CN111300418A - Clearance surface difference adjusting method in assembling process - Google Patents
Clearance surface difference adjusting method in assembling process Download PDFInfo
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- CN111300418A CN111300418A CN202010174614.7A CN202010174614A CN111300418A CN 111300418 A CN111300418 A CN 111300418A CN 202010174614 A CN202010174614 A CN 202010174614A CN 111300418 A CN111300418 A CN 111300418A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
- B25J9/1687—Assembly, peg and hole, palletising, straight line, weaving pattern movement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/10—Aligning parts to be fitted together
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
- B23P2700/50—Other automobile vehicle parts, i.e. manufactured in assembly lines
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Abstract
The invention discloses a clearance surface difference adjusting method in an assembling process.A plurality of structured light sensors respectively collect structured light images of specific positions to be measured in an area to be assembled after an assembling body reaches an assembling station; determining a clearance value and/or a face difference value; calculating the gap fraction and/or the surface difference number at each position to be measured and the corresponding weight coefficient; marking the position to be adjusted according to the score value, calculating offset based on the position to be adjusted, feeding the offset back to the robot, adjusting the current pose of the robot, changing the position of the part to be assembled in the area to be assembled, and continuously fine-tuning to know that the clearance surface difference of the part to be assembled meets the process requirement; completing the assembly process; the method realizes the automatic adjustment of the gap and the surface difference, the time consumption of the whole process is less than 45 seconds, and the qualification rate of the gap and the surface difference of the product can reach 100 percent.
Description
Technical Field
The invention relates to the field of assembly, in particular to a clearance surface difference adjusting method in the assembly process.
Background
The assembly process is an important link in production and processing, the accuracy of the assembly of parts directly influences the overall performance and the attractiveness of a product, the assembly of the parts is mainly completed manually for a long time, along with the development of computers and robot technologies, a robot and visual guide method is adopted in the modern precision assembly process, the deviation between a characteristic hole and a standard position is analyzed in real time based on image information, and then a robot is regulated to grab and load a piece through a deviation value, so that the assembly efficiency and the assembly accuracy are improved by the method, but only the positioning error of a certain point or multiple points is considered, and the process parameters of gaps and surface differences generated after the assembly of the parts lack of attention; because of manufacturing errors, robot positioning errors and vision measurement errors, gaps and surface differences of installed workpieces are difficult to be strictly controlled within a process requirement range, and the sizes of the gaps and the surface differences are accurate or not, so that the attractiveness and the sealing performance of the whole product are related, the gaps and the surface differences are very important parameters in quality monitoring, and if the covering part is large in size errors in the production process of an automobile, the gaps and the surface differences of the automobile body are large, so that the appearance, the wind dryness, the sealing and the like of the whole automobile are influenced.
Disclosure of Invention
Aiming at the problems, the invention provides a clearance surface difference adjusting method in the assembling process, which utilizes the line structure light vision detection technology, arranges a structure light vision sensor (comprising a projector and a camera) in the area to be assembled, actively projects line structure light to the position of the clearance and the surface difference to be measured, and determines the size parameters of the clearance and the surface difference through the deformation (protrusion, depression, fluctuation and the like) of the line structure light; the technical scheme of the invention is that the robot is adjusted based on the position offset with the lowest score by performing score evaluation on each position to be measured, and a plurality of iteration processes are set to continuously fine-tune parts until the positions of the parts meet the process requirements of gaps and surface differences; the automatic adjustment of the gap and surface difference is realized, the time consumption of the whole process is less than 45 seconds, and the qualification rate of the gap and surface difference of the product can reach 100%.
