【摘要】：電弧增材制造技術(shù)(Wire Arc Additive Manufacture,WA-AM)是通過焊接電弧瞬間產(chǎn)生高溫將金屬絲材熔化,焊槍按照預(yù)設(shè)的焊接路徑將熔融態(tài)金屬逐層堆積,從而實(shí)現(xiàn)金屬零件的成形目的,具備快速成形大尺寸零件的能力。WA-AM成形過程中,對熱輸入量有直接影響的因素有焊接電流電壓、并行加工的焊槍數(shù)量及焊槍移動速度等,這些因素均會對金屬熔池的形態(tài)、構(gòu)件溫場的分布和金屬凝固的時間產(chǎn)生影響,是制造過程中金屬構(gòu)件成形穩(wěn)定性、形變量和表面質(zhì)量的重要因素影響。本文以多熱源大型電熔增材制造生產(chǎn)過程中構(gòu)件表面的三維重建為研究對象,以準(zhǔn)確獲取比較復(fù)雜或者有較大深度變化部件的三維表面尺寸和溫度數(shù)據(jù)為目標(biāo),在對計算機(jī)視覺中雙目立體視覺原理模型、標(biāo)定、雙目矯正、立體匹配算法和三維重建研究的基礎(chǔ)上,設(shè)計了可見光攝像機(jī)和紅外熱像儀聯(lián)合標(biāo)定的方法以及紅外熱圖像三維重建的方法。在Intel計算機(jī)視覺庫OpenCV提供的視覺開發(fā)平臺下,首先進(jìn)行了可見光雙目立體視覺的研究和實(shí)現(xiàn),包括軟硬件平臺的搭建、攝像機(jī)的標(biāo)定、雙目矯正、雙目立體匹配、三維重建以及重建結(jié)果精度分析,并結(jié)合MATLAB進(jìn)行對比分析,得到的標(biāo)定精度重投影誤差不超過0.5個像素,三維重建誤差約為4mm;然后此基礎(chǔ)上將可見光雙目立體與熱像儀相結(jié)合,搭建了三目視覺系統(tǒng)以實(shí)現(xiàn)紅外圖像的三維重建;針對紅外熱像儀成像特點(diǎn),設(shè)計了一種基于可見光雙目立體視覺和熱像儀三目攝像機(jī)聯(lián)合標(biāo)定的方法,該標(biāo)定方法過程簡單、操作較方便,重投影誤差不超過1個像素,能夠滿足實(shí)際的應(yīng)用需求;最后根據(jù)聯(lián)合標(biāo)定得到的投影矩陣等參數(shù),將可見光雙目圖像的三維重建點(diǎn)云投影到紅外熱像儀成像平面,完成紅外圖像的三維重建,重建誤差約為30mm。
[Abstract]:(Wire Arc Additive manufacture WA-AM) is to melt the metal wire at high temperature through the welding arc, and the welding torch piles the molten metal layer by layer according to the preset welding path, so as to realize the forming purpose of the metal parts. In the process of rapid prototyping large size parts, the factors that have direct influence on the heat input are welding current and voltage, the number of welding torch processed in parallel and the moving speed of welding torch. All these factors will affect the shape of metal melting pool. The distribution of temperature field and the time of solidification are the important factors affecting the forming stability, shape variables and surface quality of metal components. In this paper, the 3D reconstruction of the component surface is studied in the process of manufacturing the large fused material with multiple heat sources. The objective of this paper is to accurately obtain the 3D surface size and temperature data of the more complicated or the parts with large depth variation. On the basis of the research of binocular stereo vision principle model, calibration, binocular correction, stereo matching algorithm and 3D reconstruction, The calibration method of visible light camera and infrared thermal imager and the method of 3D reconstruction of infrared thermal image are designed. Based on the visual development platform provided by Intel computer vision library OpenCV, the research and implementation of binocular stereo vision are first carried out, including the construction of hardware and software platform, camera calibration, binocular correction and binocular stereo matching. The accuracy of 3D reconstruction and reconstruction results are analyzed and compared with MATLAB. The calibration accuracy reprojection error is less than 0.5 pixels, and the 3D reconstruction error is about 4 mm. Then, the binocular stereo of visible light is combined with the thermal imager. A trinocular vision system is set up to realize the 3D reconstruction of infrared image. According to the imaging characteristics of infrared thermal imager, a combined calibration method based on the binocular stereo vision of visible light and the trinocular camera of thermal imager is designed, and the calibration process is simple. The reprojection error is less than 1 pixel, which can meet the practical application requirements. Finally, according to the projection matrix and other parameters of joint calibration, The 3D reconstruction point cloud of the binocular image of visible light is projected to the imaging plane of the infrared thermal imager, and the 3D reconstruction of the infrared image is completed. The reconstruction error is about 30 mm.
【學(xué)位授予單位】：哈爾濱工業(yè)大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG444;TP391.41

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