发动机支架2及试车台支架4基础上实现，包括位姿测量单元、数据处理单元和位姿调整单元。Specifically, the present invention first provides an alignment system for engine testing, as shown in Figures 1 to 4. When the engine is transported to the lower part of the test bench bracket, the automatic docking system is turned on to automatically dock with the system-optimized measuring tool shown in Figure 3, including an engine bracket flange measuring tool 12 and a test bench bracket flange measuring tool 13. As shown in Figure 1, the alignment system is implemented on the basis of the existing engine automatic transport and docking platform 1, engine bracket 2 and test bench bracket 4, and includes a posture measurement unit, a data processing unit and a posture adjustment unit.
具体地，自动转运对接平台用于将发动机支架及携带的发动机3从准备间转运至试车台支架下方；位姿测量单元，设置在自动转运对接平台1上，用于获取发动机支架的法兰图像和试车台支架的法兰图像；数据处理单元，用于识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，并提取多个法兰安装孔的圆心坐标值；求取发动机支架法兰安装孔5的圆心坐标值与对应试车台支架法兰安装孔6的圆心坐标值的差值，并将差值转换为脉冲值；位姿调整单元，用于根据脉冲值控制自动转运对接平台1的移动方向，调节发动机支架2的位置，使发动机支架2的法兰与试车台支架4的法兰的安装孔垂直对接。Specifically, the automatic transfer and docking platform is used to transfer the engine bracket and the carried engine 3 from the preparation room to the bottom of the test bench bracket; the posture measurement unit is arranged on the automatic transfer and docking platform 1, and is used to obtain the flange image of the engine bracket and the flange image of the test bench bracket; the data processing unit is used to identify the flange image of the engine bracket and the multiple flange mounting holes in the flange image of the test bench bracket, and extract the center coordinate values of the multiple flange mounting holes; calculate the difference between the center coordinate value of the flange mounting hole 5 of the engine bracket and the center coordinate value of the corresponding flange mounting hole 6 of the test bench bracket, and convert the difference into a pulse value; the posture adjustment unit is used to control the moving direction of the automatic transfer and docking platform 1 according to the pulse value, adjust the position of the engine bracket 2, and make the flange of the engine bracket 2 vertically dock with the flange mounting hole of the test bench bracket 4.
如图4所示，本实施例中位姿测量单元包括两个双目相机7，两个双目相机7分别设置在自动转运对接平台的顶部两侧，用于拍摄发动机支架和试车台支架法兰测量工装上的标志点位置图像。数据处理单元和位姿调整单元均设置在高性能计算机。As shown in Fig. 4, the posture measurement unit in this embodiment includes two binocular cameras 7, which are respectively arranged on both sides of the top of the automatic transfer docking platform to capture the position images of the marker points on the engine bracket and the test bench bracket flange measurement tooling. The data processing unit and the posture adjustment unit are both arranged on a high-performance computer.
各部分主要功能如下：The main functions of each part are as follows:
（1）自动转运对接平台（AGV车），自动转运对接平台用于将发动机从准备间转运至试车台支架下方，再通过视觉定位引导与调姿机构运动实现发动机与试车台支架的精准垂直对接。转运对接平台在室外依靠激光导航自主运行，在室内依靠遥控器控制运行。(1) Automatic transfer docking platform (AGV vehicle): The automatic transfer docking platform is used to transfer the engine from the preparation room to the bottom of the test bench bracket, and then achieve precise vertical docking of the engine and the test bench bracket through visual positioning guidance and posture adjustment mechanism movement. The transfer docking platform operates autonomously outdoors with laser navigation and operates indoors with remote control.
（2）位姿测量单元，即两个双目相机7，布置在自动转运对接平台的顶部两侧，设置在相机保护支架10上，实时测量发动机支架和试车台支架法兰测量工装上的标志点坐标值，间接解算法兰安装孔相对空间位置姿态，为转运对接平台移动和调姿机构运动提供依据。自动转运对接平台上还设置了监视相机11，辅助整个对正过程。(2) The position and posture measurement unit, namely two binocular cameras 7, are arranged on both sides of the top of the automatic transfer docking platform and are set on the camera protection bracket 10. They measure the coordinate values of the marking points on the engine bracket and the test bench bracket flange measurement tooling in real time, and indirectly solve the relative spatial position and posture of the flange mounting holes, providing a basis for the movement of the transfer docking platform and the movement of the posture adjustment mechanism. A monitoring camera 11 is also set on the automatic transfer docking platform to assist the entire alignment process.