A clearance surface difference adjusting method in an assembling process is characterized in that a plurality of structured light sensors are fixedly arranged in an assembling station, and when an assembling body reaches the assembling station, a robot moves a part to be assembled to an assembling area of the assembling body and stops; at the moment, the plurality of structured light sensors respectively collect structured light images at each specific position to be detected in the region to be assembled; recording the space coordinates of each position to be measured in a global coordinate system according to the structured light image, and determining a gap numerical value and/or a surface difference numerical value of a certain position to be measured;
adjusting the clearance and/or the surface difference during the assembly process by:
1) calculating the gap fraction and/or the area difference fraction at a single position to be measured:
fraction of said gap
Setting a corresponding weight coefficient; wherein d isxThe absolute value of the difference between the gap value and the standard gap value at the position is shown, and t is the process error allowable value of the gap at the position;
difference number of said surface
Setting a corresponding weight coefficient; wherein u isxThe absolute value of the difference between the surface difference value and the standard surface difference value at the position is taken as k, and the process error allowable value of the surface difference at the position is taken as k;
traversing each position to be detected by adopting the same method to obtain a gap fraction and/or a surface difference fraction of each position to be detected and a corresponding weight coefficient; the sum of all weight coefficients equals 1;
2) traversing all the gap scores and the surface difference scores, judging whether a position to be measured with the score of 0 exists, if so, recording the position to be measured with the score of 0 as a position to be adjusted, and recording the gap and/or surface difference characteristics corresponding to the score as direction characteristics; performing step 3);
if not, calculating the matching degree; the matching degree is the sum of the characteristic values of all positions to be detected;
if the single position to be measured only comprises one of the gap fraction or the surface difference fraction, the characteristic value is the product of the gap fraction or the surface difference fraction and the weight coefficient of the gap fraction or the surface difference fraction; if the single position to be measured contains the gap fraction and the surface difference fraction, respectively calculating the product of the gap fraction and the weight coefficient thereof and the product of the surface difference fraction and the weight coefficient thereof, and then recording the sum of the two products as the characteristic value;
judging whether the matching degree is greater than a preset value B, if so, determining that the position of the current component to be assembled meets the requirement, and directly performing the step 4) without adjustment;
if not, recording the position to be measured with the lowest score as the position to be adjusted, and recording the clearance and/or surface difference characteristics corresponding to the score as the direction characteristics; performing step 3);
3) translating the space coordinates of the position to be adjusted, and recording the translation amount when the direction characteristics meet the process error allowable range; translating the space coordinates of other positions to be measured according to the translation amount, and recording other positions to be measured on the edge of the position to be adjusted as associated position points;
if the number of the associated position points is more than one, fitting and solving the rotation amount between the space coordinate of the associated position point after translation and the space coordinate of the target position point by using a least square method; the target position point is a position point when the clearance/surface difference value of the associated position point is adjusted to a standard value;
if there is only one associated position point, the rotation amount θ is calculated as follows:
wherein S represents a gap/surface difference value after the translation of the associated position point; s' represents a standard value of the gap/surface difference of the associated position point; l represents a distance value between the associated position point and the position to be adjusted;
feeding the translation amount and the rotation amount back to the robot, adjusting the current pose of the robot, changing the position of the to-be-assembled part in the to-be-assembled area, recording the space coordinates of each to-be-assembled position in the global coordinate system after adjustment, recalculating the gap value and/or the surface difference value of each to-be-assembled position, and judging again by adopting the same method;
4) and fixing the current component to be assembled on the assembling body to finish the assembling process.
Further, the assembly body is an automobile body in white, and the parts to be assembled comprise an automobile door, a top cover, a front cover, a rear cover and a fender.
Furthermore, the preset value B is 0.4-0.8.
Further, when the component to be assembled is an automobile door, the positions to be measured are selected as follows: at least two positions to be detected are selected on the upper/lower edge of the vehicle door, and at least two positions to be detected are selected on the edge of the vehicle door close to the vehicle tail.
Furthermore, at least two positions to be measured are respectively selected on the edges of two sides of the long axis of the top cover, and at least two positions to be measured are selected on the edge of one side of the short axis of the top cover.
Further, when the number of the positions to be detected selected on a single edge is more than two, the positions to be detected are uniformly distributed on the edge;
when the number of the positions to be measured selected on the single edge is equal to two, the distance between the positions to be measured and the positions to be measured is 1/5-1/3.
Further, if a plurality of positions to be measured with the scores of 0 or the lowest score exist, one of the positions to be measured is optionally marked as a position to be adjusted.
