Machine vision methods are widely applied in detection tasks during the machining process, such as indexing fixture angle measurement, gear profile inspection, crankshaft processing, headphone jack manufacturing, intelligent grinding, and CNC machine tool automatic tool alignment.In earlier years, traditional manual lathe machining of conductive slip ring copper rings had many drawbacks. Therefore, the introduction of machine vision methods in the manufacturing and inspection of conductive slip ring copper rings not only ensures higher accuracy and efficiency but also avoids the subjectivity and individual differences associated with manual inspection.
To address the challenges faced during the machining process of precise conductive slip ring grooves, a positioning solution based on image measurement and analysis principles has been proposed.This solution utilizes machine vision methods to obtain the cutting position for each pass and ultimately generates the G-code required for machine tool processing, achieving the automation of precise conductive slip ring groove machining. As a method for automation in the process of conductive slip ring manufacturing, machine vision measurement technology demonstrates rationality and scientific basis but also complexity. The following analysis delves into this issue.
The process of measuring and machining conductive slip ring grooves within the machine involves several cumbersomesteps. The specific process is as follows: 1) Mount the precise conductive slip ring onto the lathe. 2) Install the measuring head on the machine tool and position it at the initial location. 3) Capture four sets of images at the initial position of the slip ring, 90°, 180°, and 270°, respectively. 4)Process each set of images and calculate the average values of the four sets of data. 5) Based on the measurement results and the machine tool’s movement mode,calculate the machining position of the groove and generate the corresponding G-code. 6) Remove the measuring head, install the machining tool, and run themeasurement G-code for machining.
To ensure precise measurement and control of conductive slip ring groove machining using machine vision measurement systems, a complex hardware setup is required. This setup includes industrial cameras, dual-telecentric lenses, lighting sources, mechanical structures, and measurement fixtures, among others. Undoubtedly, this increases costs, and the complexity of the system also introduces risks of reduced stability. Therefore,when applying machine vision measurement technology, it is necessary to enhance its reliability and ensure long-term stable operation before deployment, which inevitably adds to the costs. However, in the current context, intelligent high-end machine tools have been widely adopted in the field of mechanical machining. For the processing of conductive slip ring copper rings, complex machine vision measurement technology is generally no longer required.