（3）如图5所示，通讯控制系统，操作引导对接控制面板9上位机软件，启动自动引导对接流程，控制双目视觉相机进行拍摄，相机采集到的大量图片通过有线的方式传输至控制面板下方的高性能计算机中，通过数据处理单元和位姿调整单元完成数据处理与解算，测量结果可实时显示在控制面板上位机软件界面中，并且测量结果通过有线的方式实时发送给转运对接平台控制器，控制转运对接平台移动和调姿机构运动，完成发动机垂直精准装配对接。(3) As shown in FIG5 , the communication control system operates the upper computer software of the docking control panel 9 to start the automatic docking process and control the binocular vision camera to take pictures. A large number of pictures collected by the camera are transmitted to the high-performance computer under the control panel by wired means. The data processing and solving are completed by the data processing unit and the posture adjustment unit. The measurement results can be displayed in real time in the upper computer software interface of the control panel, and the measurement results are sent to the transfer docking platform controller in real time by wired means to control the movement of the transfer docking platform and the movement of the posture adjustment mechanism to complete the vertical precision assembly docking of the engine.
发动机转运导航与自动对接技术完成发动机的转运、对接安装工作，其中包括通过自动引导将AGV车（含发动机）运输到试验车间的地埋升降机上，地埋升降机托举AGV车到平板车高度，完成后AGV车自动引导到试车台支架下部，最后通过自动对接系统实现发动机机架与试车台转接架的位置关系自动对正。The engine transfer navigation and automatic docking technology completes the transfer, docking and installation of the engine, which includes automatically guiding the AGV vehicle (including the engine) to the underground elevator in the test workshop. The underground elevator lifts the AGV vehicle to the height of the flatbed truck. After completion, the AGV vehicle is automatically guided to the lower part of the test bench bracket. Finally, the automatic docking system is used to automatically align the position relationship between the engine frame and the test bench adapter frame.
发动机在AGV车上准备完毕后，手动将发动机机架与AGV车的四根立柱（靠锁链）连接，将平板运输车开至地埋升降机侧部，并确保其与地埋升降机的间隙处于10-20mm之间，并将地埋升降机与平板车之间连接板翻起，整个引导道路上的连接钢板放置在指定位置，做好发动机AGV车导航调度系统的准备，准备进入引导对接环节。After the engine is prepared on the AGV, manually connect the engine frame to the four columns of the AGV (by chains), drive the flatbed transport truck to the side of the underground elevator, and ensure that the gap between it and the underground elevator is between 10-20mm, and flip up the connecting plate between the underground elevator and the flatbed truck, place the connecting steel plate on the entire guide road in the designated position, prepare the navigation and dispatching system of the engine AGV, and prepare to enter the guidance docking link.
基于同一个发明构思，本发明还提供了一种发动机试验用对正方法，采用该方法进行对正之前，首先需要建立各坐标系，如图6所示，包括发动机支架坐标系、试车台支架坐标系和AGV车坐标系。Based on the same inventive concept, the present invention also provides an alignment method for engine testing. Before using this method for alignment, it is first necessary to establish various coordinate systems, as shown in FIG6 , including an engine bracket coordinate system, a test bench bracket coordinate system, and an AGV vehicle coordinate system.
该方法的实施包括以下步骤：The implementation of this method includes the following steps:
步骤1、开启对正系统，发动机AGV车导航调度系统工作正常，将AGV车调整至使用状态，确定相关各设备与调度系统连接正常，任务已下达到各相关设备，自动对接调度系统与MES系统连接正常；使用调度系统开启发动机AGV车导航调度系统。对正系统控制AGV按预定路线，使用激光引导系统将发动机自准备间工位引导运输至地埋升降机上部中间位置，到达位置后自动调度控制系统发出指令，地埋升降机升降至预定高度。地埋升降机升降到预定高度后，自动对接控制系统发出指令，AGV车按预定路线移动到平板车中部指定位置。AGV车到达预定位置后，试车台平板车运行，将AGV车及试验发动机3运输至试车台支架4下部。Step 1. Turn on the alignment system, the navigation and dispatching system of the engine AGV vehicle is working properly, adjust the AGV vehicle to the use state, confirm that the relevant equipment is connected to the dispatching system normally, the task has been assigned to each relevant equipment, and the automatic docking dispatching system is connected to the MES system normally; use the dispatching system to turn on the navigation and dispatching system of the engine AGV vehicle. The alignment system controls the AGV to follow the predetermined route, and uses the laser guidance system to guide the engine from the preparation room station to the middle position of the upper part of the underground elevator. After reaching the position, the automatic dispatching control system issues a command, and the underground elevator is lifted to the predetermined height. After the underground elevator is lifted to the predetermined height, the automatic docking control system issues a command, and the AGV vehicle moves to the designated position in the middle of the flatbed truck according to the predetermined route. After the AGV vehicle arrives at the predetermined position, the test bench flatbed truck starts to operate and transports the AGV vehicle and the test engine 3 to the lower part of the test bench bracket 4.
