CN107861483B - Workpiece neglected loading monitoring system based on ultrasonic induction and detection method thereof - Google Patents
Workpiece neglected loading monitoring system based on ultrasonic induction and detection method thereof Download PDFInfo
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- G05B19/00—Programme-control systems
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- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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Abstract
The invention discloses a workpiece neglected loading monitoring system based on ultrasonic induction and a detection method thereof, wherein the monitoring system comprises an information acquisition system, an information processing system and a display alarm system: the information acquisition system comprises an ultrasonic correlation device, a power amplifier and a first direct-current power supply; the information processing system comprises a signal conditioning circuit, an information collector, a control computer and a second direct-current power supply; the display alarm system comprises a projector and an audible and visual alarm. The workpiece neglected loading monitoring system of the production line comprises an information acquisition system, an information processing system and a display alarm system, can automatically monitor whether the workpiece neglected loading exists on the production line in real time, realizes open non-contact detection, only needs to carry out parameter setting at the initial stage, does not need manual intervention in the monitoring process, reduces unnecessary manpower and time waste, helps to reduce the workpiece neglected loading rate in the production process, and improves the overall quality and the safety performance of a product assembled by workpieces.
Description
Technical Field
The invention relates to the field of workpiece neglected loading monitoring, in particular to a workpiece neglected loading monitoring system based on ultrasonic induction and a detection method thereof.
Background
In order to detect neglected loading of workpieces in manual assembly processes of various industrial productions (particularly, automobile industrial productions), special devices and methods have been adopted at home and abroad. Although the currently adopted neglected loading detection methods have respective advantages, the methods have many disadvantages, such as incapability of realizing real-time detection, single detection object (only one device can realize the neglected loading of a certain specific object), and various limiting conditions of detection.
In terms of the commonly used workpiece neglected loading detection method at present: 1) the manual detection method comprises the following steps: and (4) carrying out comprehensive and specific neglected loading inspection on each workpiece on the station by a specially-assigned person, and judging whether the workpiece is neglected loaded or not. Although the method can achieve the purpose of neglected loading detection and can determine the specific position of the neglected loading of the workpiece, the method needs special personnel for operation, consumes more labor and time and has poor detection real-time performance; 2) the weight checking and detecting method comprises the following steps: and accurately weighing the assembled workpiece, comparing the obtained data with standard weight data of the assembled workpiece, and observing whether the workpiece is neglected to be installed or not. The method has the advantages of simple principle and convenient operation. The defect is that the detection real-time performance is poor, the workpiece neglected loading position cannot be positioned, and the requirement cannot be met to realize timely detection when more workpieces need to be detected; 3) the image identification detection method comprises the following steps: by collecting various image data and processing and analyzing the image data, whether the workpiece is neglected to be installed or not and whether the workpiece is wrongly installed or not are judged. The method has the advantages of good stability and high accuracy. The disadvantages are that corresponding devices must be designed according to the detected object, and the monitoring equipment has high cost, large volume and very complex installation.
At present, in the assembly production of workpieces, the phenomenon of workpiece neglected loading caused by various reasons can affect the performance of products needing to be provided with the neglected loading workpieces, and can cause the products to have faults or even cause accidents in the using process, thereby endangering the safety of users. In addition, although many factory enterprises currently adopt some advanced methods and apparatuses to enhance the detection of missing workpiece, the phenomenon of missing workpiece still exists more generally. Therefore, it becomes very important to design an ideal workpiece neglected loading monitoring system for the production line.
An ultrasonic sensor is a sensor that converts an ultrasonic signal into another energy signal (typically an electrical signal). Ultrasonic waves are mechanical waves with vibration frequencies above 20 KHz. It has the features of high frequency, short wavelength, less diffraction, high directivity, directional propagation, etc. The penetration of ultrasonic waves into liquids and solids is great, especially in sunlight-opaque solids. Ultrasonic waves hitting impurities or interfaces can generate significant reflection to form echoes, and the Doppler effect can be generated when the ultrasonic waves hit a moving object. The ultrasonic sensor is widely applied to the aspects of industry, national defense, biomedicine and the like.
