PROCESS METHOD FOR CONFORMAL PROCESSING OF CYLINDRICAL SHELL INNER WELD SEAM BY SPECIAL MOBILE ROBOT

Abstract

The present invention relates to a process method for conformal processing of a cylindrical shell inner weld seam by a special mobile robot, a laser scanner is used to scan a cylindrical shell inner weld seam to obtain point cloud data of a contour of a weld seam area first. Weld seam feature identification is carried out to each generatrix, and misidentified generatrices are filtered out to obtain weld seam left and right boundaries. An ideal weld seam processing contour is generated conformally according to the appearance of the weld seam area, weld seam coarse grinding is carried out after correction and compensation, and weld seam contour information after coarse grinding is obtained by scanning after the coarse grinding is completed. Process parameters of the grinding are controlled according to an actual weld seam contour, and weld seam fine grinding is carried out to obtain a smooth weld seam contour.

Claims

1. A process method for conformal processing of a cylindrical shell inner weld seam by a special mobile robot, wherein in the method, a weld seam contour is scanned and measured to obtain point cloud data of a contour of a weld seam area first; then weld seam feature identification is carried out to each generatrix, and misidentified generatrices are filtered out to obtain weld seam left and right boundaries; an ideal weld seam processing contour is generated conformally according to the appearance of the weld seam area, and weld seam coarse grinding is carried out after correction and compensation; weld seam contour information after coarse grinding is obtained by scanning again after the coarse grinding is completed; process parameters of the grinding are controlled according to an actual weld seam contour, weld seam fine grinding is carried out, and shape of an inner weld seam contour is trimmed to complete the conformal processing; and the method comprises the following specific steps: step 1: first weld seam contour measurement and feature identification putting a robot in a cylindrical shell, stopping the robot after the robot is judged to reach a weld seam according to a real-time image collected by a wide-angle camera (8), and using a laser scanner (3) to measure an annular weld seam area in the cylindrical shell; matching measurement data of the laser scanner (3) with position information of each kinematic axis of a three-axis drive mechanism (2) to obtain point cloud data of a contour of a cylindrical shell inner weld seam area; representing the obtained point cloud data as N generatrices (K.sub.1, K.sub.2, . . . K.sub.N) in an X-R plane in a cylindrical coordinate system (X-R-A coordinate system); then carrying out weld seam feature identification to each generatrix in the X-R plane; taking the M.sup.th generatrix K.sub.M as an example, selecting the leftmost m points [(x.sub.1, r.sub.1), (x.sub.2, r.sub.2) . . . (x.sub.m, r.sub.m)] within the range of the generatrix as initial points, and fitting a left inner wall contour line according to formula (1); starting from the (u=m+1).sup.th leftmost point, calculating a distance d.sub.u.sup.l from each point to the left inner wall contour line in sequence from left to right according to formula (2); $\begin{array}{cc}\{\begin{array}{c}r=ax+b\\ a=\frac{\underset{i=1}{\overset{n}{.Math.}}{x}_i{r}_i-n\overline{x}.Math.\overline{r}}{\underset{i=1}{\overset{n}{.Math.}}{x}_i^2-n{\overline{x}}^2}\\ b=\overline{r}-a\overline{x}\end{array}& \left(1\right)\end{array}$ where, (x.sub.i, r.sub.i) is a coordinate of a point involved in fitting, and n is the number of points involved in fitting; x is an x average value of the points involved in fitting; r is an r average value of the points involved in fitting; and r=ax+b is the fitted inner wall contour line; $\begin{array}{cc}{d}_u^l=\frac{.Math.{\mathrm{ax}}_i-r_i+b.Math.}{\sqrt{a^2+1}}& \left(2\right)\end{array}$ where, (x.sub.i, r.sub.i) is a point coordinate; and r=ax+b is a straight-line formula; setting a threshold d.sub.0.sup.l for judgement: if d.sub.u.sup.l≤d.sub.0.sup.l, it is judged that a point u is still an inner wall contour point, re-fitting the left inner wall contour line by the leftmost u points, and letting an u=u+1 to continue the judgement of a next data point; if d.sub.u.sup.l>d.sub.0.sup.l, and considering an error in identification, an actual weld seam feature point should be on the left side of point u; setting a compensation amount v (which is an integer of 5-12) according to the actual condition of the weld seam to carry out compensation, then the (u-v).sup.th point is judged as a weld seam left feature point P.sub.ML, the judgement cycle is ended, and a final left inner wall contour line is l.sub.ML similarly, fitting a right inner wall contour line by the rightmost points, and judging each point from right to left to obtain a weld seam right feature point P.sub.MR and a final right inner wall contour line l.sub.MR; taking a middle