According to the technical scheme, the technical indexes of gaps and surface differences of assembled parts are mainly considered, fraction evaluation is carried out on each position to be measured, the robot is adjusted based on the position offset with the lowest fraction, multiple iteration processes are set, and the parts are continuously finely adjusted until the positions of the parts meet the technological requirements of the gaps and the surface differences; compared with the prior machine vision guiding method, the qualification rate of product gaps and surface differences is 50-75%, and the unqualified products need to be measured by a vernier caliper (feeler gauge) and manually adjusted, so that the accuracy and the production rhythm are seriously influenced; the method realizes the automatic adjustment of the gap and the surface difference, the time consumption of the whole process is less than 45 seconds, and the qualification rate of the gap and the surface difference of the product can reach 100 percent.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a schematic diagram illustrating the selection of a position to be measured of the front door in embodiment 1;
FIG. 3 is a schematic diagram illustrating the selection of a position to be measured of the rear door in embodiment 2;
fig. 4 is a schematic diagram illustrating selection of a position to be measured of the top cover in embodiment 3.
Detailed Description
The technical solution of the present invention is described in detail below with reference to the accompanying drawings and the detailed description.
The scheme of the invention can be applied to various automatic assembly processes, the assembly body can be an industrial assembly part, a furniture assembly part, an electronic product assembly part and the like, for example, the assembly body can be an automobile body-in-white, a high-speed rail body, an airplane body and the like, and the corresponding parts to be assembled can be a door, a window, a front cover, a rear cover and the like;
specifically, when the assembly body is an automobile body in white, the parts to be assembled include an automobile door, a top cover, a front/rear cover, and a fender.
Example 1
As an embodiment of the present invention, taking the assembly of an automobile door as an example, a clearance surface difference adjustment method in the assembly process is as follows:
the method comprises the following steps that a plurality of structured light sensors are fixedly arranged in an assembly station, and when an assembly body reaches the assembly station, a robot moves a part to be assembled to an area to be assembled of the assembly body and stops; at the moment, the plurality of structured light sensors respectively collect structured light images at specific positions to be detected in the region to be assembled; recording the space coordinates of each position to be measured in a global coordinate system according to the structured light image, and determining a gap numerical value and/or a surface difference numerical value of a certain position to be measured;
the positions to be measured are selected as follows: selecting at least two positions to be detected on the upper/lower edge of the vehicle door, and selecting at least two positions to be detected on the edge of the vehicle door close to the vehicle tail;
specifically, as shown in fig. 2, a schematic diagram of positions to be measured of the rear door of the automobile is selected, three positions to be measured are uniformly selected on the side edge of the automobile door close to the tail of the automobile and are marked as S1, S2 and S5, the three positions to be measured are used for simultaneously measuring a gap value and a surface difference value, and a gap fraction and a surface difference fraction are calculated; two positions to be measured are selected on the upper edge of the vehicle door and marked as S8 and S9, and the distance between a single position point and the edge end part is 1/5-1/3; in this embodiment, the gap score is calculated by measuring only the gap value at 1/5 at the two positions to be measured;
as shown in fig. 1, the clearance and/or the surface difference during the assembly process are adjusted by the following steps:
1) calculating the gap fraction and/or the area difference fraction at a single position to be measured:
fraction of gap
Setting a corresponding weight coefficient; wherein d isxIs the absolute value of the difference between the gap value and the standard gap value at the position, and t is the process error allowable value of the gap at the position;
number of surface differences
Setting a corresponding weight coefficient; wherein u isxThe absolute value of the difference between the surface difference value and the standard surface difference value at the position is k, and the process error allowable value of the surface difference at the position is k; t is 0.2-1 mm, k is 0.2-0.8 mm;
traversing each position to be detected by adopting the same method to obtain a gap fraction and/or a surface difference fraction of each position to be detected and a corresponding weight coefficient; the sum of all weight coefficients equals 1;
in this embodiment, when the score is calculated, t is 1mm, and k is 0.5 mm; the gap requirements of S1, S2, S5 are: the standard clearance value is 3.75 +/-0.5 mm, and the surface difference requirement is as follows: the standard surface difference value is 0+0.5 mm;
