In the integrated processing of large components in the aerospace field, for the end servo industrial robot positioning accuracy needs, often using binocular vision positioning method. This method can accurately measure the end position but is limited by the restricted field of view and small depth of field. So, a monocular camera is needed for servo-guiding the processing end of the robot arm. Therefore, a monocular depth estimation method based on improved Yolov8 and CNN fusion for mobile machining with large field-of-view is proposed in this paper. Firstly, a dataset construction method based on virtual-real fusion is proposed to solve the problem that the depth information corresponding to the training set images is difficult to measure; secondly, the proposed Yolov8sim-CNN cascade neural network can realize the measurement of fast localization and depth prediction of the target machining workpiece and realize the servo-guidance of the robot arm end. The experimental results show that the proposed Yolov8sim-CNN network can ensure high detection accuracy, and the detection accuracy is substantially improved compared with the method of CNN-only, which indicates that the proposed method has better fitting ability and higher accuracy.
Transmitted torque of permanent magnet couplers (PMCs) is the core index to evaluate its transmission performance. A semi-analytical calculation method for transmitted torque of the PMC is established to solve those problems that the analytic method is difficult to fully consider the specific details of the three-dimensional (3D) PMC, the calculation accuracy is insufficient, and the finite element model (FEM) has numerical oscillation and the calculation accuracy is float. The analytical model and the FEM are combined in this method, can effectively calculate and predict the transmission performance of the permanent magnet coupler. First, according to geometric structure, a magnetic equivalent circuit model is established to solve internal magnetic induction intensity. Based on the relationship between the eddy current density and the magnetic induction intensity, and considering the 3D end effect, an analytical model of transmitted torque is constructed. Second, a 3D FEM of the unipolar PMC is established, and the transmission performance by the finite element calculation is obtained. On this basis, using the entropy method to combine the magnetic circuit equivalent model with the FEM, a semi-analytical calculation method for the transmitted torque is presented. Finally, an experimental platform is built to verify the method. The results show that under normal working conditions, the proposed method for calculating the transmitted torque has a good consistency, and the relative error is within 6.5%. This method can provide a theoretical basis for the analysis, design, and optimization of PMCs.
Drag reduction is one of the main problems in aircraft design and a meaningful way to save fuel and improve efficiency. Surface microgrooves can reduce the frictional resistance of aircraft walls and become one of the main ways to reduce aircraft drag. A nanosecond laser can prepare microgrooves. However, the recast layers under high laser energy during processing deteriorate the processing quality. How to improve processing quality while ensuring processing efficiency is a challenge. By replacing the target feature analysis model in the original genetic algorithm with an optimization target model based on the response surface method, this study proposes an optimization method for the nanosecond laser processing of the microgroove. This method uses the difficult-to-machine aerospace material TC4 titanium alloy as the target. The Box–Behnken design method is used to design the laser processing experiment of the microgroove. The validity and reliability of the proposed optimization method are verified. It is worth mentioning that the proposed method can obtain satisfactory optimization results with fewer parameter variables and fewer experiments, with low experimental cost and high optimization efficiency compared to genetic algorithms. Furthermore, the optimized process parameters will provide initial parameters for the high-quality preparation of large-scale microgrooves on the TC4 surface through the nanosecond pulsed laser layer-by-layer scanning processing way. And the optimization method is suitable for optimizing short-pulse and long-pulse laser processing parameters of microgrooves on metal surfaces and has practical engineering value.
Frictional resistance significantly reduces the energy efficiency of aircraft. The ridge surface has a drag reduction effect, and its processing has become one of the important ways for improving the energy efficiency of aircraft. The micro-ridge and microgroove are the basic units of the ridge surface. A nanosecond laser can prepare them. However, numerous parameters and complex laser etching mechanisms make it difficult to determine their molding conditions, the forming quality of which is difficult to guarantee. This problem restricts the high-precision preparation of the ridge surface, which inevitably affects its drag reduction performance. Therefore, it is crucial to determine the high-quality molding conditions of the microgroove and micro-ridge to ensure the drag reduction effect of the ridge surface. Here, we focus on aviation titanium alloy TC4. Through an etching experiment of the straight section, the influence of parameters on the feature size of its cross-section profile is systematically studied. The recast layer scale, symmetry, and smoothness of the cross-section profile are used to evaluate the molding quality of microgrooves. The symmetry of the cross-section profile assesses the molding quality of micro-ridges. The forming parameter range and high-quality forming condition of microgrooves and the high-quality forming parameter range of micro-ridges are determined. Finally, the morphology evolution rule and mechanism of the nanosecond laser etching TC4 is revealed based on this research. The direct molding rules and parameter range of micro-ridges on the TC4 surface are reported and show a broadening of the nanosecond laser micromachining range. Moreover, this study will provide a process window for optimizing nanosecond laser processing for microgrooves and micro-ridges on the TC4 surface.