point P.sub.MC of the left and right feature points as a weld seam center feature point of the generatrices K.sub.M thus to obtain left feature points (P.sub.1L, P.sub.2L, . . . P.sub.NL) right feature points (P.sub.1R, P.sub.2R, . . . P.sub.NR) center feature points (P.sub.1C, P.sub.2C, . . . P.sub.NC), left inner wall contour lines (l.sub.1L, l.sub.2L, . . . l.sub.NL) and right inner wall contour lines (l.sub.1R, l.sub.2R, . . . l.sub.NR) of the generatrices; step 2: filtering out of weld seam feature misidentified generatrices caused by debris and oil stains completing weld seam feature point identification of each generatrix in sequence, and filtering out weld seam feature misidentified generatrices; taking the M.sup.th generatrix K.sub.M as an example, and obtaining weld seam width by calculation from left and right weld seam feature points P.sub.ML(x.sub.PML, r.sub.PML) and P.sub.MR(x.sub.PMR, r.sub.PMR) of the generatrix according to formula (3);
w.sub.M=x.sub.PMR−x.sub.PML  (3) setting the minimum weld width w.sub.min and the maximum weld width w.sub.max according to actual inner weld seam features, and judging generatrices with w.sub.M>w.sub.max and w.sub.M<w.sub.min as weld seam width identification abnormal generatrices; in a rectangular coordinate system, fitting a plane L.sub.T by the weld seam center feature points (P.sub.1C, P.sub.2C, . . . P.sub.NC) of various generatrices according to formula (4), and calculating a distance d.sub.M.sup.f from a weld seam center feature point P.sub.MC of the generatrix K.sub.M to the plane L.sub.T according to formula (5); $$\begin{gathered} \begin{array}{cc}\{\begin{array}{c}\mathrm{Ax}+\mathrm{By}+\mathrm{Cz}+D=0,\left(C\ne 0\right)\\ .Math.\begin{array}{ccc}.Math.x_i^2& .Math.x_i{y}_i& .Math.x_i\\ .Math.x_i{y}_i& .Math.y_i^2& .Math.y_i\\ .Math.x_i& .Math.y_i& n\end{array}.Math.\left(\begin{array}{c}{a}_0\\ a_1\\ a_2\end{array}\right)=\left(\begin{array}{c}.Math.x_i{z}_i\\ .Math.y_i{z}_i\\ .Math.z_i\end{array}\right)\end{array} \\ \mathrm{where}, \\ {a}_0=-\frac{A}{C},a_1=-\frac{B}{C},a_2=-\frac{D}{C}& \left(4\right)\end{array} \end{gathered}$$ where, Ax+By+Cz+D=0 is a plane generated by fitting; n is the quantity of the points involved in fitting; and (x.sub.i, y.sub.i, z.sub.i) is a three-dimensional coordinate of a point involved in fitting; $\begin{array}{cc}{d}^f=\frac{.Math.{\mathrm{Ax}}_i+B{y}_i+C{z}_i+D.Math.}{\sqrt{A^2+B^2+C^2}}& \left(5\right)\end{array}$ where, d.sup.f is a distance from a point to a plane; (x.sub.i, y.sub.i, z.sub.i) is a point coordinate; and Ax+By+Cz+D=0 is a plane formula; setting a threshold for a distance d.sub.0.sup.f from a weld seam center point to a fitted plane, and judging a generatrix with d.sub.M.sup.f>d.sub.0.sup.f as a weld seam position identification abnormal generatrix; filtering out weld seam feature misidentified generatrices by the above two judgement methods, with the remaining Z qualified generatrices being (K.sub.1′,K.sub.2′, . . . K.sub.Z′); step 3: obtaining of maximum boundary of weld seam fitting a weld seam center plane L.sub.c by inner weld seam center feature points (P.sub.1C′, P.sub.2C′, . . . P.sub.ZC′) of the remaining Z qualified generatrices (K.sub.1′, K.sub.2′, . . . K.sub.Z′), and calculating distances (d.sub.1L′, d.sub.2L′, . . . d.sub.ZL′) from left feature points (P.sub.1L′, P.sub.2L′, . . . P.sub.ZL′) of the qualified generatrices to the weld seam center plane L.sub.c according to formula (5); taking the maximum distance d.sub.L′=max(d.sub.1L′, d.sub.2L′, . . . d.sub.ZL′), and generating a parallel surface L.sub.l at a distance d.sub.L′ from the left side of the weld seam center plane L.sub.c, namely a weld seam left boundary plane; obtaining a weld seam right boundary plane L.sub.r in a similar way; finally, in a three-dimensional coordinate system, calculating intersection points of the left inner wall contour lines (l.sub.1L, l.sub.2L, . . . l.sub.NL) and the weld seam left boundary plane L.sub.l in all of the N generatrices (K.sub.1, K.sub.2, . . . K.sub.N), namely weld seam left boundary points (T.sub.1L, T.sub.2L, . . . T.sub.NL) of the generatrices; obtaining weld seam right boundary points (T.sub.1R, T.sub.2R, . . . T.sub.NR) of the generatrices in a similar way; thus, obtaining of maximum boundary of inner weld seam is completed; step 4: ideal weld seam contour conformal generation and coarse grinding after obtaining of maximum boundary of weld seam is completed, conformally generating an ideal weld seam contour, and carrying out coarse processing; taking the M.sup.th generatrix K.sub.M as an example, and calculating a middle position x.sub.TMC=(x.sub.TML+x.sub.TMR)/2 of a left boundary point T.sub.ML(x.sub.TML, r.sub.TML) and a right boundary point T.sub.MR(x.sub.TMR, r.sub.TMR); calculating a point (x.sub.TMC, r.sub.1) of the left inner wall contour line l.sub.ML at the middle position and a point (x.sub.TMC, r.sub.2) of the right inner wall contour line l.sub.MR at the middle position; considering the influence of seam misalignment during