基于机器人3D视觉引导的汽车空腔自动发泡研究

Automatic Foaming Application of Automobile Cavity Based on Robot 3D Vision Guidance

为解决人工加注汽车空腔双组分聚氨酯泡沫时生产效率低和质量稳定性差的问题,对视觉检测技术、发泡工艺和机器人自动化应用进行研究,提出一种3D视觉引导机器人进行汽车空腔自动发泡的方案。通过地面安装的3台相机组成3D视觉系统,拍照检出汽车车身在工作站内的静止位置,计算出车身实际位置与标定的基准位置之间的偏差,引导机器人进入车身空腔填充泡沫的工作区域,保证机器人末端安装的3D激光视觉传感器拍摄加注孔的位置相对不变。机器人手持3D激光视觉传感器,检测车身加注孔在立体空间中的坐标位置,计算出加注孔的实际位置与标定的基准位置之间的偏差,引导加注枪头精确插入加注孔,防止发生干涉甚至碰撞。机器人与液压定比计量系统通信,传递双组分聚氨酯的加注量信息;液压定比计量系统以一定的流量和压力输送双组分聚氨酯材料进入加注枪的混合室,充分混合并注入空腔发生化学反应,实现在汽车空腔内自动发泡。将该方案应用于某主机厂的涂装车间,生产节拍显著提高,制造质量一致性良好。

In order to solve the problems of low production efficiency and poor quality stability of manual filling of automobile cavity two-component polyurethane foam,the foaming process,vision inspection technology and robot automation application were studied,and a set of automatic foaming scheme based on robot 3D vision guidance was proposed.Through the 3D vision system composed of 3 cameras installed on the ground,through taking pictures,the rest position of the car white body in the workstation was checked out,the deviation between the actual position and the benchmark of the white body was calculated.The robot was led into the white body cavity filling foam work area,the position that the 3D vision sensor took photographs of filling hole should be relatively constant.The robot held a 3D vision sensor to detect the coordinate position of the body-in-white filling hole in the three-dimensional space,the deviation between the actual position of the filling hole and the calibrated reference position was calculated,the filling gun was guided to insert the filling hole accurately to prevent interference or even collision.The robot communicated with the hydraulic constant ratio metering system to transfer the filling amount information of the two-component polyurethane.The hydraulic constant ratio metering system delivered the two-component polyurethane material into the mixing chamber of the filling gun at a certain flow rate and pressure.The material was fully mixed and injected into the cavity for chemical reaction to realize automatic foaming in the automobile cavity.This scheme was applied to the painting workshop of an automobile factory,and the production beat was significantly improved with good consistency of manufacturing quality.