Binocular stereo vision technology plays an essential role in the intelligent manufacturing system due to the advantages of high accuracy and non-contact. However, for the measurement of components with highly reflective surfaces such as metal and ceramic, the specular reflections affected by the complex light field lead to the failure of feature matching and the decrease of measurement accuracy. This paper proposes an imaging strategy for binocular vision and a high dynamic image processing method to suppress the effect of specular reflection for stereo matching. Firstly, the mechanism of highlight generation in the image is analyzed by combining the illumination reflection theory of the BRDF model. Then, a binocular vision system with a parallel optical axis is built to capture images under different illumination conditions. The image processing algorithm of high dynamic range image fusion is studied, and an algorithm based on tone mapping and weight fusion is implemented to remove the high-lights. Finally, an experiment was performed to verify the effectiveness of the proposed method by a robust and fast matching algorithm. An image evaluation method based on BRISQUE further demonstrates the effectiveness of the method. Compared to the original images, the quality score of the HDR images is lower, which means that the processed images are of better quality. Moreover, the method provides an increase of 23.33% in image matching accuracy, which verifies the availability applied in the measurement of highly reflective surface components.
The permanent magnetic couple is a non-contact transmission device with higher transmission efficiency than a traditional rigid transmission device. Slotting the copper conductor disc on the permanent magnetic coupler can further improve the transmission performance. This paper proposes an optimization calculation model for the slotted permanent magnetic coupler, uses ANSYS Maxwell to simulate and verifies the model to improve the transmission performance. The value of magnet pairs and the slots are 6 and 35 respectively; then we simulate output torque when the slot ratio changes from 0.5 to 0.9. The simulation results verify the accuracy of the optimization model. This paper obtains the optimization scheme of the slotted permanent magnetic coupler under different parameters. The calculation model can guide the determination of a slotted permanent magnetic coupler, which is of great significance to improve the efficiency of the transmission system.
KEYWORDS: Clouds, Denoising, Digital filtering, Signal to noise ratio, Image segmentation, Optical filters, Visualization, Data acquisition, Principal component analysis
The assembly gap between components is very vital for the evaluation of assembly quality of aircrafts. Due to the limits of gap size and operation space, the assembly gap needs to be indirectly calculated by the measurements of surface of components instead of plug gauge test. However, the surface constituted of point cloud is usually mixed with different types of noise ,which severely affects the evaluation of assembly gap. To remove these different types of noise simultaneously with high efficiency, a classified denoising method combining with an improved bilateral filtering and median filtering was proposed. Firstly, based on the principal component analysis, a new coordinate system was established to achieve the homogeneity of coordinates of point cloud. Then, an improved median filtering method on the basis of region segmentation (RSMF) was used to remove large-scale noise. Next, the fast bilateral filtering method based on threshold segmentation (TSBF) was proposed to remove small-scale noise. Finally, a measurement experiment of aircraft component was performed to verify the effectiveness of the proposed method. Experimental results showed that the proposed method could not only reduce measurement error including RMSE (Root Mean Square Error), but also improve SNR (Signal Noise Ratio) and PSNR (Peak Signal to Noise Ratio) of point cloud data.
For improving the measurement accuracy of aviation part’s profile, a high-accuracy profile measurement method based on step boundary model is proposed in this paper. Firstly, the cases of light stripe imaging in the target boundary are analysed, and the corresponding ideal boundary models are built to determine the ideal boundary locations. Then, a subpixel boundary extraction method based on feature moment is presented, which can obtain sub-pixel boundary locations on the basis of the crude boundary detection. Next, based on the reconstruction algorithms, the profile of aviation part is measured. At last, experiments using a standard part are conducted to verify the accuracy of this method and a measurement experiment is carried to verify the effectiveness of the boundary extraction. Experiment results show that the presented method can achieve the object boundary extraction in complex background interference and light environment. The extraction method can reach an accuracy of 0.056% and satisfy the requirements of field measurement.
KEYWORDS: Cameras, Distortion, Calibration, 3D modeling, Visual process modeling, Imaging systems, 3D image processing, 3D metrology, 3D acquisition, Cesium
The traditional vision measurement model has difficulty in guaranteeing the accuracy of measurement in the depth of field. And in this way, high-precision measurement of large components parts in three-dimensional large scale space can hardly be realized. To solve this problem, a binocular measuring method based on 3D image distortion compensation is proposed. Considering the rule of image distortion in the three-dimensional space, and combining with binocular vision measurement principle, a new binocular vision measurement model, based on 3D image distortion compensation, is established in the paper. And the model is based on the rule of image distortion in the three-dimensional space, and combined with binocular vision measurement principle. Besides, a new calibration method is proposed. This method is for the distortion parameters of the model and the intrinsic parameters of the cameras. Experimental results show that the proposed binocular vision measurement method in this paper is much more effectively than the traditional method. The results indicate that the proposed method largely improves the measurement accuracy under the condition of large depth of field. Meanwhile, this method also significantly improves the measurement accuracy in the three-dimensional space.