the gap requirements of S6 and S9 are that the standard gap value is 12.5 +/-1.0 mm;
the gap weight of the position to be measured S1, the position to be measured S2 and the position to be measured S5 is 0.2; the surface difference weight of the position to be measured S1, the position to be measured S2 and the position to be measured S5 is 0.1; the gap weight of the position to be measured S8 and the position to be measured S9 is 0.05;
calculating to obtain a position to be measured S1 (gap fraction R is 0, plane difference M is 0.43), S2 (gap fraction R is 0.12, plane difference M is 0.45), S5 (gap fraction R is 0.13, plane difference M is 0.45), S8 (gap fraction R is 0.33) and S9 (gap fraction R is 0.56);
2) traversing all the gap scores and the surface difference scores, judging whether a position to be measured with the score of 0 exists, if so, recording the position to be measured with the score of 0 as a position to be adjusted, and recording the gap and/or surface difference characteristics corresponding to the score as direction characteristics; performing step 3);
if not, calculating the matching degree; the matching degree is the sum of the characteristic values of all positions to be detected;
if the single position to be measured only contains one of the gap fraction or the surface difference fraction, the characteristic value is the product of the gap fraction or the surface difference fraction and the weight coefficient of the gap fraction or the surface difference fraction; if the single position to be measured contains the gap fraction and the surface difference fraction, respectively calculating the product of the gap fraction and the weight coefficient thereof and the product of the surface difference fraction and the weight coefficient thereof, and recording the sum of the two products as a characteristic value;
judging whether the matching degree is greater than a preset value B, if so, determining that the position of the current component to be assembled meets the requirement, and directly performing the step 4) without adjustment; in this embodiment, the preset value B is 0.5;
if not, recording the position to be measured with the lowest score as the position to be adjusted, and recording the clearance and/or surface difference characteristics corresponding to the score as the direction characteristics; performing step 3);
recording the position to be measured S1 as a position to be adjusted and recording the corresponding gap characteristic as a direction characteristic through the analysis; performing step 3);
3) translating the space coordinates of the position S1 to be adjusted, and recording the translation amount (moving 0.65mm in the rear direction of the vehicle) when the direction characteristics meet the allowable range of the process error;
translating the space coordinates of other positions to be measured according to the translation amount, and recording other positions to be measured on the edge of the position to be adjusted as associated position points (S2 and S5);
if the number of the associated position points is more than one, fitting and solving the rotation amount between the space coordinate of the associated position point after translation and the space coordinate of the target position point by using a least square method; the target position point is the position point when the clearance/surface difference value of the associated position point is adjusted to a standard value;
the method specifically comprises the following steps: retrieving the gap value at the translated associated position points (S2 and S5)Setting the door rotation angle as theta for Gap2_ M and Gap5_ M, and calculating the distance between the measuring points of S2 and S1 as ls1s2And the distance between the points S5 and S1 is ls1s5Then, the Gap values Gap2 and Gap5 at S2 and S5 after rotation by the rotation angle θ are obtained:
Gap2＝Gap2_M-lS1S2*tanθ
Gap5＝Gap5_M-lS1S5*tanθ
fitting and solving the rotation amount theta between the space coordinates of the correlation position points after translation and the space coordinates of the target position points by a least square method; so as to make residual error
At a minimum, the formula for the residual is as follows:
wherein, Gap2_ S, Gap5_ S respectively represents the standard clearance values at S2 and S5, and the final rotation amount is 0.21 degree around the Y axis;
feeding the translation amount and the rotation amount back to the robot, adjusting the current pose of the robot, changing the position of the to-be-assembled part in the to-be-assembled area, recording the space coordinates of each to-be-assembled position in the global coordinate system after adjustment, recalculating the gap value and/or the surface difference value of each to-be-assembled position, and judging again by adopting the same method;
4) and fixing the current component to be assembled on the assembling body to finish the assembling process.
In the implementation process, the robot is adjusted for 2 times, the final rear door installation matching degree P value is 0.48, and all positions to be measured meet tolerance requirements; a single adjustment took 27.5 seconds;
and after the assembly body is assembled, the assembly body is moved to the next station through the roller bed, and meanwhile, the next assembly body reaches the assembly station to carry out assembly operation.
