摘要
火车轴在高温锻造后,表面形状不规则,且在冷却过程中,轴体可能变形,给粗削工序的轴心点定位带来挑战和困难。现有方法,如两点法、光学投影法、回转轴法等,或只考虑端面中心与局部表面,忽略轴体变形与表面不规则形状,存在效率低、无法加工、产品损耗大的问题等。针对现有方法存在的问题,提出一种火车轴粗削最优加工的标记方法,首先通过扫描仪扫描得到3D轴体点云,先后对点云进行坐标系转换、对变换点云进行切片、计算初始加工轴;然后分析产品加工CAD(computer aided design)模型在轴体点云空间余量分布情况,采用梯度下降法优化策略来调整加工轴位置;最终计算得到火车轴粗削加工的最优标记点,再通过激光打标机标记在轴体上。该方法使用C++与PCL(point cloud library)混合编码实现,在中车现场实践验证长达一个月,数据统计表明准确性>98%,效率相比人工提升了3~6倍。该方法提高了火车轴粗削工序的生产效率,降低了生产过程的报废率,同时保证车削加工过程中余量充分性和旋转平衡性。
The surface shape of the train shaft is irregular after hot forge,and the shaft body may deform during the cooling process,which poses challenges and difficulties for the positioning of the axis point in the primary turnery process.The existing methods,such as two-point method,optical projection method,rotation axis method,etc.,or only consider the center and local surface,ignoring the deformation of the axis and the irregular shape of the surface,have problems such as low efficiency,inability to manufacture,and large product loss and so on.This paper proposes a marking method for the optimal manufacturing of train axle in primary turnery to address the problems,which in existing methods.Firstly,obtaining a 3D point cloud of the axle by a scanner.Then,the point cloud is successively transformed into another coordinate system,cut into discrete slices,and calculated to getting the initial machining axis.Next,the spatial margin distribution of the product machining computer aided design(CAD)model in the axle point cloud is analyzed.Simultaneously,the gradient descent optimization strategy is used to adjust the machining axis position.Finally,the optimal marking point for rail axle to processing optimal manufacturing is calculated,and then marked on the axle by the laser marking machine.This method is implemented using the mixed encoding of C++and point cloud library(PCL),and has been validated on site by China railway rolling stock corporation(CRRC)for up to a month,and data statistics show an accuracy of over 98%,with an efficiency improvement of 3~6 times compared to the operator.This method improves the production efficiency of the primary turnery process for rail axles,reduces the scrap rate in the production process,and ensures the margin adequacy and rotational balance during the turning process.
作者
刘仁明
张耀
贺文斌
Liu Renming;Zhang Yao;He Wenbing(Changsha Hibay Intelligent Technology Co.,Ltd.,Changsha 410100,China;The Greater Bay Area Institute for Innovation,Hunan University,Guangzhou 510250,China;School of Electrical and Information Engineering,Hunan University,Changsha 410082,China)
出处
《电子测量与仪器学报》
北大核心
2025年第6期212-220,共9页
Journal of Electronic Measurement and Instrumentation
基金
国家自然科学基金(62303172,62133005)项目资助。
作者简介
通信作者:刘仁明,2012年于长沙学院获得学士学位,2016年于湖南大学获得硕士学位,现为长沙海贝智能科技有限公司工程师,主要研究方向为计算机视觉、图像处理、智能控制。E-mail:ming27456@126.com;张耀,分别在2009年、2012年、2022年于湖南大学获得学士学位、硕士学位和博士学位,现为湖南大学广州大湾区创新研究院的研究员,主要研究方向为图像处理及其视觉、自动化设备。E-mail:zy85721@126.com;贺文斌,2020年于河南工业大学获得学士学位,2022年于湖南大学获得硕士学位,现为湖南大学博士研究生,主要研究方向为机器人制造和检测,深度学习和智能信号处理。E-mail:hwenbin@hnu.edu.cn。