步骤2、获取发动机支架的法兰图像和试车台支架的法兰图像。具体地，本实施例中，通过两个双目相机7分别获取发动机支架的法兰图像和试车台支架的法兰图像。Step 2: Acquire the flange image of the engine bracket and the flange image of the test bench bracket. Specifically, in this embodiment, the flange image of the engine bracket and the flange image of the test bench bracket are acquired respectively by two binocular cameras 7 .
步骤3、对各法兰图像依次进行去噪、图像增强的预处理，以提高后续处理的效果。Step 3: Perform denoising and image enhancement preprocessing on each flange image in turn to improve the effect of subsequent processing.
步骤4、识别发动机支架的法兰图像和试车台支架的法兰图像中的多个法兰安装孔，基于建立的各坐标系，提取多个法兰安装孔的圆心坐标值；求取发动机支架法兰安装孔5的圆心坐标值与对应试车台支架法兰安装孔6的圆心坐标值的差值，并将圆心坐标值的差值转换为脉冲值。Step 4, identify multiple flange mounting holes in the flange image of the engine bracket and the flange image of the test bench bracket, and extract the center coordinate values of the multiple flange mounting holes based on the established coordinate systems; calculate the difference between the center coordinate value of the engine bracket flange mounting hole 5 and the center coordinate value of the corresponding test bench bracket flange mounting hole 6, and convert the difference in the center coordinate value into a pulse value.
本实施例中，发动机支架法兰安装孔5和对应试车台支架法兰安装孔6内均设置有标志物，标志物在圆心处设置有标志点8，上下成对安装的两个法兰安装孔内的标志点编号相同。In this embodiment, the engine bracket flange mounting hole 5 and the corresponding test bench bracket flange mounting hole 6 are both provided with markers, and the markers are provided with a marking point 8 at the center of the circle, and the marking points in the two flange mounting holes installed in pairs up and down have the same number.
具体地，本实施例采用霍夫圆变换算法识别发动机支架的法兰图像和试车台支架的法兰图像中的多个圆形特征，并提取多个圆心坐标。Specifically, this embodiment uses the Hough circle transform algorithm to identify multiple circular features in the flange image of the engine bracket and the flange image of the test bench bracket, and extract multiple circle center coordinates.
具体地，本实施例中，求取发动机支架法兰安装孔5的圆心坐标值与对应试车台支架法兰安装孔6的圆心坐标值的差值，具体为：在空间坐标系，求取上下成对安装的两个标志点编号相同的法兰安装孔在x轴、y轴和z轴三个方向的轴向偏差量和旋转偏差量。Specifically, in this embodiment, the difference between the center coordinate value of the engine bracket flange mounting hole 5 and the center coordinate value of the corresponding test bench bracket flange mounting hole 6 is obtained, specifically: in the spatial coordinate system, the axial deviation and rotational deviation of the two flange mounting holes with the same marking point number installed in pairs in the upper and lower directions of the x-axis, y-axis and z-axis are obtained.
进一步地，本实施例中，将圆心坐标值的差值转换为脉冲值，具体为：确定单位坐标差值对应的单位脉冲数量，单位坐标差值对应的单位脉冲数量进行换算将圆心坐标值的差值转换为相应的脉冲值。Furthermore, in this embodiment, the difference in the center coordinate values is converted into a pulse value, specifically: the number of unit pulses corresponding to the unit coordinate difference is determined, and the number of unit pulses corresponding to the unit coordinate difference is converted to convert the difference in the center coordinate values into a corresponding pulse value.
步骤5、根据脉冲值控制自动转运对接平台1的移动方向，调节发动机支架2的位置，使发动机支架2的法兰与试车台支架3的法兰的安装孔垂直对接。Step 5: Control the moving direction of the automatic transfer docking platform 1 according to the pulse value, adjust the position of the engine bracket 2, and make the flange of the engine bracket 2 vertically dock with the mounting hole of the flange of the test bench bracket 3.