Example 2
As another embodiment of the present invention, as shown in fig. 3, a schematic diagram of the positions to be measured of the front door of the automobile is selected, two positions to be measured are selected on the side edge of the door close to the tail of the automobile and are marked as S6 and S7, the two positions to be measured simultaneously measure the gap value and the surface difference value, and calculate the gap fraction and the surface difference fraction; two positions to be measured are selected from the upper edge of the vehicle door and marked as S3 and S4, the two positions to be measured only measure the gap value, and the gap fraction is calculated;
each position point to be detected is 1/5-1/3 away from the end part of the edge; in this example, choose at 1/4; when the fraction is calculated, t is 0.2-1 mm, and k is 0.2-0.8 mm; the preset value B is 0.8;
in this embodiment, when the score is calculated, t is 0.5mm, and k is 1 mm; the gap requirements of S6 and S7 are as follows: the standard clearance value is 3.5 +/-0.5 mm, and the surface difference requirement is as follows: the standard surface difference value is 0+0.5 mm;
the gap requirements of S3 and S4 are that the standard gap value is 13.5 +/-1.0 mm;
the gap weight of the position to be measured S3 and the position to be measured S4 is 0.1; the gap weight of the position to be measured S6 and the position to be measured S7 is 0.2; the surface difference weight of the position to be measured S6 and the position to be measured S7 is 0.1;
calculating to obtain a position to be measured S3 (gap fraction R is 0.66), S4 (gap fraction R is 0.38), S6 (gap fraction R is 0.33, plane difference M is 0.13), and S7 (gap fraction R is 0.6, plane difference M is 0.65) through step 1);
recording the position S6 to be measured as a position to be adjusted and recording the corresponding surface difference characteristic as a direction characteristic by the judgment of the step 2); performing step 3);
3) translating the space coordinates of the position S6 to be adjusted, and recording the translation amount (moving 0.47mm towards the direction in the vehicle) when the direction characteristics meet the process error allowable range; translating the space coordinates of other positions to be measured according to the translation amount, and recording other positions to be measured on the edge where the position to be adjusted is located as associated position points (S7);
if there is only one associated position point, the rotation amount θ is calculated as follows:
wherein S represents a gap/surface difference value after the translation of the associated position point; s' represents a standard value of the gap/surface difference of the associated position point; l represents a distance value between the associated position point and the position to be adjusted;
specifically, the method comprises the following steps: after translation, the numerical value of the S7 surface difference is Flush7_ M, the rotation angle of the car recording door is theta, and the distance between the measuring points S7 and S6 is ls7s6And Flush7 represents the standard surface deviation from S7.
Finally, the rotation angle is calculated to be-0.15 degrees;
feeding the translation amount and the rotation amount back to the robot, adjusting the current pose of the robot, changing the position of the to-be-assembled part in the to-be-assembled area, recording the space coordinates of each to-be-assembled position in the global coordinate system after adjustment, recalculating the gap value and/or the surface difference value of each to-be-assembled position, recalculating the score and judging the to-be-assembled position by the same method;
4) and fixing the current component to be assembled on the assembling body to finish the assembling process.
In the implementation process, the robot is adjusted for 3 times, and the time consumed by single adjustment is 38.7 seconds; finally, the mounting matching degree P of the rear door is 0.88, the absolute value of the difference between the gap and surface difference values of S6 and S7 and the standard value is less than or equal to 0.16mm, the absolute value of the difference between the gap and standard value of S3 and S4 is less than or equal to 0.18, and the gap and surface difference of all positions to be measured can be controlled within 0.2mm, so that the tolerance requirement is met.
Example 3
In this embodiment, taking a component to be assembled as an automobile roof as an example, the positions to be measured are selected as follows: at least two positions to be measured are selected on the edges of two sides of the long shaft of the top cover respectively, and at least two positions to be measured are selected on the edge of one side of the short shaft of the top cover.
