面向轨道车辆车体表面质量的检修工艺技术

Research on Maintenance Process Technology for Rail Vehicle Carbody Surface Quality

[目的]针对人工对轨道车辆车体表面进行打磨作业后,油漆缺陷部位需进行找补时,因车辆运用环境不确定性及车体表面油漆失效程度不同,导致表面检修作业过程难以管控,且工艺不稳定等问题,需研究面向轨道车辆车体表面质量的检修工艺技术。[方法]建立轨道车辆车体打磨机器人工艺系统,采用视觉传感器依据车体表面打磨路径获取表面油漆黄斑、划痕、脱落等缺陷并进行图像处理;变换为油漆缺陷区域中心坐标,运用“九点法”对机器人进行手眼标定并求出变换矩阵;将图像采集的中心坐标转化为机器人工作空间坐标,以路经最短原则运用改进自适应遗传算法对机器人坐标进行路径优化;形成机器人车体表面缺陷打磨最优路径。[结果及结论]该系统能够根据获取图像自动提取缺陷区域中心坐标,并转化为机器人工件坐标系内的末端移动坐标,通过改进自适应遗传算法优化机器人缺陷打磨路径,改善人工作业效率的同时提升车体表面质量检修工艺稳定性。

[Objective]After manually polishing the surface of railway vehicle carbodies and subsequently repairing paint defects,because of uncertainties in the vehicle operating environment and varying degrees of paint deterioration,the surface maintenance process becomes difficult to control,leading to instability in the process.Therefore,it is necessary to study the maintenance technology for the surface quality of railway vehicle carbodies.[Method]A rail vehicle carbody grinding robot process system is established,employing visual sensors to detect surface paint defects such as yellow spots,scratches,and peeling along the grinding path.The defects are processed through image analysis,and converted into central coordinates of the paint defect areas.The′nine-point method′is applied for hand-eye calibration of the robot to calculate the transformation matrix.The central coordinates obtained from image acquisition are transformed into the robot working space coordinates.Using an improved adaptive genetic algorithm based on the shortest path principle,the robot coordinates are optimized for path planning to form the most efficient route for defect grinding on vehicle carbody surface.[Result&Conclusion]The system automatically extracts defect area central coordinates from captured images and converts them into end-effector movement coordinates in robot workspace.Through the optimization of robot defect grinding paths using the above algorithm,the system improves the efficiency of manual operation while enhancing the stability of surface quality maintenance technology for vehicle carbodies.