Disclosure of Invention
The invention aims to solve the technical problems and provides a workpiece neglected loading monitoring system based on ultrasonic induction and a detection method thereof.
The invention is realized by the following technical scheme:
the utility model provides a work piece neglected loading monitored control system based on ultrasonic wave response, includes information acquisition system, information processing system and display alarm system:
the information acquisition system comprises an ultrasonic correlation device, a power amplifier and a first direct current power supply: the ultrasonic wave correlation device comprises a first ultrasonic wave correlation device arranged on two corresponding sides of a worker and a second ultrasonic wave correlation device arranged on two corresponding sides of a workpiece, each ultrasonic wave correlation device comprises an ultrasonic wave transmitting device and an ultrasonic wave receiving device, the ultrasonic wave transmitting devices are used for transmitting ultrasonic wave lines to detect the worker or the workpiece, the ultrasonic wave receiving devices are used for receiving the ultrasonic wave lines transmitted by the ultrasonic wave transmitting devices, and the output ends of the ultrasonic wave receiving devices are connected with the input end of the power amplifier; the first direct current power supply is used for providing 3.4V direct current voltage for the ultrasonic wave transmitting device;
the information processing system comprises a signal conditioning circuit, a data acquisition unit, a control computer and a second direct-current power supply: the signal conditioning circuit is used for carrying out voltage boosting, signal reduction and filtering on the induction signal, and the output end of the signal conditioning circuit is connected with the A/D conversion input end of the data acquisition unit; the data acquisition unit performs A/D conversion on the acquired signals and then sends the signals to the control computer for processing the induction signals; the control computer is used for processing the detected and collected sensing signals, judging whether the workpiece is neglected to be installed or not, if the workpiece is neglected to be installed, sending a signal to the display alarm system, controlling the display alarm system to display a production line where the neglected to be installed workpiece is located and giving out acousto-optic alarm; the second direct current power supply is used for providing 3.4V direct current voltage, and the output end of the second direct current power supply is respectively connected with the signal conditioning circuit, the data acquisition unit and the power supply input end of the control computer;
the display alarm system comprises a projector and an audible and visual alarm: the projector comprises a projector and a projector curtain, wherein the projector is provided with an amplification key, a reduction key, a function key, a determination key and an opening/suspending key, and the input end of the projector is connected with the output end of the control computer; the audible and visual alarm comprises a buzzer and an alarm lamp which are controlled by a control computer and used for giving an audible and visual alarm after the condition that the workpiece is not loaded is detected.
The ultrasonic transmitting device comprises a single chip microcomputer, a driving circuit, a modulation circuit and an ultrasonic transmitting head, the output end of the first direct-current power supply is connected with the input end of the single chip microcomputer, the ultrasonic receiving device comprises an ultrasonic receiving head and a demodulation circuit, and the demodulation circuit is connected with the signal conditioning circuit.
The method for detecting the workpiece neglected loading monitoring system based on the ultrasonic induction comprises the following steps:
1) arranging first ultrasonic correlation devices on two corresponding sides of a worker, and arranging second ultrasonic correlation devices on two corresponding sides of a workpiece;
2) setting a standard time interval of the second ultrasonic correlation device intercepted by the workpiece;
3) starting a first ultrasonic correlation device, after a worker arrives at a station, sending a signal to a control computer after the first ultrasonic correlation device is intercepted, and sending a signal to start a second ultrasonic correlation device by the control computer;
4) after the workpiece reaches the station, the second ultrasonic correlation device starts to record the time blocked by the workpiece, and feeds back the signal to the control computer, and the control computer judges whether the workpiece is neglected to be installed according to the received signal:
if the time of the second ultrasonic correlation device intercepted by the workpiece is within the standard time interval set in the step 2), the system continues to monitor the workpiece on the production line;
if the time of the second ultrasonic correlation device intercepted by the workpiece is not within the standard time interval set in the step 2), the control computer sends a signal to control a display alarm system after receiving the signal, displays the production line where the neglected-installed workpiece is located, and sends out an acousto-optic alarm.