Specifically, 2 positions to be measured are selected from the long axis edges of the two sides of the top cover respectively and are marked as S10, S11, S12 and S13, and a gap value and a surface difference value are calculated at each measuring point;
selecting 2 positions to be measured on the short axis edge of the top cover, marking as S15 and S14, and only calculating the gap value at each measuring point;
setting weights, wherein the gap weights of the position to be measured S10, the position to be measured S11, the position to be measured S12 and the position to be measured S13 are set to be 0.2;
the gap weight of the position to be measured S15 and the position to be measured S14 is 0.1;
when the fraction is calculated, t is 0.2-0.8 mm, and k is 0.2-0.8 mm; the preset value B is 0.8.
In this embodiment, when the score is calculated, t is 0.5mm, and k is 0.8 mm;
the gap requirements of S10, S11, S12 and S13 are as follows: the standard clearance value is 25 +/-0.5 mm;
the gap requirements of S14 and S15 are that the standard gap value is 27.5 +/-1.0 mm;
calculating to obtain a position to be measured S10 (gap fraction R is 0.23), S11 (gap fraction R is 0.42), S12 (gap fraction R is 0.02), S13 (gap fraction R is 0.02), S14 (gap fraction R is 0.56) and S15 (gap fraction R is 0.61) through the step 1);
recording the position S12 to be measured as a position to be adjusted and recording the corresponding gap characteristic as a direction characteristic by the judgment of the step 2); performing step 3);
3) translating the space coordinate of the position S12 to be adjusted, and recording the translation amount (moving 0.42mm along the short axis direction and in the direction of the single side of the vehicle) when the direction characteristic meets the process error tolerance range; translating the whole top cover according to the translation amount; translating the space coordinates of other positions to be measured according to the translation amount, and recording other positions to be measured on the edge where the position to be adjusted is located as associated position points (S13);
if there is only one associated position point, the rotation amount θ is calculated as follows:
wherein S represents a gap/surface difference value after the translation of the associated position point; s' represents a standard value of the gap/surface difference of the associated position point; l represents a distance value between the associated position point and the position to be adjusted;
specifically, the method comprises the following steps: calculating a Gap value Gap13_ M at the position of S13 after the top cover is translated; the standard Gap value at S13 is Gap13, ls12s13Between points S12 and S13Distance, rotation amount θ:
finally, the rotation of the lid about S12 was found to be 0.27 °.
Feeding the translation amount and the rotation amount back to the robot, adjusting the current pose of the robot, changing the position of the to-be-assembled part in the to-be-assembled area, recording the space coordinates of each to-be-assembled position in the global coordinate system after adjustment, recalculating the gap value and/or the surface difference value of each to-be-assembled position, recalculating the score and judging the to-be-assembled position by the same method;
4) and fixing the current component to be assembled on the assembling body to finish the assembling process.
In the implementation process, the preset requirement can be met by adjusting the robot for 1 time, and the time consumed by single adjustment is 17.6 seconds; finally, the mounting matching degree P of the rear top cover is 0.83, and the gaps and the surface differences of all positions to be measured can be controlled within 0.3mm, so that the tolerance requirement is met.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and its practical application to enable others skilled in the art to make and use various exemplary embodiments of the invention and various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the following claims and their equivalents.
