CN107063233B - Production line management and control device based on inertial sensor - Google Patents

Production line management and control device based on inertial sensor Download PDF

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CN107063233B
CN107063233B CN201710235275.7A CN201710235275A CN107063233B CN 107063233 B CN107063233 B CN 107063233B CN 201710235275 A CN201710235275 A CN 201710235275A CN 107063233 B CN107063233 B CN 107063233B
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worker
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CN107063233A (en
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卢赢
王卫东
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Wuxi Yance Technology Co ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01C—MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
    • G01C21/00—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00
    • G01C21/005—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 with correlation of navigation data from several sources, e.g. map or contour matching
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01C—MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
    • G01C21/00—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00
    • G01C21/10—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration
    • G01C21/12—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning
    • G01C21/16—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning by integrating acceleration or speed, i.e. inertial navigation
    • G01C21/165—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00 by using measurements of speed or acceleration executed aboard the object being navigated; Dead reckoning by integrating acceleration or speed, i.e. inertial navigation combined with non-inertial navigation instruments

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  • Automation & Control Theory (AREA)
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Abstract

The invention relates to a production line management and control device based on an inertial sensor, which comprises a production line and a bracelet, wherein the bracelet comprises a bracelet body, a data acquisition unit, a data processing unit and a data transmission unit, wherein the data acquisition unit, the data processing unit and the data transmission unit are positioned in the bracelet body; the data acquisition unit can acquire the acceleration, the angular velocity and the geomagnetic field data of the bracelet worn by a worker during working in real time, the data processing unit can realize attitude calculation, motion trail tracking and action detection of the worker during working according to the acceleration, the angular velocity and the geomagnetic field data acquired and transmitted by the data acquisition unit, then the number of finished workpieces of the worker and the operation time for finishing each workpiece are calculated according to the action detection result, and finally the number of finished workpieces and the operation time for finishing each workpiece are sent to the field information monitoring system through Bluetooth. The invention can effectively and accurately detect the number of the workpieces processed by the workers wearing the bracelet in unit time, thereby effectively evaluating the working efficiency of the workers.

Description

Production line management and control device based on inertial sensor
Technical Field
The invention relates to a monitoring device, in particular to a production line control device based on an inertial sensor, and belongs to the technical field of production line monitoring.
Background
With the high-speed development of the manufacturing industry in China, more and more factories adopt streamlined operation. The streamlined operation mode can not only improve the assembly efficiency of a factory and accelerate the production progress in an assembly enterprise, but also can count the production information condition of each worker for the investigation of management personnel. However, in a production line system, the assembly speed of a worker may affect the efficiency of the whole production line. Therefore, a pipeline monitoring system is required to monitor the work efficiency of each worker.
The current production line monitoring system mainly comprises a worker scanning bar codes on workpieces by using a collector, and judging the operation time of one worker and the number of the operated workpieces according to the work number of the worker in the collector and the bar code scanning time. Although the method can accurately detect the operation time of workers, the method needs to additionally add a bar code system and a collector on a production line, so that the workload of the workers is increased, and the working efficiency of the production line is reduced. In addition, there is also a method for monitoring the assembling operation of workers based on computer vision, which is only suitable for the case where there is no obstruction on the conveyor belt in the assembly line, and the detection method based on the image has a certain detection error, is easy to be obstructed, and is not suitable for most assembly line systems.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a production line management and control device based on an inertial sensor, which can effectively and accurately detect the actions of taking and putting back workpieces of workers, so that the working efficiency of the workers can be effectively evaluated.
According to the technical scheme provided by the invention, the production line management and control device based on the inertial sensor comprises a production line for conveying workpieces; the wrist strap is used for being worn on the wrist of an operator, and comprises a wrist strap body used for wearing the wrist, and a data acquisition unit, a data processing unit and a data transmission unit which are positioned in the wrist strap body;
the data acquisition unit can acquire the acceleration, the angular velocity and the geomagnetic field data of the bracelet worn by a worker during working in real time, the data processing unit can realize attitude calculation, motion trail tracking and motion detection of the worker during working according to the acceleration, the angular velocity and the geomagnetic field data acquired and transmitted by the data acquisition unit, calculate the number of finished workpieces of the worker and the operation time for finishing each workpiece according to the detected motion, and send the calculated number of finished workpieces and the operation time for finishing each workpiece to the field information monitoring system through the data transmission unit.
