本文關(guān)鍵詞：基于機器視覺的共軌針閥尺寸參數(shù)在線測量監(jiān)控系統(tǒng)的研究與開發(fā)　出處：《江蘇大學》2017年碩士論文　論文類型：學位論文

  更多相關(guān)文章： 機器視覺 在線檢測 共軌針閥 尺寸檢測 圖像處理

【摘要】：共軌噴油嘴針閥偶件是柴油機燃油噴射系統(tǒng)的三大精密偶件之一,在工業(yè)大馬力柴油發(fā)動機以及輕型客、轎車柴油發(fā)動機上均有使用,是保證柴油發(fā)動機燃油噴射系統(tǒng)穩(wěn)定運行的關(guān)鍵部件之一,其精度要求高、產(chǎn)量大,相應地測量精度、檢測效率等要求也隨之提高。如何實現(xiàn)共軌針閥零件尾部尺寸參數(shù)的快速、穩(wěn)定、高效、高精和全數(shù)在線測量,是目前工業(yè)生產(chǎn)中亟待解決的問題。本文圍繞某外資企業(yè)噴油嘴共軌針閥零件的尾部尺寸參數(shù)測量與過程控制所展開。針對視覺在線測量系統(tǒng)的精度、效率、穩(wěn)定性、完整性等難點,在系統(tǒng)平臺的整體設計、圖像高精度處理、系統(tǒng)參數(shù)標定、光機電一體化控制及系統(tǒng)開發(fā)等方面進行了一定的研究。本文的主要研究內(nèi)容和成果如下:首先,進行視覺在線測量監(jiān)控系統(tǒng)的整體設計。具體包括光學視覺系統(tǒng)硬件選型匹配和運動機構(gòu)方案設計。結(jié)合目標零件輪廓特征、待測尺寸、企業(yè)生產(chǎn)線狀況,確定光學視覺系統(tǒng)的打光方式,并進行相機、鏡頭及光源的選型;基于光源在視覺系統(tǒng)中的重要性,定性研究了復合光和單色光對測量系統(tǒng)的影響,得出單色光在背光方式中效果優(yōu)異;同時,研究了光強與輪廓像素定位之間的關(guān)系,得出本文視覺系統(tǒng)在某一光強范圍內(nèi),效果達到最優(yōu);根據(jù)待測零件特征,確定上料輸送、定位及分揀運動機構(gòu)方案。其次,對光學系統(tǒng)獲取的共軌針閥圖像進行處理算法設計。在降噪方面,通過濾波對比實驗,選擇了中值濾波算子,引入基于中值濾波的小區(qū)域濾波算法,大大縮短了濾波時間;在輪廓邊緣檢測方面,通過對比實驗,引入了基于Sobel的小區(qū)域定向搜索邊緣檢測算法,提高了邊緣定位效率,并采用小區(qū)域邊緣特征點跟蹤方法,基于學習訓練邏輯,完成目標特征點定位;在邊緣亞像素定位和擬合方面,引入基于穩(wěn)健線性回歸的直線擬合方法,在特定小區(qū)域下完成高精度邊緣擬合,并完成直徑、角度、距離的多參數(shù)同時計算。然后,深入地進行了視覺系統(tǒng)標定的理論研究與設計。對相機系統(tǒng)的參數(shù)標定、鏡頭的光學畸變及校正等進行了說明;分析研究了時下常用了標定方法,基于Microscape軟件系統(tǒng),采用兩步標定法,完成相機內(nèi)外參數(shù)及鏡頭畸變的標定與校正;運用標準網(wǎng)格及標準件,對相機位置及像素當量進行校準和計算。接下來,對在線視覺測量監(jiān)控系統(tǒng)軟件、硬件控制進行了具體的設計與開發(fā)。在Microscape視覺系統(tǒng)下設計圖像算法處理過程,并基于VB完成了其在視覺檢測、控制、統(tǒng)計計算、人機交互等方面的二次開發(fā);同時基于統(tǒng)計學理論設計了工序質(zhì)量實時監(jiān)控系統(tǒng),為生產(chǎn)線的實時在線監(jiān)控、統(tǒng)計和分析提供完整應用;運用CATIA軟件對整體自動化機構(gòu)進行設計,完成整體上料輸送、定位夾緊及下料分揀機構(gòu)的三維圖繪制,并設計了系統(tǒng)工作流程、自動化設備的通信與控制,完成整套系統(tǒng)的邏輯與運行控制。最后,進行了樣機研制與可靠性評價,通過測試,運行情況良好。借助專用的Q-DAS數(shù)據(jù)統(tǒng)計分析軟件,對樣機平臺系統(tǒng)的穩(wěn)定性、偏倚能力指數(shù)、重復再現(xiàn)性進行實驗及分析評價,統(tǒng)計分析表明樣機對共軌針閥零件尾部直徑、角度、距離的尺寸測量,在公差范圍內(nèi)達到了10倍以上的測量精度,系統(tǒng)亞像素分辨率達到了0.0008~0.0003mm,滿足了工業(yè)實際應用需求;并以直徑參數(shù)為例,測試了平臺的工序質(zhì)量實時監(jiān)控統(tǒng)計系統(tǒng),驗證了本文的理論研究成果的可行性、有效性。本文完成了共軌針閥零件的尾部尺寸參數(shù)在線測量監(jiān)控系統(tǒng)的研究與開發(fā),對其他同類產(chǎn)品的在線測量具有重要的借鑒作用。
[Abstract]:The common rail injector needle valve is one of the three big precision coupling of fuel injection system in diesel engine industry, and light passenger car diesel engine are used, is to ensure that the diesel engine fuel injection system is one of the key components of its stable operation, high precision, large output, the corresponding measurement accuracy so, the detection efficiency requirement is increasing. How to realize the common rail valve parts tail size parameters of fast, stable, high efficiency, high precision and full online measurement, is the current industrial production problems to be solved. This paper focuses on a foreign enterprise common rail injector needle valve parts of the tail size parameter measurement and process control. According to the visual online measurement system accuracy, efficiency, stability, integrity and other difficulties, in the overall design of system platform, high precision image processing, system calibration, optical electromechanical The research of integrated control and system development. The main research contents and results are as follows: firstly, the overall design of measuring and monitoring system for visual online. Including the design of optical vision system hardware matching and motion mechanism scheme combining the target contour features, the size to be measured, the enterprise production line status determination of the optical visual system lighting methods, and selection of camera lens and light source; light importance in the vision system based on the qualitative research on the effects of compound light and monochromatic light on the measurement system, the monochromatic light in the backlight