cylindrical shell welding, and comparing the point heights r.sub.1 and r.sub.2 the left and right inner wall contour lines l.sub.ML and l.sub.MR at the middle position; if r.sub.1>r.sub.2, it is judged that the left inner wall is higher than the right inner wall in the generatrix, and the coordinate of a middle point T.sub.MC is (x.sub.TMC, r.sub.1); if r.sub.1≤r.sub.2, it is judged that the right inner wall is higher than the left inner wall in the generatrix, and the coordinate of the middle point T.sub.MC is (x.sub.TMC, r.sub.2; connecting the three points T.sub.ML, T.sub.MC and T.sub.MR, wherein l.sub.M1 is a connecting line between the point T.sub.ML and the point T.sub.MC, l.sub.M2 is a connecting line between the point T.sub.MC and the point T.sub.MR, and T.sub.MR and l.sub.M2 form the ideal weld seam contour of the generatrix, which is represented by formula (6); $\begin{array}{cc}r=\{\begin{array}{cc}{a}_{M1}x+b_{M1}& \left(x<x_{TMC}\right)\\ a_{M2}x+b_{M2}& \left(x\ge x_{TMC}\right)\end{array}& \left(6\right)\end{array}$ where, r=a.sub.M1x+b.sub.M1 and r.sub.M2=a.sub.M2x+b.sub.M2 are respectively expressions of and l.sub.M2; and x.sub.TMC is the middle position of the left and right boundaries; due to errors in robot processing, and in order to avoid damage to the inner wall, generating a processing contour parallel to the ideal weld seam contour at a certain safe distance δ upward; discretizing the processing contour into processing points, generating a G code, and carrying out coarse grinding to a cylindrical shell inner weld seam; step 5: second weld seam contour measurement and fine grinding parameter control after the coarse grinding is completed, using the laser scanner (3) to scan again, and changing the dwell time of a flap wheel to realize grinding amount control of each part of the weld seam and realize weld seam fine grinding; first, obtaining contours after coarse grinding of generatrices (K.sub.1, K.sub.2, . . . K.sub.N) by laser scanner scanning; generating a grinding track of the flap wheel 7 according to ideal weld seam middle points (T.sub.1C, T.sub.2C, . . . T.sub.NC) of various generatrices in a three-dimensional space; taking the M.sup.th generatrix K.sub.M as an example, setting a variable contour difference ζ.sub.M to represent the difference between the weld seam contour after coarse grinding and the ideal weld seam contour of the generatrix K.sub.M, and calculating a distance d.sub.Mi from each point in the weld seam area to an ideal weld seam according to formula (7); $\begin{array}{cc}\{\begin{array}{c}{d}_{\mathrm{Mi}}=\{\begin{array}{c}r-\left(a_{M1}x-b_{M1}\right),x_{TML}\le x\le x_{TMC}\\ r-\left(a_{M2}x-b_{M2}\right),x_{TMC}<x\le x_{TMR}\end{array},\mathrm{where}i=1,2.Math.n\\ {\xi }_M=\frac{\underset{1}{\overset{n}{.Math.}}{d}_{\mathrm{Mi}}}{n}\end{array}& \left(7\right)\end{array}$ where, ζ.sub.M represents a weld seam contour difference of the generatrix K.sub.M; n represents the quantity of points in the weld seam area of the generatrix; and d.sub.Mi represents a distance from an actual weld seam contour point to the ideal weld seam contour; as the flap wheel is flexible, when used for processing the generatrix K.sub.M, the flap wheel will also have a grinding influence on the area around the generatrix K.sub.M; therefore, a grinding weight μ.sub.i is introduced to represent the grinding influence of the flap wheel on the weld beam of various generatrices when used for grinding at the generatrix K.sub.M; when the flap wheel is used for grinding at the generatrix K.sub.M, the generatrix K.sub.M is most influenced by cutting, the value of corresponding μ.sub.0 is the largest, and the weight μ.sub.i of each nearby generatrix is determined according to the degree of influence; obtaining a weld seam grinding dwell time coefficient ψ.sub.M at K.sub.M by weighted calculation of the weld seam contour difference ζ.sub.i of various generatrices according to formula (8): $\begin{array}{cc}{\psi }_M=\frac{\begin{array}{c}{\mu }_0{\xi }_M+{\mu }_1\left({\xi }_{M-1}+{\xi }_{M+1}\right)+\\ {\mu }_2\left({\xi }_{M-2}+{\xi }_{M+2}\right)+.Math.+{\mu }_n\left({\xi }_{M-n}+{\xi }_{M+n}\right)\end{array}}{{\mu }_0+2{\mu }_1+2{\mu }_2+.Math.+2{\mu }_n}& \left(8\right)\end{array}$ where, ψ.sub.M represents the grinding dwell time coefficient at the generatrix K.sub.M; represents the grinding weight; and ζ.sub.i represents the weld seam contour difference of the generatrix K.sub.M; finally, obtaining the dwell time t.sub.M of flap wheel grinding at the generatrix K.sub.M according to formula (9);
t.sub.M=ψ.sub.Mt.sub.0  (9) where, t.sub.0 represents unit dwell time; ψ.sub.M represents the dwell time coefficient; and t.sub.M represents the dwell time at the generatrix K.sub.M; similarly, calculating the dwell time (t.sub.1, t.sub.2, . . . t.sub.N) at the generatrices (K.sub.1, K.sub.2, . . . K.sub.N), generating a G code, and carrying out fine grinding to the weld seam area to complete the conformal processing of the cylindrical shell inner weld seam.