The data processing unit performs null shift compensation, smooth filtering and complementary filtering on the acceleration, the angular velocity and the geomagnetic field data transmitted by the data acquisition unit, and then performs attitude calculation, motion trajectory tracking and motion detection.
The data acquisition unit is connected with the data processing unit through an SPI bus, and the data acquisition unit comprises an accelerometer, a gyroscope and an electronic compass.
The invention has the advantages that: the data processing unit can realize attitude calculation, motion trail tracking and motion detection of workers during working according to the acceleration, the angular velocity and the geomagnetic field data collected and transmitted by the data collection unit, and transmits the calculated attitude, the tracked motion trail and the detected motion to an upper computer on a production line through the data transmission unit, so that the number of operating workpieces of the workers and the corresponding operation time are determined through statistics of the upper computer, the workpiece taking and workpiece returning actions of the workers can be effectively and accurately detected, and the working efficiency of the workers can be effectively evaluated.
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FIG. 1 is a schematic structural view of the present invention.
Fig. 2 is a block diagram of the bracelet of the present invention.
Fig. 3 is a schematic diagram of the motion trajectory of the present invention.
Description of reference numerals: 1-production line, 2-workpiece, 3-workbench, 4-data acquisition unit, 5-data processing unit, 6-data transmission unit, 7-power supply, 8-accelerometer, 8-gyroscope and 9-electronic compass.
Detailed Description
The invention is further illustrated by the following specific figures and examples.
As shown in fig. 1: in order to effectively and accurately detect the actions of taking and putting back workpieces of workers and further effectively evaluate the working efficiency of the workers, the invention comprises a production line 1 for conveying the workpieces 2; the wrist strap is worn on the wrist of an operator and comprises a wrist strap body used for wearing the wrist, and a data acquisition unit 4, a data processing unit 5 and a data transmission unit 6 which are positioned in the wrist strap body;
the data acquisition unit 4 can acquire the acceleration, the angular velocity and the geomagnetic field data of the bracelet worn by a worker during working in real time, the data processing unit 5 can realize attitude calculation, motion trail tracking and action detection of the worker during working according to the acceleration, the angular velocity and the geomagnetic field data acquired and transmitted by the data acquisition unit 4, calculate the number of finished workpieces of the worker and the operation time for finishing each workpiece according to the detected action, and send the calculated number of finished workpieces and the operation time for finishing each workpiece to the field information monitoring system through the data transmission unit 6.
Particularly, the bracelet is worn on the wrist of an operator, can adopt a structural form commonly used in the technical field, in the process of taking the workpiece 2 from the production line 1, processing the workpiece 2 and putting the workpiece 2 back on the production line 1 by an operator, the data acquisition unit 4 of the bracelet can acquire the acceleration, the angular velocity and the geomagnetic field data of the bracelet in motion, therefore, the data processing and collecting unit 5 realizes the posture resolving, the motion trail tracking and the action detection of the worker during the work according to the acceleration, the angular velocity and the geomagnetic field data transmitted by the data collecting unit 4, and the number of the workpieces completed by the worker and the operation time for completing each workpiece are calculated according to the detected actions, and the calculated number of workpieces completed and the operation time for completing each workpiece are transmitted to the on-site information monitoring system through the data transmission unit 6.
As shown in fig. 2, the data acquisition unit 4 is connected to the data processing unit 5 through an SPI bus, and the data acquisition unit 4 includes an accelerometer 8, a gyroscope 9, and an electronic compass 10.
In the embodiment of the invention, a power supply 7 is further arranged in the bracelet, the power supply 7 provides working power supplies for the accelerometer, the gyroscope 9, the electronic compass 10, the data processing unit 5 and the data transmission unit 6, the data processing unit 5 comprises a microprocessor, and the data transmission unit 6 comprises a Bluetooth module.
