核主泵复杂零件机器人在位自动光学检测系统开发  

The Development of Onsite-Automatic-Optical Inspection System with Robot for Complex Parts of Nuclear Main Pump

作　　者：李文龙[1] 李中伟[2] 毛金城[1,3] 王刚[1] LI Wenlong;LI Zhongwei;MAO Jincheng;WANG Gang(State Key Laboratory of Digital Manufacturing Equipment and Technology,Huazhong University of Science and Technology,Wuhan 430074;State Key Laboratory of Material Processing and Die&Mould Technology,Huazhong University of Science and Technology,Wuhan 430074;School of Mechanical&Electrical Engineering,Wuhan Institute of Technology,Wuhan 430205)

机构地区：[1]华中科技大学数字制造装备与技术国家重点实验室,武汉430074 [2]华中科技大学材料成形与模具技术国家重点实验室,武汉430074 [3]武汉工程大学机电工程学院,武汉430205

出　　处：《机械工程学报》2020年第13期179-191,共13页Journal of Mechanical Engineering

基　　金：国家自然科学基金(51535004,91648111);湖北省杰出青年基金(2017CFA045);中央高校基本科研业务费(2019kfyXKJC046)资助项目。

摘　　要：采用机器人在位光学检测系统实现法兰密封型面误差检测与表面缺陷识别是解决核电现场人工检修可靠性差、存在核辐射伤害等问题的有效途径,但如何在狭小空间生成无干涉碰撞扫描测量路径、实现多次测量数据融合与型面误差计算是目前面临的主要难题。为此设计了具有6自由度运动功能的机器人在位自动光学检测系统,单幅测量范围200mm×160mm^800mm×640mm、测量景深400~800mm、机器人工作半径1200mm,研究了测量系统手-眼标定矩阵计算与扫描位姿优化方法,并根据法兰密封型面完整测量需求生成扫描工位与机器人运动路径,提出面向法兰密封型面特定结构的测量数据融合与型面误差计算方法,开发出具备机器人测量路径控制、大规模测量点云预处理、三维匹配与色谱显示、型面误差计算与技术报告输出等功能的RobotScan软件。按照德国VDI/VDE标准对机器人检测系统精度进行了验证,单球直径、双球球心距的最大偏差小于0.025mm、平均偏差小于0.02mm,可满足核主泵复杂零件在位自动光学检测应用需求。It is effective method to deal with the problem of poor reliability and potential nuclear radiation from artificial maintenance,by using robot onsite-optical inspection system to calculate Flange seal profile error and identify surface detection.However,how to generate scanning path without interference,perform multiple measuring data fusion and calculate the profile error are the main challenges.This paper designs a robot onsite-automatic-optical inspection system with 6 degrees of freedom motion,which has 200 mm×160 mm^800 mm×640 mm measuring range,400~800 mm measuring depth and 1200 mm motion radius.The method of hand-eye calibration matrix calculation and scanning pose optimization is investigated,and the required scanning station as well as robot motion path is generated according to a global measuring requirement of the Flange seal profile.Following that,the method of the measuring data fusion and profile error calculation for Flange profile structure is proposed,and a RobotScan software is developed with the functional of robot measuring path control,point cloud pre-processing,3 D matching with chromatography display,profile error calculation and inspection report output.Finally,the accuracy of robot inspection system is tested according to the German VDI/VDE standard,the maximum deviations and absolute deviations of single-sphere diameter/double-ball center distance are within 0.025 mm and 0.02 mm respectively,which can meet the onsite-automatic-optical inspection requirement of complex parts of nuclear main pump.

关 键 词：核主泵复杂零件 机器人光学检测 扫描位姿优化 测量数据融合 RobotScan软件 

分 类 号：TP29[自动化与计算机技术—检测技术与自动化装置]