The beneficial effects are that: the system comprises an information acquisition system, an information processing system and a display alarm system, wherein the information acquisition system applies an ultrasonic correlation device, so that the system has good sensing capability and can automatically monitor whether the workpiece is neglected for loading on a production line in real time or not in time. Only initial parameter setting is needed, manual intervention is not needed in the monitoring process, unnecessary labor and time waste is reduced, the missing rate of workpieces in the production process is reduced, and the overall quality and safety performance of products assembled by the workpieces are improved.
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In order to more clearly illustrate the technical solution in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly described below. It is clear that the described figures are only some embodiments of the invention, not all embodiments, and that a person skilled in the art can also derive other designs and figures from them without inventive effort.
FIG. 1 is a schematic view of the overall structure of the present invention;
FIG. 2 is a block diagram of a system module of the present invention;
fig. 3 shows the sound pressure variation of the ultrasonic wave received by the ultrasonic wave receiving device.
Detailed Description
The conception, the specific structure, and the technical effects produced by the present invention will be clearly and completely described below in conjunction with the embodiments and the accompanying drawings to fully understand the objects, the features, and the effects of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and those skilled in the art can obtain other embodiments without inventive effort based on the embodiments of the present invention, and all embodiments are within the scope of the present invention. In addition, all the connection relations mentioned herein do not mean that the components are directly connected, but mean that a better connection structure can be formed by adding or reducing connection accessories according to the specific implementation situation. All technical characteristics in the invention can be interactively combined on the premise of not conflicting with each other.
As shown in fig. 1 to 2, an ultrasonic sensing-based workpiece neglected loading monitoring system includes an information acquisition system 1, an information processing system 2 and a display alarm system 3, where the information acquisition system 1 may be a plurality of information acquisition systems 1 distributed on different production lines at the same time, they transmit the acquired data to the information processing system 2, and the information processing system 2 makes a judgment, where:
the information acquisition system 1 comprises an ultrasonic correlation device, a power amplifier 12 and a first direct current power supply 13: the ultrasonic wave opposite-emitting device includes a first ultrasonic wave opposite-emitting device disposed at both sides corresponding to the worker, and a second ultrasonic wave opposite-emitting device disposed at both sides corresponding to the workpiece, each of the ultrasonic wave opposite-emitting devices includes an ultrasonic wave emitting device 111 and an ultrasonic wave receiving device 112, the ultrasonic wave emitting device 111 is used for emitting ultrasonic wave lines to detect the worker or the workpiece, the ultrasonic wave receiving device 112 is used for receiving the ultrasonic wave lines emitted from the ultrasonic wave emitting device 111, as shown in fig. 3, when the ultrasonic wave line emitted from the ultrasonic wave emitting device 111 is blocked by the workpiece, the sound pressure of the ultrasonic wave line received by the ultrasonic wave receiving device 112 becomes low, according to the duration time of the ultrasonic line with the reduced sound pressure, the estimated time of workpiece assembly can be judged, and then the estimated time of workpiece assembly is compared with the approximate time required by the conventional workpiece assembly, so that whether the workpiece is likely to have the condition of neglected assembly can be judged. The output end of the ultrasonic receiving device 112 is connected with the input end of the power amplifier 12; the first direct current power supply 12 is used for providing 3.4V direct current voltage for the ultrasonic wave transmitting device 111, and ensuring that the ultrasonic wave transmitting device 111 can continuously transmit ultrasonic wave lines through the ultrasonic wave transmitting head;
the information processing system 2 comprises a signal conditioning circuit 21, a data acquisition unit 22, a control computer 23 and a second direct current power supply 24: the signal conditioning circuit 21 is used for performing voltage boosting, signal reduction and filtering on the induction signal, and the output end of the signal conditioning circuit is connected with the A/D conversion input end of the data acquisition unit 22; the data acquisition unit 22 performs A/D conversion on the acquired signals and then sends the signals to the control computer 23 for processing the induction signals; the control computer 23 is used for processing the detected and collected sensing signals, judging whether the workpiece is neglected for loading or not, if the workpiece is neglected for loading, sending a signal to the display alarm system 3, and controlling the display alarm system 3 to display a production line where the neglected-loading workpiece is located and give out an audible and visual alarm; the second dc power supply 24 is used for providing 3.4V dc voltage, and its output terminal is connected to the input terminals of the signal conditioning circuit 21, the data collector 22 and the control computer 23.