2. The process method for conformal processing of a cylindrical shell inner weld seam by a special mobile robot according to claim 1, wherein a special mobile robot used in the process method is composed of a robot body unit (I) and a measuring and grinding unit (II); the robot body unit (I) is composed of motion and support mechanisms (1) and the three-axis drive mechanism (2); a total of 6 motion and support mechanisms (1) are provided, which are circumferentially and uniformly distributed at 120° intervals in a front row and a back row; a supporting force is provided by a cylinder to drive the robot to change diameter and support in a thin-walled cylindrical shell; motion and support mechanisms in the front row is equipped with a driving motor which outputs a driving force to drive the robot to walk in the cylindrical shell; the three-axis drive mechanism (2) is composed of an axial motor, a circumferential motor and a radial motor, and is used for driving the measuring and grinding unit (II) to move along an axial direction X, a rotating direction A and a radial direction R to meet the measurement and processing requirements of the robot in space; the measuring and grinding unit (II) is composed of the laser scanner (3), an electric spindle for coarse grinding (4), an electric spindle for fine grinding (5), an arc grinding wheel (6), the flap wheel (7) and the wide-angle camera (8); the laser scanner (3) used for obtaining position and contour of the inner weld seam of the cylindrical shell is installed at the front end of the measuring and grinding unit (II); the arc grinding wheel (6) is driven by the electric spindle for coarse grinding (4), and is used for carrying out coarse grinding to the inner weld seam, removing materials and reducing reinforcement of the inner weld seam; the flap wheel (7) is driven by the electric spindle for fine grinding (5), and is used for carrying out fine grinding to the inner weld seam, removing burrs and trimming shape of the contour of the inner weld seam; the wide-angle camera (8) used for observing the current position and processing condition of the robot is installed on one side of the measuring and grinding unit (II).

