虚实融合的液压支架浮动连接机构位姿监测方法

A pose monitoring method for floating connection mechanism of a hydraulic support based on virtual-real integration

  • 摘要: 针对液压支架浮动连接机构(FCM)无法直接获取各部件位姿且整体位姿获取精度受限的问题,提出了一种虚实融合的液压支架FCM位姿监测方法。通过安装在液压支架顶梁的相机采集FCM深度图像和RGB图像,生成真实点云的三维坐标信息并存储在指定文件中;文件转换后由Unity读取并创建对应坐标数据的方块,实现真实点云的映射;构建液压支架、FCM和刮板输送机的数字孪生体,在Unity中添加父子关系、物理引擎和碰撞体,创建虚拟相机来获取FCM推杆上表面的虚拟点云,使用迭代最近点(ICP)算法将推杆上表面虚拟点云和裁剪后的真实点云配准得到推杆平移旋转矩阵,将其转换为Unity驱动数据后驱动推杆运动并在父子关系、物理引擎和碰撞体的限制下带动FCM其余部件运动,实现FCM所有部件的位姿监测。实验结果表明:该方法监测的FCM推移量误差在3.5 cm以内,推杆俯仰角误差在1.1°以内,推杆偏转角误差在0.5°以内,连接头偏转角误差在0.8°以内,FCM位姿整体监测精度较高。

     

    Abstract: To address the problem that the Floating Connection Mechanism (FCM) of a hydraulic support cannot directly obtain the pose of its components and that the accuracy of the overall pose acquisition is limited, this study proposed a pose monitoring method for the hydraulic support FCM based on virtual-real integration. By using a camera installed on the top beam of the hydraulic support to collect depth and RGB images of the FCM, the system generated three-dimensional coordinate information of the real point cloud and stored it in a specified file. After file conversion, Unity read the coordinate data and created corresponding cubes to map the real point cloud. Digital twins of the hydraulic support, FCM, and scraper conveyor were constructed. Parent-child relationships, physics engines, and colliders were added in Unity. A virtual camera was created to capture the virtual point cloud of the upper surface of the FCM push rod. The Iterative Closest Point (ICP) algorithm was used to register the virtual point cloud of the push rod’s upper surface with the cropped real point cloud to obtain the translation and rotation matrix of the push rod. This matrix was then converted into Unity to drive the movement of the push rod. Under the constraints of the parent-child relationships, physics engines, and colliders, it further drove the movement of other FCM components, thus achieving pose monitoring of all FCM components. Experimental results showed that the proposed method achieved a monitoring error of less than 3.5 cm in FCM displacement, less than 1.1° in push rod pitch angle, less than 0.5° in push rod deflection angle, and less than 0.8° in connector deflection angle, indicating high accuracy in overall FCM pose monitoring.

     

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