In specific implementation, the data acquisition unit 4 adopts a nine-axis inertial sensor MPU9250 manufactured by invansese company, the nine-axis inertial sensor MPU9250 is a digital sensor for globally integrating nine-axis motion attitude detection, and a three-axis accelerometer, a three-axis gyroscope and a three-axis electronic compass are integrated in the data acquisition unit. The measuring range of the accelerometer 8 can reach +/-16 g, and the angular speed measuring range 2000 of the gyroscope 9oAnd s. The MPU9250 sensor data adopts a serial Peripheral interface SPI (Serial Peripheral interface) or I2C (Inter-Integrated Circuit) bus mode to carry out high-speed communication with the singlechip; book (I)In the embodiment of the invention, the SPI mode is adopted to carry out data interaction with the microprocessor, and the transmission speed can reach 1 MHz. The data processing unit 5 comprises a microprocessor adopting an STM32 single chip microcomputer, the model is STM32F302K8, the microprocessor is small in size and low in power consumption, and meanwhile, the microprocessor is internally provided with a DSP (digital Signal processor) and an FPU (FloatPoint Unit) and can rapidly carry out data calculation and motion detection. The data transmission unit 6 adopts a Bluetooth serial port transparent transmission module HC-05 which has small volume, low power consumption, maximum transmitting power of 8db and maximum transmission distance of 80m, and can conveniently carry out wireless communication with an upper computer monitoring system.
Further, the data processing unit 5 performs null shift compensation, smooth filtering and complementary filtering on the acceleration, the angular velocity and the geomagnetic field data transmitted by the data acquisition unit 4, and then performs attitude calculation, motion trajectory tracking and motion detection.
In the embodiment of the present invention, the data processing unit 5 may implement null shift compensation, smooth filtering and complementary filtering by using a common technical means in the technical field to obtain accurate acceleration, angular velocity and geomagnetic field data, and the process of implementing null shift compensation, smooth filtering and complementary filtering is well known to those skilled in the art and will not be described herein again. When the attitude calculation is performed, the euler angles, namely the yaw angle, the roll angle and the pitch angle of the moving carrier can be calculated by adopting a quaternion-based strapdown inertial navigation method, the three can describe the real-time attitude of the moving carrier in the space, and the specific attitude calculation process is well known by the persons skilled in the art and is not repeated herein.
In order to detect the operation action of a worker, the real-time position information of the worker on the bracelet needs to be determined at first, and then a complete motion track is drawn. Therefore, the work trajectory of the worker needs to be tracked in real time before the motion is detected.
The motion track of the bracelet is drawn according to the position information obtained by a series of processing of the motion data acquired by the data acquisition unit 4,
and the quaternion representing the space state information of the carrier can be solved by the acceleration, the angular velocity and the geomagnetic field data through filtering, attitude calculation and Kalman filtering. The quaternion is a hypercomplex number, and the expression is:
Q(q0,q1,q2,q3)＝q0+q1i+q2j+q3k (1)
wherein q is0、q1、q2、q3Is a real number, i, j, k are units of imaginary numbers and are mutually orthogonal. The motion acceleration after gravity removal can be obtained through the solved quaternion
Figure BDA0001267762900000031
And the attitude matrix converted between the carrier coordinate system (system b) and the inertial navigation coordinate system (system n)
Figure BDA0001267762900000032
Figure BDA0001267762900000033
The acceleration of the carrier in the spatial position relative to the ground can be determined from the formula (2)
Figure BDA0001267762900000034
Figure BDA0001267762900000041
Is the acceleration of motion after gravity is removed, i.e. the absolute acceleration in space.
According to the formula (3), for
Figure BDA0001267762900000042
The movement speed of the carrier can be obtained by carrying out one-time integration
Figure BDA0001267762900000043
In the formula (I), the compound is shown in the specification,
Figure BDA0001267762900000044
is the velocity at time t, t0Representing the initial time, is a determined quantity, with no change in the middle, tnRepresenting the time instant of the nth sample point.
Figure BDA0001267762900000045
Then represents t0The speed of movement of the rotor.
According to the formula (4), the displacement of the carrier motion can be obtained by integrating the motion speed again
Figure BDA0001267762900000046
Wherein the content of the first and second substances,
Figure BDA0001267762900000047
for the displacement at the time t, the displacement is,
Figure BDA0001267762900000048
represents t0The displacement of the moment.
In the embodiment of the present invention, the main detection actions are the following four actions: empty hand pick-up, tape return, workpiece replacement and hand retraction. The motion trace diagram (XY plane) shown in fig. 3 can be obtained by acquiring all actions of the operation worker in the process of completely assembling the workpiece through the inertial sensor after trace tracking. As is evident from fig. 3: the tracks of the empty-hand pickup and the return of the tape are basically overlapped, and the process of picking up the tape can be summarized; the device can stay on the workbench for a long time in the working process; the action of putting back the workpiece and the action of retracting the hand are basically coincident, and the process of putting the workpiece can be concluded.