Description

DESCRIPTION OF DRAWINGS

[0036] FIG. 1 is a structural schematic diagram of a special processing robot. In the figure: 1—motion and support mechanisms; 2—three-axis drive mechanism; 3—laser scanner; 4—electric spindle for coarse grinding; 4—electric spindle for fine grinding; 6—arc grinding wheel; 7—flap wheel; 8—wide-angle camera.

[0037] FIG. 2 is a flow chart of a process method for conformal processing of a cylindrical shell inner weld seam.

[0038] FIG. 3a) is a point cloud chart of a contour of a cylindrical shell inner weld seam area, and FIG. 3b) is a local enlarged view.

[0039] FIG. 4 is a schematic diagram of inner weld seam feature identification of a generatrix K.sub.M. In the figure: l.sub.ML—final left inner wall contour line; l.sub.MR—final right inner wall contour line; P.sub.ML—left feature point; P.sub.MR—right feature point; P.sub.MC—center feature point; d.sub.0.sup.l—threshold from point to inner wall contour line.

[0040] FIG. 5 is a schematic diagram of ideal weld seam contour generation of a generatrix K.sub.M. In the figure: T.sub.ML—left boundary point; T.sub.MR—left boundary point; T.sub.MC—middle point; l.sub.M1—connecting line between point T.sub.ML and point T.sub.MC, l.sub.M2—connecting line between point T and point T.sub.MR, and l.sub.M1 and l.sub.M2 also form an ideal weld seam contour of the generatrix; δ—safe distance.

[0041] FIG. 6 is a schematic diagram of conformal processing of an inner weld seam.

DETAILED DESCRIPTION

[0042] Detailed description of the present invention is described below in detail in combination with drawings and the technical solution.

[0043] A working flow of a special mobile robot is as follows: putting a robot in a cylindrical shell, making the robot crawl towards a welded area of the cylindrical shell, stopping the robot after the robot is judged to reach a weld seam according to a real-time image collected by a wide-angle camera 8, exerting forces and supporting tightly by motion and support mechanisms 1 to ensure that the robot and the shell are relatively static, thus a robot motion tracking process is completed, and starting measurement and processing of a cylindrical shell inner weld seam by a three-axis drive mechanism 2 in combination with a measuring and grinding unit II.

[0044] FIG. 3 is a point cloud chart of a contour of a cylindrical shell inner weld seam area. The special mobile robot is used for precision processing of a cylindrical shell inner weld seam with a diameter of 400 mm, a thickness of 2 mm, a distance to port of 2.1 m and a width of about 6 mm.