In order to realize the precision machining and assembly of the parts, the geometrical dimensions of the surface of the local assembly surfaces need to be strictly guaranteed. In this paper, a local high-precision three-dimensional measurement method based on line laser measuring instrument is proposed to achieve a high degree of accuracy of the three-dimensional reconstruction of the surface. Aiming at the problem of two-dimensional line laser measuring instrument which lacks one-dimensional high-precision information, a local three-dimensional profile measuring system based on an accurate single-axis controller is proposed. First of all, a three-dimensional data compensation method based on spatial multi-angle line laser measuring instrument is proposed to achieve the high-precision measurement of the default axis. Through the pretreatment of the 3D point cloud information, the measurement points can be restored accurately. Finally, the target spherical surface is needed to make local three-dimensional scanning measurements for accuracy verification. The experimental results show that this scheme can get the local three-dimensional information of the target quickly and accurately, and achieves the purpose of gaining the information and compensating the error for laser scanner information, and improves the local measurement accuracy.
An accurate measurement of large aviation part plays a key role in the assembly of aircraft. However, due to the limitation of spatial size, a calibration with large field of view and an accurate surface measurement of large part is hard to achieve. In this paper, an improved measurement method with spatial constraint calibration method and feature compression extraction method is proposed. Firstly, based on the proposed spatial constraint calibration method, the vision system is conveniently and precisely calibrated by using the designed SBA and SLT. Images of scanning laser stripes are captured by the calibrated cameras, simultaneously. Then the proposed feature compression extraction method is adopted to accurately extract centers of laser stripes. Finally, based on the binocular vision principle, the surface of part is reconstructed. The accuracy of proposed calibration method is verified in the lab. The results of the measurement of a standard part show the validity and precision of the proposed method.
Dimensional measurement for hot forgings is a key factor to improve the level of forging technology in industry field. However, the high temperature, large size and hostile environment increase difficulties to guarantee the robustness and speed of the measurement. In this paper, a robust real-time image processing method based on laser-aided binocular machine vision system is proposed. Firstly, images with clear laser stipes are acquired using spectral selection method, by which the influences of thermal radiation and ambient light can be reduced. Then, to improve the speed of extraction and the robustness of matching, an extraction method based on the information consistency of the images acquired by the system and a matching method based on sequential consistency and epipolar constraints are presented. Dimensional reconstruction models for square and axial forgings are built. Finally, the image processing results are used to reconstruct the feature dimensions of a ceramic plate in the laboratory as well as forgings in a forge. Experiments show that, the root-mean-square error of the reconstructed points is 0.002mm and the relative error for width reconstruction is 0.638% in a cold state. Lengths and diameters of hot large forgings are reconstructed robustly and in real time. It is verified that the method proposed in this paper can satisfy the requirements of precision, speed and robustness for measurement of large hot forgings in industrial field.
With the rapid development of aviation and aerospace, the demand for metal coating parts such as antenna reflector, eddy-current sensor and signal transmitter, etc. is more and more urgent. Such parts with varied feature dimensions, complex three-dimensional structures, and high geometric accuracy are generally fabricated by the combination of different manufacturing technology. However, it is difficult to ensure the machining precision because of the connection error between different processing methods. Therefore, a precise positioning method is proposed based on binocular micro stereo vision in this paper. Firstly, a novel and efficient camera calibration method for stereoscopic microscope is presented to solve the problems of narrow view field, small depth of focus and too many nonlinear distortions. Secondly, the extraction algorithms for law curve and free curve are given, and the spatial position relationship between the micro vision system and the machining system is determined accurately. Thirdly, a precise positioning system based on micro stereovision is set up and then embedded in a CNC machining experiment platform. Finally, the verification experiment of the positioning accuracy is conducted and the experimental results indicated that the average errors of the proposed method in the X and Y directions are 2.250 μm and 1.777 μm, respectively.
Large-scale triangulation scanning measurement systems are widely used to measure the three-dimensional profile of large-scale components and parts. The accuracy and speed of the laser stripe center extraction are essential for guaranteeing the accuracy and efficiency of the measuring system. However, in the process of large-scale measurement, multiple factors can cause deviation of the laser stripe center, including the spatial light intensity distribution, material reflectivity characteristics, and spatial transmission characteristics. A center extraction method is proposed for improving the accuracy of the laser stripe center extraction based on image evaluation of Gaussian fitting structural similarity and analysis of the multiple source factors. First, according to the features of the gray distribution of the laser stripe, evaluation of the Gaussian fitting structural similarity is estimated to provide a threshold value for center compensation. Then using the relationships between the gray distribution of the laser stripe and the multiple source factors, a compensation method of center extraction is presented. Finally, measurement experiments for a large-scale aviation composite component are carried out. The experimental results for this specific implementation verify the feasibility of the proposed center extraction method and the improved accuracy for large-scale triangulation scanning measurements.
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.