The display alarm system 3 includes a projector 31 and an audible-visual alarm 32: the projector 31 comprises a projector and a projector curtain, wherein the projector is provided with an amplification key, a reduction key, a function key, a determination key and an opening/suspending key, various parameters and placing positions of the projector can be adjusted according to the position to be projected in advance, so that the projection can be clearly displayed on the projector curtain, the input end of the projector 31 is connected with the output end of the control computer 23, and the projector 31 can display a production line where a missed workpiece is positioned after receiving a signal from the control computer 23; the audible and visual alarm 32 comprises a buzzer and an alarm lamp which are controlled by the control computer 23, and after the condition that the workpiece is not loaded is detected, the buzzer sends out a buzzing alarm sound, and the alarm lamp lights red light to give an alarm.
The ultrasonic transmitting device 111 comprises a single chip microcomputer, a driving circuit, a modulation circuit and an ultrasonic transmitting head, the output end of the first direct current power supply 13 is connected with the input end of the single chip microcomputer, the ultrasonic receiving device 112 comprises an ultrasonic receiving head and a demodulation circuit, and the demodulation circuit is connected with the signal conditioning circuit 21.
The method for detecting the workpiece neglected loading monitoring system based on the ultrasonic induction comprises the following steps:
1) arranging first ultrasonic correlation devices on two corresponding sides of a worker, and arranging second ultrasonic correlation devices on two corresponding sides of a workpiece;
2) setting a standard time interval of the second ultrasonic correlation device intercepted by the workpiece for 15 to 20 seconds;
3) starting the first ultrasonic correlation device, after the worker arrives at the station, the first ultrasonic correlation device sends a signal to the control computer 23 after being intercepted, and the control computer 23 sends a signal to start the second ultrasonic correlation device;
4) after the workpiece reaches the station, the second ultrasonic correlation device starts to record the time blocked by the workpiece (the time blocked by the workpiece is also the time consumed by workpiece assembly), and feeds back the signal to the control computer 23, and the control computer 23 judges whether the workpiece is neglected to be installed according to the received signal:
if the time of the second ultrasonic opposite-emitting device interrupted by the workpiece is within the standard time interval set in the step 2), namely within 15 to 20 seconds, the system continues to monitor the workpiece on the production line;
if the time for the second ultrasonic correlation device to be intercepted by the workpiece is not within the standard time interval set in the step 2), namely within 15 to 20 seconds, the control computer 23 sends a signal to control the display alarm system 3 after receiving the signal, displays the production line where the workpiece is not installed, and sends out an audible and visual alarm.
The above embodiments are not limited to the technical solutions of the embodiments themselves, and the embodiments may be combined with each other into a new embodiment. The above embodiments are only for illustrating the technical solutions of the present invention and are not limited thereto, and any modification or equivalent replacement without departing from the spirit and scope of the present invention should be covered within the technical solutions of the present invention.