[0045] A structure of the special mobile robot is shown in FIG. 1, and the special mobile robot is composed of a robot body unit I and the measuring and grinding unit II. The robot body unit I is composed of the motion and support mechanisms 1 and the three-axis drive mechanism 2; a total of 6 motion and support mechanisms 1 are provided, which are circumferentially and uniformly distributed at 120° intervals in a front row and a back row; a supporting force is provided by a cylinder to drive the robot to change diameter and support in the cylindrical shell. Motion and support mechanisms in the front row is equipped with a driving motor which outputs a driving force to drive the robot to walk in the cylindrical shell. The three-axis drive mechanism 2 is composed of an axial motor, a circumferential motor and a radial motor, and can be used for driving the measuring and grinding unit II to move along an axial direction X, a rotating direction A and a radial direction R to meet the measurement and processing requirements of the robot in space.

[0046] The measuring and grinding unit II is composed of a laser scanner 3, an electric spindle for coarse grinding 4, an electric spindle for fine grinding 5, an arc grinding wheel 6, a flap wheel 7 and the wide-angle camera 8. The laser scanner 3 is installed at the forefront of the measuring and grinding unit II and is used for obtaining position and contour of the cylindrical shell inner weld seam. The arc grinding wheel 6 is driven by the electric spindle for coarse grinding 4, and is used for carrying out coarse grinding to the inner weld seam, removing materials and reducing reinforcement of the inner weld seam. The flap wheel 7 is driven by the electric spindle for fine grinding 5, and is used for carrying out fine grinding to the inner weld seam, removing burrs and trimming shape of the contour of the inner weld seam. The wide-angle camera 8 is installed on one side of the measuring and grinding unit II, and is used for observing the current position and processing condition of the robot.

[0047] FIG. 2 is a flow chart of a process method for conformal processing of a cylindrical shell inner weld seam. In the method, a weld seam contour is scanned and measured to obtain point cloud data of a contour of a weld seam area first; then weld seam feature identification is carried out to each generatrix, and misidentified generatrices are filtered out to obtain weld seam left and right boundaries; an ideal weld seam processing contour is generated conformally according to the appearance of the weld seam area, and weld seam coarse grinding is carried out after correction and compensation; weld seam contour information after coarse grinding is obtained by scanning again after the coarse grinding is completed. Process parameters of the grinding are controlled according to an actual weld seam contour, weld seam fine grinding is carried out, and shape of an inner weld seam contour is trimmed to complete the conformal processing. The method comprises the following specific implementation steps:

[0048] Step 1: Weld Seam Contour Measurement and Feature Identification

[0049] First, driving the laser scanner 3 of the measuring and grinding unit II to measure an annular weld seam area in the cylindrical shell by rotation of the three-axis drive mechanism 2 of the robot along a direction A in FIG. 1. Matching measurement data of the laser scanner 3 with position information of each kinematic axis of the three-axis drive mechanism 2 to obtain point cloud data of a contour of a cylindrical shell inner weld seam area. Representing the obtained point cloud data as 1440 generatrices (K.sub.1, K.sub.2, . . . K.sub.1440) in an X-R plane in a cylindrical coordinate system (X-R-A coordinate system).

[0050] Carrying out weld seam feature identification to each generatrix in the X-R plane, as shown in FIG. 4. Taking the M.sup.th generatrix K.sub.M as an example, selecting the leftmost 40 points [(x.sub.1, r.sub.1),(x.sub.2, r.sub.2) . . . (x.sub.40, r.sub.40)] within the range of the generatrix as initial points, and fitting a left inner wall contour line according to formula (1). Starting from the (u=41).sup.th leftmost point, calculating a distance d.sub.u.sup.l from each point to the left inner wall contour line from left to right according to formula (2).