转运过程完毕后对正系统将向MES系统上报对接完毕，并将主要参数（引导时间）进行上报。流程完毕后转运对接平台运行至指定位置，等待发动机试车。After the transfer process is completed, the alignment system will report the completion of the docking to the MES system and report the main parameters (guidance time). After the process is completed, the transfer docking platform will run to the designated location and wait for the engine test run.
由于布局紧凑，从双目相机7的角度采集到的视频，可能会因为角度产生畸变，为此在标志点设置上进行了畸变对照点，数据分析上进行了防畸变处理Due to the compact layout, the video collected from the binocular camera 7 may be distorted due to the angle. For this reason, distortion control points are set in the landmark point setting, and anti-distortion processing is performed in the data analysis.
其分析处理方法如下：The analysis and processing methods are as follows:
在每一个标志点的四周设置了畸变分析标准圆。利用其不同方向的直径变化为参考，对测量到的图像进行修正，实现了快速可靠地畸变修正，获取了修正后的图像，为视觉识别提供管理图像基础。A standard circle for distortion analysis is set around each mark point. The measured image is corrected by using the diameter change in different directions as a reference, achieving fast and reliable distortion correction, obtaining the corrected image, and providing a management image basis for visual recognition.
同时，在此基础上本实施例包括在对正过程中获取自动转运对接平台1的加速度值及四周力矩，针对摩擦式驱动的麦克纳母轮高精度补偿定位，具体为：通过自动转运对接平台1的加速度及四周力矩对发动机支架2与试车台支架3的位置进行补偿，包括：At the same time, on this basis, this embodiment includes obtaining the acceleration value and the surrounding torque of the automatic transfer docking platform 1 during the alignment process, and high-precision compensation positioning of the friction-driven McNabb mother wheel, specifically: compensating the positions of the engine bracket 2 and the test bench bracket 3 through the acceleration and surrounding torque of the automatic transfer docking platform 1, including:
计算当前发动机支架2的法兰某个安装孔的位移量与实际位移量的差值，得到过冲量；Calculate the difference between the displacement of a mounting hole of the flange of the current engine bracket 2 and the actual displacement to obtain the overshoot;
A、加速度及速度参数的干预：通过测量加速度值并通过测量到的数值对对接过程进行干预，等对接接近目标值30%，降低加速度值，提升对接精度，并通过加速度值结合每次对接的过冲量进行对接预修正，提升对接精度。A. Intervention of acceleration and speed parameters: By measuring the acceleration value and intervening in the docking process through the measured value, when the docking is close to 30% of the target value, the acceleration value is reduced to improve the docking accuracy. The docking pre-correction is performed through the acceleration value combined with the overshoot of each docking to improve the docking accuracy.
通过加速度值结合每次对接的过冲量进行对接预修正，其计算公式为：The docking pre-correction is performed by combining the acceleration value with the overshoot of each docking. The calculation formula is:
其中修正度就是修正距离，用来判断修正结果是否达到要求，当修正度与1的差小于0.01时，采用第n项修正系数为最终的修正系数。The correction degree is the correction distance, which is used to determine whether the correction result meets the requirements. When the difference between the correction degree and 1 is less than 0.01, the nth correction coefficient is used as the final correction coefficient.
B、四周力矩进行过冲量的预估及修正：通过测量发动机放置轴的弯矩对对接过程中的过冲进行计算，修订对接移动量，提升对接精度。B. Prediction and correction of overshoot by using the four-way torque: By measuring the bending moment of the engine placement shaft, the overshoot during the docking process is calculated, the docking movement amount is revised, and the docking accuracy is improved.
通过四周力矩M结合每次对接的过冲量进行对接预修正，通过现场的多次调试拟合如下的快速调整公式：The docking pre-correction is performed by combining the four-way moment M with the overshoot of each docking. The following quick adjustment formula is fitted through multiple on-site commissioning:
当修正度与1的差小于0.01时，采用第n项修正系数为最终的修正系数。When the difference between the correction degree and 1 is less than 0.01, the nth correction coefficient is used as the final correction coefficient.
本发明的主要修正流程如下：The main modification process of the present invention is as follows:
1、首先使用视觉对接系统将自动转运对接平台上放置的发动机与试车台支架之间的位置关系进行确认，确保其之间的相对误差在X方向和Y方向小于150mm，Z轴的旋转角度小于10度，以确保其初始位置满足自动对接系统的要求。1. First, use the visual docking system to confirm the positional relationship between the engine placed on the automatic transfer docking platform and the test bench bracket, ensuring that the relative error between them is less than 150mm in the X and Y directions, and the rotation angle of the Z axis is less than 10 degrees, to ensure that its initial position meets the requirements of the automatic docking system.