According to the motion trail diagram shown in fig. 3, the position area of the worker during operation can be accurately judged. Before the motion judgment is carried out by using the track, in order to eliminate the jitter of a person in motion, the position coordinate needs to be subjected to smooth filtering processing, and because the smooth filtering processing is carried out in microprocessing, the system adopts a mode of averaging data for many times to carry out smooth filtering. The smoothing filter formula is:
Figure BDA0001267762900000049
tnrepresents the nth sample point time, tiRepresents the time of the ith sample point and N represents the number of sample points to be smoothed.
After the real-time position coordinates are obtained, whether the worker is in the working process, the workpiece taking process or the workpiece placing process during operation can be judged according to the sizes of x and y in the coordinates. Generally, when the absolute values of the x coordinate and the y coordinate are both less than 0.4, the working process is determined; when x is less than-0.4 and y is more than 0.4, judging the pickup process; and when x is greater than 0.4 and y is greater than 0.4, judging that the piece placing process is performed.
And judging whether the worker completes one complete workpiece operation after judging whether the worker is in the workpiece taking process or the workpiece placing process. In the processes of taking and putting back workpieces, the movement tracks of workers are overlapped, so that the movement direction needs to be judged. The two processes have a certain similarity, and how to determine the moving direction will be described below by taking the process of replacing the workpiece as an example.
And in the judgment of the motion direction, the first order differential calculation of the coordinates of the motion of the carrier is adopted. Namely, it is
Δx(ti)＝x(ti)-x(ti-1) (7)
Δy(ti)＝y(ti)-y(ti-1) (8)
In the formula, x (t)i)、y(ti) Is tiCoordinates of the carrier position at the moment. Δ x (t)i) Represents tiFirst order differential Δ y (t) of the x variable in the coordinates of the time instantsi) Represents tiFirst order differential of the y variable in the coordinates of the time instants.
Direction vector in motion of carrier
Figure BDA0001267762900000051
After the direction vector is obtained by the formula (9), whether the workpiece is taken by an empty hand or returned by a belt piece in the workpiece taking process or whether the workpiece is put back or the hand is retracted in the workpiece putting process can be judged.
When the complete picking process, working process and placing process are continuously detected, the worker can be judged to finish the operation of one workpiece, the number of the workpieces finished by the worker is increased by one, the time required for finishing the process is recorded, and finally the data is sent to the upper computer information monitoring system in a Bluetooth mode. Thus, a motion detection process is completed.

Claims (2)

1. A production line management and control device based on an inertial sensor comprises a production line (1) for conveying workpieces (2); the method is characterized in that: the wrist strap is characterized by further comprising a hand strap used for being worn on the wrist of an operator, wherein the hand strap comprises a hand strap body used for wearing the wrist, and a data acquisition unit (4), a data processing unit (5) and a data transmission unit (6) which are located in the hand strap body;
the data acquisition unit (4) can acquire the acceleration, the angular velocity and the geomagnetic field data of the bracelet worn by a worker during working in real time, the data processing unit (5) can realize attitude calculation, motion trail tracking and action detection of the worker during working according to the acceleration, the angular velocity and the geomagnetic field data acquired and transmitted by the data acquisition unit (4), calculate the number of workpieces completed by the worker and the operation time for completing each workpiece according to the detected action, and send the calculated number of workpieces and the operation time for completing each workpiece to the field information monitoring system through the data transmission unit (6);
the data processing unit (5) performs null shift compensation, smooth filtering and complementary filtering on the acceleration, the angular velocity and the geomagnetic field data transmitted by the data acquisition unit (4), and then performs attitude calculation, motion trajectory tracking and motion detection;
the data processing unit (5) can solve quaternion representing the space state information of the carrier through filtering, attitude resolving and Kalman filtering according to the acceleration, the angular velocity and the geomagnetic field data; the quaternion is a hypercomplex number, and the expression is:
Q(q0,q1,q2,q3)＝q0+q1i+q2j+q3k (1)
wherein q is0、q1、q2、q3Is a real number, i, j, k are units of imaginary numbers and are mutually orthogonal; calculating the motion acceleration after removing the gravity through the solved quaternion
Figure FDA0002413147670000011
And the attitude matrix converted between the b system of the carrier coordinate system and the n system of the inertial navigation coordinate system
Figure FDA0002413147670000012
Figure FDA0002413147670000013
