In digital alignment systems, ensuring fast and accurate alignment between the ball head on large aircraft components and the ball socket of the positioner is the key to aircraft assembly efficiency and quality. Image-based visual servoing is one of the most advanced techniques with high efficiency and positioning accuracy, but it does not account for measuring the ball-head position. Moreover, variable target positions, similar feature interference, and poor lighting conditions pose great challenges to the fast and robust visual measurement of ball-head position. Hence, an online visual measurement method is introduced to measure the absolute position of the ball head in real time. An adaptive region of interest extraction algorithm and an improved edge following method are introduced to extract the elliptical contour from the ball-head image, and ellipse detection is achieved through a simple triplet selection algorithm. A geometric model based on the perspective projection of the sphere is established for estimating the ball-head center. Then, the simplified image-based visual servoing method is developed by constantizing the image Jacobian matrix. Next, an adaptive positioning method of large-scale aircraft components with multiple ball heads is proposed from a holistic perspective. Finally, experiments show that the final positioning accuracy of each ball head in the X/Y plane is less than ± 0.05 mm, with an efficiency almost ten times that of the conventional method. After adaptive adjustment, the position and angle errors of the simulated component are reduced within 0.6 mm and 0.3°, respectively.
Read full abstract