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为了使机器人准确高效地完成复杂形貌零件修复,开发了一套基于三维视觉的激光再制造机器人离线自动编程系统。系统主要包含6个功能模块:机器视觉测量、三维建模、再制造规划、自动编程、仿真优化和通信模块。基于HALCON软件采用标准标定板进行视觉系统的标定,应用梯度重心法对采集到的激光光条图像进行光条中心提取,依据极限几何理论进行特征匹配,根据三角原理获取零件表面点云数据。然后逆向重建零件三维模型并提取出修复区域,根据工艺规划参数,自动进行再制造路径规划和机器人加工程序编制,并通过机器人主控方式实现多个设备之间的联动和时序控制。试验表明,该方法能提高激光再制造机器人编程效率和精度,且机器人动作连贯,修复路径与设计吻合,满足零件修复要求。
In order to make the robot accurately and efficiently complete the repair of the complex shape parts, a set of automatic remanufacturing robot offline programming system based on 3D vision was developed. The system mainly consists of 6 functional modules: machine vision measurement, 3D modeling, remanufacturing planning, automatic programming, simulation optimization and communication module. HALCON software was used to calibrate the vision system using standard calibration plate. The center of gravity of the laser light bar was extracted by using the gradient centroid method. The light bar center was extracted according to the limit geometry theory and the point cloud data of the part surface was obtained according to the triangular principle. Then the three-dimensional model of the part is reversely rebuilt and the repair area is extracted. According to the process planning parameters, remanufacturing path planning and robot programming are automatically performed. The mastering mode of the robot realizes the linkage and timing control of multiple devices. Experiments show that this method can improve the programming efficiency and accuracy of laser remanufacturing robots, and the robot movement is consistent. The repair path is consistent with the design to meet the requirements of part repair.