Research on Forging Dimension Online Measuring System Based on Vibration Point Cloud Compensation

Abstract

Mechanical vibration in the high-temperature forging production line often causes large forging thermal dimensional measurement error in the detection task, so a vibration point cloud compensation method based on an acceleration sensor is proposed in this study. First, the vibration signal is obtained through the built-in acceleration sensor in the laser camera. After the acceleration of the camera vibration is detected, the displacement of the camera in three directions is solved by secondary integration. Subsequently, the coordinate value of the corresponding point is obtained by the rotation matrix transformation so as to compensate and correct the point cloud deviation caused by the camera vibration. Finally, the forging point cloud is matched using the surface matching algorithm in Halcon. An automatic forging production line for wheel hubs has been built, and the key dimensions of high-temperature forging products have been measured online using the developed method. After the forging point cloud is compensated, the average measurement error of dimensions is reduced from ±0.9 mm to ±0.1 mm, and the standard deviation is reduced from 0.52 mm to 0.056 mm. Using the vibration point cloud compensation method based on the acceleration sensor, as well as using silica aerogel insulation, vibration structural parts, heat insulation and constant temperature, a blue-violet 3D laser camera, and other measures, the dimensional detection accuracy of high-temperature forgings in the forging production line can be improved, and the instability of dimensional detection can be reduced.