in excellent effect; at the same time, study the relation between the light intensity and the contour pixel location. The visual system in a certain intensity range, to achieve the optimal effect; according to the features of parts to be measured to determine material conveying, sorting and positioning movement mechanism second scheme, Processing algorithm design of common rail valve image optical system is obtained. In denoising, filtering through the contrast experiment, choose the median filtering operator, introduce small domain filtering algorithm based on median filtering, greatly shorten the filtering time; in the edge detection, through the contrast experiment, introduces the search algorithm of edge detection area orientation based on Sobel, and improves the edge localization efficiency, and the tracking feature point area edge training logic based on target feature points, positioning; in sub-pixel edge locating and fitting, introducing the linear fitting method of linear regression based on the completion of high precision edge fitting in specific area, and complete the diameter at the same time, angle, distance calculation of multi parameter. Then, in-depth theoretical research and design of the vision system calibration. The calibration parameters of the camera lens system. The head of the optical distortion and correction are described; analysis of the nowadays commonly used calibration method, based on Microscape software, using two step calibration method, calibration and calibration of camera parameters and lens distortion; using standard grid and standard parts, calibration and calculation of the camera position and the pixel equivalent. Next, the online visual measurement monitoring system software, hardware control is designed and developed. The design of specific image processing algorithms in the process of Microscape vision system based on VB, and completed its control in visual inspection, statistical calculation, two times the development of human-computer interaction and so on; at the same time, based on statistical theory and design of real-time monitoring system of process the quality of real-time online monitoring for production line, to provide a complete application of statistics and analysis; application of integrated automation mechanism design CATIA software, complete the whole conveying, set A three-dimensional map of clamping and cutting the sorting mechanism is drawn, and the design of the workflow system, communication and control automation equipment, complete set of logic and operation control system. Finally, the prototype development and reliability evaluation, through the test, running in good condition. With the help of Q-DAS data for statistical analysis software, the stability of the prototype the platform system, the bias capability index, repeatability of experimental evaluation and analysis, statistical analysis showed that the prototype of common rail valve parts, tail diameter, distance measurement, the measurement accuracy reached more than 10 times in the tolerance range, sub-pixel resolution system has reached 0.0008~0.0003mm, and meets the requirements of industrial application; and the diameter of parameters for example, process quality real-time monitoring and statistical system platform test, verify the feasibility of this paper, the theoretical research results. The validity of this paper. It has become the research and development of on-line measurement and monitoring system for tail size parameters of common rail needle valve parts, which has important reference for other similar products online measurement.

【學位授予單位】：江蘇大學
【學位級別】：碩士
【學位授予年份】：2017
【分類號】：TP391.41;TP277

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