2、将x,y自动转运对接平台移动速度设置为5mm/s，z轴的旋转速度设置为0.1/s。2. Set the movement speed of the x,y automatic transfer docking platform to 5mm/s and the rotation speed of the z-axis to 0.1/s.
3、驱动AGV车进行第一步骤自动对。3. Drive the AGV to perform the first step of automatic alignment.
4、调整速度进行精确对接x,y，调整速度为3mm/s，10mm内为0.5mm/s。4. Adjust the speed for precise docking x,y, the adjustment speed is 3mm/s, 0.5mm/s within 10mm.
具体调姿流程为，第一步调整Rz至满足要求，第二步调整x、y至满足要求，第三步调整z至满足要求（z调至50mm，即法兰对接面相距50mm停止），第四步重新调整x、y，调整Rx,Ry至满足要求。The specific posture adjustment process is as follows: the first step is to adjust Rz to meet the requirements, the second step is to adjust x and y to meet the requirements, the third step is to adjust z to meet the requirements (z is adjusted to 50mm, that is, the flange joint surfaces stop at 50mm apart), and the fourth step is to readjust x and y, and adjust Rx and Ry to meet the requirements.
5、不断使用视觉对接系统对发动机和试车台支架的相对位姿中x,y,z,Rx,Ry,Rz六个偏差量调整到规定数值后（x,y,z的调整阈值设置为±0.5mm，Rx,Ry,Rz的调整阈值设置为±0.1°），自动对接完成，位姿测量单元停止拍照，执行机构停止运动，“对接中”指示灯绿色熄灭，“对接完成”指示灯绿色常亮。5. After continuously using the visual docking system to adjust the six deviations of x, y, z, Rx, Ry, and Rz in the relative posture of the engine and the test bench bracket to the specified values (the adjustment thresholds of x, y, and z are set to ±0.5mm, and the adjustment thresholds of Rx, Ry, and Rz are set to ±0.1°), the automatic docking is completed, the posture measurement unit stops taking pictures, the actuator stops moving, the "Docking" indicator light turns off, and the "Docking Completed" indicator light turns on green.
对接过程中，突发情况人为停止，需要重启遥控器和执行机构控制器，再继续完成对接。During the docking process, if an emergency occurs and the process is manually stopped, the remote controller and actuator controller need to be restarted before the docking can be completed.
对接过程中，如果编码点被遮挡，则自动停止对接。During the docking process, if the coding point is blocked, the docking will stop automatically.
本发明结合现场热流场测量及模拟分析，开展了基于标志点视角的畸变最小目标的光学定位过程优化，实现了光学对接视角的最优化，并且该标志点设置方法，成本低、定位精度高，对现有发动机对接流程影响小，提升了自动对接可靠性，降低对相关流程的影响，实现了自动对接时间＜10min，对接精度优于2mm的发动机自动对接目标。本发明通过一系列新的创新，实现了基于麦克纳母轮驱动方式的高精度定位，保证了自动对接系统的高精度定位。The present invention combines on-site thermal flow field measurement and simulation analysis to optimize the optical positioning process of the target with minimum distortion based on the mark point viewing angle, and realizes the optimization of the optical docking viewing angle. In addition, the mark point setting method has low cost and high positioning accuracy, and has little impact on the existing engine docking process, thereby improving the reliability of automatic docking and reducing the impact on related processes, and realizing the automatic docking time of <10min and the docking accuracy better than 2mm for the engine automatic docking target. Through a series of new innovations, the present invention realizes high-precision positioning based on the McNabb mother wheel drive method, and ensures high-precision positioning of the automatic docking system.