The acceleration of the carrier in the spatial position relative to the ground can be determined from the formula (2)
Figure FDA0002413147670000014
Figure FDA0002413147670000015
Is the motion acceleration after gravity removal, i.e. the absolute acceleration in space;
according to the formula (3), for
Figure FDA0002413147670000016
The movement speed of the carrier can be obtained by carrying out one-time integration
Figure FDA0002413147670000017
In the formula (I), the compound is shown in the specification,
Figure FDA0002413147670000018
is the velocity at time t, t0Representing the initial time, is a determined quantity, with no change in the middle, tnRepresents the time of the nth sample point;
Figure FDA0002413147670000019
then represents t0The speed of motion of the time;
according to the formula (4), the displacement of the carrier motion can be obtained by integrating the motion speed again
Figure FDA00024131476700000110
Wherein the content of the first and second substances,
Figure FDA00024131476700000111
for the displacement at the time t, the displacement is,
Figure FDA00024131476700000112
represents t0Displacement of the moment;
the main detected actions of the bracelet are the following four actions: taking a workpiece by an empty hand, returning the workpiece with the workpiece, putting back the workpiece and retracting the hand; acquiring all actions of an operator in the complete workpiece assembling process through an inertial sensor, and obtaining a motion trail diagram XY plane after tracing the actions; in the motion trail diagram: the tracks of the empty-hand pickup and the return of the tape are basically overlapped, and the process of picking up the tape can be summarized; the device can stay on the workbench for a long time in the working process; the action of putting back the workpiece and the action of retracting the hand are basically coincident, and the process of putting the workpiece can be summarized;
the position area of the worker during operation can be accurately judged according to the motion trail diagram; before the action judgment is carried out by using the track, in order to eliminate the jitter of a person in motion, the position coordinate needs to be subjected to smooth filtering processing, and because the smooth filtering processing is carried out in microprocessing, the system adopts a mode of averaging data for many times to carry out smooth filtering; the smoothing filter formula is:
Figure FDA0002413147670000021
tnrepresents the nth sample point time, tiRepresenting the moment of the ith sampling point, wherein N represents the number of sampling points to be subjected to smooth filtering;
after the real-time position coordinates are obtained, whether the worker is in the working process, the workpiece taking process or the workpiece placing process during operation is judged according to the sizes of x and y in the coordinates; when the absolute values of the coordinate x and the coordinate y are both less than 0.4, judging the working process; when x is less than-0.4 and y is more than 0.4, judging the pickup process; when x is larger than 0.4 and y is larger than 0.4, judging that the workpiece is placed;
judging whether the worker finishes one complete workpiece operation after judging whether the worker is in the workpiece taking process or the workpiece placing process; in the processes of taking and putting back workpieces, the movement tracks of workers are overlapped, so that the movement direction needs to be judged; the two processes have certain similarity, and then the process of putting back the workpiece is taken as an example to describe how to judge the motion direction;
in the judgment of the motion direction, the first order differential of the coordinate of the motion of the carrier is adopted for calculation; namely, it is
Δx(ti)＝x(ti)-x(ti-1) (7)
Δy(ti)＝y(ti)-y(ti-1) (8)
In the formula, x (t)i)、y(ti) Is tiCoordinates of the time carrier position; Δ x (t)i) Represents tiFirst order differential Δ y (t) of the x variable in the coordinates of the time instantsi) Represents tiFirst order differentiation of the y variable in the time coordinate;
direction vector in motion of carrier
Figure FDA0002413147670000022
After the direction vector is obtained by the formula (9), whether the workpiece is taken by an empty hand or returned by a belt piece in the workpiece taking process or whether the workpiece is put back or the hand is retracted in the workpiece putting process can be judged;
when the complete picking process, working process and placing process are continuously detected, the worker is judged to finish the operation of one workpiece, the number of workpieces finished by the worker is increased by one, the time required for finishing the process is recorded, and finally the data is sent to an upper computer information monitoring system in a Bluetooth mode; thus, a motion detection process is completed.
2. The production line management and control device based on the inertial sensor as claimed in claim 1, wherein: the data acquisition unit (4) is connected with the data processing unit (5) through an SPI bus, and the data acquisition unit (4) comprises an accelerometer (8), a gyroscope (9) and an electronic compass (10).
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CN108548520A (en) * 2018-02-25 2018-09-18 中国电信股份有限公司盐城分公司 A kind of antenna attitude remote data acquisition system based on NB-IOT
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