[0051] Setting a threshold d.sub.0.sup.l=0.08 mm for judgement: if d.sub.u.sup.l≤d.sub.0.sup.l, it is judged that a point u is still an inner wall contour point, re-fitting the left inner wall contour line by the leftmost u points, and letting u=u+1 to continue the judgement of a next data point; if d.sub.u.sup.l≤d.sub.0.sup.l, and considering an error in identification, an actual weld seam feature point should be on the left side of point setting a compensation amount v=6 to carry out compensation, then the (u−6).sup.th point is judged as a weld seam left feature point P.sub.ML, the judgement cycle is ended, and a final left inner wall contour line is l.sub.ML. Similarly, fitting a right inner wall contour line by the rightmost points, and judging each point from right to left to obtain a weld seam right feature point P.sub.MR and a final right inner wall contour line l.sub.MR. Taking a middle point P.sub.MC of the left and right feature points as a weld seam center feature point of the generatrices K.sub.M. Based on such method, left feature points (P.sub.1L, P.sub.2L, . . . P.sub.1440L) right feature points (P.sub.1R, P.sub.2R, . . . P.sub.1440R) center feature points (P.sub.1C, P.sub.2C, . . . P.sub.1440C), left inner wall contour lines (l.sub.1L, l.sub.2L, . . . l.sub.1440L) and right inner wall contour lines (l.sub.1R, l.sub.2R, . . . l.sub.1440R) of the generatrices can be obtained.

[0052] Step 2: Filtering Out of Weld Seam Feature Misidentified Generatrices Caused by Debris and Oil Stains

[0053] Completing weld seam feature point identification of each generatrix in sequence, and filtering out weld seam feature misidentified generatrices. Taking the M.sup.th generatrix K.sub.M as an example, and obtaining weld seam width by calculation from left and right weld seam feature points P.sub.ML(x.sub.PML, r.sub.PML) and P.sub.MR(x.sub.PMR, r.sub.PMR) of the generatrix according to formula (3).

[0054] Setting the minimum weld width w.sub.min=4 mm and the maximum weld width w.sub.max=8 mm according to actual inner weld seam features, and judging generatrices with w.sub.M>w.sub.max and w.sub.M<w.sub.min as weld seam width identification abnormal generatrices. In a rectangular coordinate system, fitting a plane L.sub.T by the weld seam center feature points (P.sub.1C, P.sub.2C, *P.sub.1440C) of various generatrices according to formula (4), and calculating a distance d.sub.M.sup.f from a weld seam center feature point P.sub.MC of the generatrix K.sub.M to the plane L.sub.T according to formula (5). Setting a threshold for a distance d.sub.0.sup.f=1.5 mm from a weld seam center point to a fitted plane, and judging a generatrix with d.sub.M.sup.f>d.sub.0.sup.f as a weld seam position identification abnormal generatrix. Filtering out weld seam feature misidentified generatrices by the above two judgement methods.

[0055] Step 3: Obtaining of Maximum Boundary of Weld Seam

[0056] After filtering out of misidentified generatrices is completed, obtaining maximum boundary of weld seam. Fitting a weld seam center plane L.sub.c by inner weld seam center feature points (P.sub.1C′, P.sub.2C′, . . . P.sub.1380C) of the remaining 1380 qualified generatrices (K.sub.1′, K.sub.2′, . . . K.sub.1380′), and calculating distances (d.sub.1L′, d.sub.2L′, . . . d.sub.1380L′) from left feature points (P.sub.1L′, P.sub.2L′, . . . P.sub.1380L) of the qualified generatrices to the weld seam center plane L.sub.c according to formula (5). Taking the maximum distance d.sub.L′=max(d.sub.1L′, d.sub.2L′, . . . P.sub.1380L), and generating a parallel surface L.sub.l at a distance d.sub.L′ from the left side of the weld seam center plane L.sub.c, namely a weld seam left boundary plane. Obtaining a weld seam right boundary plane L.sub.r in a similar way. Finally, in a three-dimensional coordinate system, calculating intersection points of the left inner wall contour lines (l.sub.1L, l.sub.2L, . . . l.sub.1440L) and the weld seam left boundary plane L.sub.1 in all of the 1440 generatrices (K.sub.1, K.sub.2, . . . K.sub.1440), namely weld seam left boundary points (T.sub.1L, T.sub.2L, . . . , T.sub.1440L) of the generatrices. Obtaining weld seam right boundary points (T.sub.1R, T.sub.2R, . . . , T.sub.1440R) of the generatrices in a similar way. Thus, obtaining of maximum boundary of inner weld seam is completed.