本发明适应现场复杂环境满足高可靠性，高效率的发动机自动引导对接方法。该技术主要创新点为：针对试车台的现场复杂环境，尤其是试验车间，存在着高温环境及爆炸风险，区别于常规的引导及对接标志点设计，视觉覆盖范围上均存在着视角小，标志点易受环境影响，最优标志点受热环境影响及发动机故障模式中易损坏的问题，该方法结合现场热流场测量及模拟分析，开展了基于标志点视角的畸变最小目标的光学定位过程优化，实现了光学对接视角的最优化，并且该标志点设置方法，成本低、定位精度高，对现有发动机对接流程影响小，提升了自动对接可靠性，降低对相关流程的影响，实现了自动对接时间＜10min，对接精度优于2mm的发动机自动对接目标。The present invention is a method for automatically guiding and docking engines that is adaptable to complex on-site environments and meets high reliability and high efficiency. The main innovations of this technology are: in view of the complex on-site environment of the test bench, especially the test workshop, there are high temperature environments and explosion risks. Different from the conventional guidance and docking mark point design, the visual coverage range has the problems of small viewing angle, the mark points are easily affected by the environment, the optimal mark points are affected by the heat environment and are easily damaged in the engine failure mode. This method combines on-site thermal flow field measurement and simulation analysis to carry out the optimization of the optical positioning process of the target with the minimum distortion based on the mark point viewing angle, and realizes the optimization of the optical docking viewing angle. In addition, the mark point setting method has low cost and high positioning accuracy, and has little impact on the existing engine docking process, thereby improving the reliability of automatic docking and reducing the impact on related processes. The automatic docking time is less than 10 minutes, and the docking accuracy is better than 2mm. The engine automatic docking target.
本领域内的技术人员应明白，本发明的实施例可提供为方法、系统、或计算机程序产品。因此，本发明可采用完全硬件实施例、完全软件实施例、或结合软件和硬件方面的实施例的形式。而且，本发明可采用在一个或多个其中包含有计算机可用程序代码的计算机可用存储介质(包括但不限于磁盘存储器、CD-ROM、光学存储器等)上实施的计算机程序产品的形式。Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
本发明是参照根据本发明实施例的方法、装置(系统)和计算机程序产品的流程图和/或方框图来描述的。应理解可由计算机程序指令实现流程图和/或方框图中的每一流程和/或方框、以及流程图和/或方框图中的流程和/或方框的结合。可提供这些计算机程序指令到通用计算机、专用计算机、嵌入式处理机或其他可编程数据处理设备的处理器以产生一个机器，使得通过计算机或其他可编程数据处理设备的处理器执行的指令产生用于实现在流程图一个流程或多个流程和/或方框图一个方框或多个方框中指定的功能的装置。The present invention is described with reference to the flowcharts and/or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present invention. It should be understood that each process and/or box in the flowchart and/or block diagram, as well as the combination of the processes and/or boxes in the flowchart and/or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device produce a device for implementing the functions specified in one or more processes in the flowchart and/or one or more boxes in the block diagram.
这些计算机程序指令也可存储在能引导计算机或其他可编程数据处理设备以特定方式工作的计算机可读存储器中，使得存储在该计算机可读存储器中的指令产生包括指令装置的制造品，该指令装置实现在流程图一个流程或多个流程和/或方框图一个方框或多个方框中指定的功能。These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory produce a manufactured product including an instruction device that implements the functions specified in one or more processes in the flowchart and/or one or more boxes in the block diagram.
这些计算机程序指令也可装载到计算机或其他可编程数据处理设备上，使得在计算机或其他可编程设备上执行一系列操作步骤以产生计算机实现的处理，从而在计算机或其他可编程设备上执行的指令提供用于实现在流程图一个流程或多个流程和/或方框图一个方框或多个方框中指定的功能的步骤。These computer program instructions may also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, whereby the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in one or more processes in the flowchart and/or one or more boxes in the block diagram.
应当指出，以上所述具体实施方式可以使本领域的技术人员更全面地理解本发明创造，但不以任何方式限制本发明创造。因此，尽管本说明书和实施例对本发明创造已进行了详细的说明，但是，本领域技术人员应当理解，仍然可以对本发明创造进行修改或者等同替换；而一切不脱离本发明创造的精神和范围的技术方案及改进，其均涵盖在本发明创造发明的保护范围当中。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。It should be noted that the above-described specific embodiments can enable those skilled in the art to more fully understand the invention, but do not limit the invention in any way. Therefore, although the present specification and embodiments have described the invention in detail, those skilled in the art should understand that the invention can still be modified or replaced by equivalents; and all technical solutions and improvements that do not deviate from the spirit and scope of the invention are included in the protection scope of the invention. Any figure mark in the claims should not be regarded as limiting the claims involved.
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| CN202410458022.6ACN118090217B (en) | 2024-04-17 | 2024-04-17 | Alignment method and system for engine test |
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| CN109738061A (en)* | 2019-01-11 | 2019-05-10 | 华南理工大学 | A method and system for automatic alignment of illuminometer position for illuminometer verification |
| CN116072583A (en)* | 2023-02-13 | 2023-05-05 | 无锡星微科技有限公司 | Wafer pre-alignment platform and alignment method based on vision |
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