Claims (2)
1. A detection method of a workpiece neglected loading monitoring system based on ultrasonic induction is characterized in that the monitoring system comprises an information acquisition system, an information processing system and a display alarm system:
the information acquisition system comprises an ultrasonic correlation device, a power amplifier and a first direct current power supply: the ultrasonic wave correlation device comprises a first ultrasonic wave correlation device arranged on two corresponding sides of a worker and a second ultrasonic wave correlation device arranged on two corresponding sides of a workpiece, each ultrasonic wave correlation device comprises an ultrasonic wave transmitting device and an ultrasonic wave receiving device, the ultrasonic wave transmitting devices are used for transmitting ultrasonic wave lines to detect the worker or the workpiece, the ultrasonic wave receiving devices are used for receiving the ultrasonic wave lines transmitted by the ultrasonic wave transmitting devices, and the output ends of the ultrasonic wave receiving devices are connected with the input end of the power amplifier; the first direct current power supply is used for providing 3.4V direct current voltage for the ultrasonic wave transmitting device;
the information processing system comprises a signal conditioning circuit, a data acquisition unit, a control computer and a second direct-current power supply: the signal conditioning circuit is used for carrying out voltage boosting, signal reduction and filtering on the induction signal, and the output end of the signal conditioning circuit is connected with the A/D conversion input end of the data acquisition unit; the data acquisition unit performs A/D conversion on the acquired signals and then sends the signals to the control computer for processing the induction signals; the control computer is used for processing the detected and collected sensing signals, judging whether the workpiece is neglected to be installed or not, if the workpiece is neglected to be installed, sending a signal to the display alarm system, controlling the display alarm system to display a production line where the neglected to be installed workpiece is located and giving out acousto-optic alarm; the second direct current power supply is used for providing 3.4V direct current voltage, and the output end of the second direct current power supply is respectively connected with the signal conditioning circuit, the data acquisition unit and the power supply input end of the control computer;
the display alarm system comprises a projector and an audible and visual alarm: the projector comprises a projector and a projector curtain, wherein the projector is provided with an amplification key, a reduction key, a function key, a determination key and an opening/suspending key, and the input end of the projector is connected with the output end of the control computer; the audible and visual alarm comprises a buzzer and an alarm lamp which are controlled by a control computer and used for giving an audible and visual alarm after the condition that the workpiece is neglected to be installed is detected;
the detection method comprises the following steps:
1) arranging first ultrasonic correlation devices on two corresponding sides of a worker, and arranging second ultrasonic correlation devices on two corresponding sides of a workpiece;
2) setting a standard time interval of the second ultrasonic correlation device intercepted by the workpiece;
3) starting a first ultrasonic correlation device, after a worker arrives at a station, sending a signal to a control computer after the first ultrasonic correlation device is intercepted, and sending a signal to start a second ultrasonic correlation device by the control computer;
4) after the workpiece reaches the station, the second ultrasonic correlation device starts to record the time blocked by the workpiece, and feeds back the signal to the control computer, and the control computer judges whether the workpiece is neglected to be installed according to the received signal:
if the time of the second ultrasonic correlation device intercepted by the workpiece is within the standard time interval set in the step 2), the system continues to monitor the workpiece on the production line;
if the time of the second ultrasonic correlation device intercepted by the workpiece is not within the standard time interval set in the step 2), the control computer sends a signal to control a display alarm system after receiving the signal, displays the production line where the neglected-installed workpiece is located, and sends out an acousto-optic alarm.
2. A monitoring system using the detection method of claim 1, characterized in that: the ultrasonic transmitting device comprises a single chip microcomputer, a driving circuit, a modulation circuit and an ultrasonic transmitting head, the output end of the first direct-current power supply is connected with the input end of the single chip microcomputer, the ultrasonic receiving device comprises an ultrasonic receiving head and a demodulation circuit, and the demodulation circuit is connected with the signal conditioning circuit.
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| CN101907730A (en) * | 2010-06-28 | 2010-12-08 | 重庆大学 | Electromagnetic induction type metal part neglected loading detection and detection method |
| CN102672457A (en) * | 2012-06-05 | 2012-09-19 | 震宇（芜湖）实业有限公司 | Part assembling tool with misloading prevention function and process method for assembling parts by using assembling tool |
| CN103777562A (en) * | 2012-10-24 | 2014-05-07 | 亿和精密工业（苏州）有限公司 | Detection missing prevention device |
| CN105364489A (en) * | 2015-12-11 | 2016-03-02 | 江苏宏宝工具有限公司 | Machine drilling device |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101406135B1 (en) * | 2013-03-12 | 2014-06-12 | 정의종 | System for detecting defect of ultrasonic sound scan apparatus having electricity equipment |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101907730A (en) * | 2010-06-28 | 2010-12-08 | 重庆大学 | Electromagnetic induction type metal part neglected loading detection and detection method |
| CN102672457A (en) * | 2012-06-05 | 2012-09-19 | 震宇（芜湖）实业有限公司 | Part assembling tool with misloading prevention function and process method for assembling parts by using assembling tool |
| CN103777562A (en) * | 2012-10-24 | 2014-05-07 | 亿和精密工业（苏州）有限公司 | Detection missing prevention device |
| CN105364489A (en) * | 2015-12-11 | 2016-03-02 | 江苏宏宝工具有限公司 | Machine drilling device |
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