[0057] Step 4: Ideal Weld Seam Contour Conformal Generation and Coarse Grinding

[0058] After obtaining of maximum boundary of weld seam is completed, conformally generating an ideal weld seam contour, and carrying out coarse processing. As shown in FIG. 5, taking the M.sup.th generatrix K.sub.M as an example, and calculating a middle position x.sub.TMC=(x.sub.TML+x.sub.TMR)/2 of a left boundary point T.sub.ML (x.sub.TML, r.sub.TML) and a right boundary point T.sub.MR (x.sub.TMR, r.sub.TMR). Calculating a point (x.sub.TMC, r.sub.1) of the left inner wall contour line l.sub.mL at the middle position and a point (x.sub.TMC, r.sub.2) of the right inner wall contour line l.sub.MR at the middle position. Considering the influence of seam misalignment during cylindrical shell welding, and comparing the point heights r.sub.1 and r.sub.2 the left and right inner wall contour lines l.sub.ML and at the middle position; if r.sub.1>r.sub.2, it is judged that the left inner wall is higher than the right inner wall in the generatrix, and the coordinate of a middle point T.sub.MC, is (x.sub.TMC, r.sub.1). Connecting the three points T.sub.ML, T.sub.MC and T.sub.MR, wherein l.sub.M1 is a connecting line between the point T.sub.ML and the point T.sub.MC, l.sub.M2 is a connecting line between the point T.sub.MC and the point T.sub.MR, and l.sub.M1 and l.sub.M2 form the ideal weld seam contour of the generatrix, which is represented by formula (6).

[0059] Due to errors in robot processing, and in order to avoid damage to the inner wall, generating a processing contour parallel to the ideal weld seam contour at a certain safe distance δ=0.1 mm upward. Discretizing the processing contour into processing points, generating a G code, and carrying out conformal coarse grinding to a cylindrical shell inner weld seam.

[0060] Step 5: Second Weld Seam Contour Measurement and Fine Grinding Parameter Control

[0061] After the coarse grinding is completed, using the laser scanner 3 to scan again, and changing the dwell time of a flap wheel to realize grinding amount control of each part of the weld seam and realize weld seam fine grinding. First, obtaining contours after coarse grinding of generatrices (K.sub.1, K.sub.7, . . . K.sub.1440) by laser scannerscanning Generating a grinding track of the flap wheel 7 according to ideal weld seam middle points (T.sub.1C, T.sub.2C, . . . T.sub.1440C) of various generatrices in a three-dimensional space. Taking the M.sup.th generatrix K.sub.M as an example, setting a variable contour difference to represent the difference between the weld seam contour after coarse grinding and the ideal weld seam contour of the generatrix K.sub.M, and calculating a distance from each point in the weld seam area to an ideal weld seam according to formula (7). As the flap wheel is flexible, when used for processing the generatrix K.sub.M, the flap wheel will have a grinding influence on nearby generatrices (K.sub.M−4, . . . K.sub.M−1,K.sub.M+1, . . . K.sub.M+4). Therefore, a grinding weight is introduced to represent the grinding action of the flap wheel on the weld beam of various generatrices when used for grinding at the generatrix K.sub.M. Weights μ.sub.0=8, μ.sub.1=5, μ.sub.2=4, μ.sub.3=3, μ.sub.4=1. Obtaining a weld seam grinding dwell time coefficient ψ.sub.M at K.sub.M by weighted calculation of the weld seam contour difference, of each generatrix according to formula (8). Finally, obtaining the dwell time t.sub.M of flap wheel grinding at the generatrix K.sub.M according to formula (9). Similarly, calculating the dwell time (t.sub.1, t.sub.2, . . . t.sub.1440) at the generatrices (K.sub.1, K.sub.2, . . . K.sub.1440), generating a G code, and carrying out fine grinding to the weld seam area to complete the conformal processing of the cylindrical shell inner weld seam.

[0062] The process method for conformal processing of a cylindrical shell inner weld seam by a special mobile robot of the present invention realizes conformal processing of a cylindrical shell inner weld seam by a special mobile robot, and improves the processing efficiency and quality of the cylindrical shell inner weld seam.