Claims (7)
1. A clearance surface difference adjusting method in an assembling process is characterized in that a plurality of structured light sensors are fixedly arranged in an assembling station, and when an assembling body reaches the assembling station, a robot moves a part to be assembled to an assembling area of the assembling body and stops; at the moment, the plurality of structured light sensors respectively collect structured light images at each specific position to be detected in the region to be assembled; recording the space coordinates of each position to be measured in a global coordinate system according to the structured light image, and determining a gap numerical value and/or a surface difference numerical value of a certain position to be measured;
the method is characterized in that the clearance and/or the surface difference in the assembling process are adjusted through the following steps:
1) calculating the gap fraction and/or the area difference fraction at a single position to be measured:
fraction of said gap
Setting a corresponding weight coefficient; wherein d isxThe absolute value of the difference between the gap value and the standard gap value at the position is shown, and t is the process error allowable value of the gap at the position;
difference number of said surface
Setting a corresponding weight coefficient; wherein u isxThe absolute value of the difference between the surface difference value and the standard surface difference value at the position is taken as k, and the process error allowable value of the surface difference at the position is taken as k;
traversing each position to be detected by adopting the same method to obtain a gap fraction and/or a surface difference fraction of each position to be detected and a corresponding weight coefficient; the sum of all weight coefficients equals 1;
2) traversing all the gap scores and the surface difference scores, judging whether a position to be measured with the score of 0 exists, if so, recording the position to be measured with the score of 0 as a position to be adjusted, and recording the gap and/or surface difference characteristics corresponding to the score as direction characteristics; performing step 3);
if not, calculating the matching degree; the matching degree is the sum of the characteristic values of all positions to be detected;
if the single position to be measured only comprises one of the gap fraction or the surface difference fraction, the characteristic value is the product of the gap fraction or the surface difference fraction and the weight coefficient of the gap fraction or the surface difference fraction; if the single position to be measured contains the gap fraction and the surface difference fraction, respectively calculating the product of the gap fraction and the weight coefficient thereof and the product of the surface difference fraction and the weight coefficient thereof, and then recording the sum of the two products as the characteristic value;
judging whether the matching degree is greater than a preset value B, if so, determining that the position of the current component to be assembled meets the requirement, and directly performing the step 4) without adjustment;
if not, recording the position to be measured with the lowest score as the position to be adjusted, and recording the clearance and/or surface difference characteristics corresponding to the score as the direction characteristics; performing step 3);
3) translating the space coordinates of the position to be adjusted, and recording the translation amount when the direction characteristics meet the process error allowable range; translating the space coordinates of other positions to be measured according to the translation amount, and recording other positions to be measured on the edge of the position to be adjusted as associated position points;
if the number of the associated position points is more than one, fitting and solving the rotation amount between the space coordinate of the associated position point after translation and the space coordinate of the target position point by using a least square method; the target position point is a position point when the clearance/surface difference value of the associated position point is adjusted to a standard value;
if there is only one associated position point, the rotation amount θ is calculated as follows:
wherein S represents a gap/surface difference value after the translation of the associated position point; s' represents a standard value of the gap/surface difference of the associated position point; l represents a distance value between the associated position point and the position to be adjusted;
feeding the translation amount and the rotation amount back to the robot, adjusting the current pose of the robot, changing the position of the to-be-assembled part in the to-be-assembled area, recording the space coordinates of each to-be-assembled position in the global coordinate system after adjustment, recalculating the gap value and/or the surface difference value of each to-be-assembled position, and judging again by adopting the same method;
4) and fixing the current component to be assembled on the assembling body to finish the assembling process.
2. The clearance face difference adjustment method in the assembling process according to claim 1, wherein: the assembly body is an automobile body in white, and the parts to be assembled comprise an automobile door, a top cover, a front cover, a rear cover and a fender.
3. The clearance face difference adjustment method in the assembling process according to claim 2, wherein: the preset value B is 0.4-0.8.
4. The clearance face difference adjustment method in the assembling process according to claim 2, wherein: when the part to be assembled is an automobile door, the positions to be tested are selected as follows: at least two positions to be detected are selected on the upper/lower edge of the vehicle door, and at least two positions to be detected are selected on the edge of the vehicle door close to the vehicle tail.
5. The clearance face difference adjustment method in the assembling process according to claim 2, wherein: when the part to be assembled is the automobile roof, the positions to be tested are selected as follows: at least two positions to be measured are selected on the edges of two sides of the long shaft of the top cover respectively, and at least two positions to be measured are selected on the edge of one side of the short shaft of the top cover.
6. The clearance face difference adjustment method in the assembling process according to claim 4 or 5, wherein: when the number of the positions to be detected selected on a single edge is more than two, the positions to be detected are uniformly distributed on the edge;
when the number of the positions to be measured selected on the single edge is equal to two, the distance between the positions to be measured and the positions to be measured is 1/5-1/3.
7. The clearance face difference adjustment method in the assembling process according to claim 1, wherein: and if a plurality of positions to be measured with the scores of 0 or the lowest score exist, one of the positions to be measured is optionally marked as a position to be adjusted.
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