CN109227205A - A kind of control method and system for double-station robot machine loading and unloading - Google Patents
A kind of control method and system for double-station robot machine loading and unloading Download PDFInfo
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- CN109227205A CN109227205A CN201811438285.1A CN201811438285A CN109227205A CN 109227205 A CN109227205 A CN 109227205A CN 201811438285 A CN201811438285 A CN 201811438285A CN 109227205 A CN109227205 A CN 109227205A
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- 238000012545 processing Methods 0.000 claims abstract description 77
- 230000007246 mechanism Effects 0.000 claims abstract description 53
- 238000004519 manufacturing process Methods 0.000 claims abstract description 36
- 230000008569 process Effects 0.000 claims description 39
- 230000009471 action Effects 0.000 claims description 25
- 238000007599 discharging Methods 0.000 claims description 22
- 238000003754 machining Methods 0.000 claims description 6
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 238000012913 prioritisation Methods 0.000 claims description 3
- 238000003860 storage Methods 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 5
- 230000003993 interaction Effects 0.000 description 4
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q7/00—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting
- B23Q7/04—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting by means of grippers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
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Abstract
The invention discloses a kind of control method for double-station robot machine loading and unloading, including feeding judgment step, production and processing step, wherein production and processing step includes that material step, lathe loading and unloading step, production and processing step, workpiece put step；By industrial personal computer feedback image processing result, realize that PLC controls robot feeding；By override mechanism, PLC can control robot when executing production and processing step to a station, carries out image procossing to another station and data are transmitted；By machine feedback information, the protection mechanism and lathe feeding failure handling mechanism of robot disengaging lathe are realized；It also introduces and lacks material notification mechanisms.The present invention improves double-station robot charge efficiency and fault-tolerant processing ability, and can continue to realize automated production in a station fault, ensure that production capacity.The invention also discloses a kind of double-station robot charge systems using the control method.
Description
Technical Field
The invention relates to the field of industrial automation, in particular to a method and a system for controlling feeding and discharging of a double-station robot machine tool.
Background
Through the development of nearly 50 years, the PLC has the advantages of high operation speed, subminiature volume, more reliable industrial anti-interference design, analog operation, PID function, extremely high cost performance and the like, and is widely applied to industrial automation equipment. Since its birth, industrial robots have been used in many industrial scenes where the working environment is severe or the contents of work are simple and repetitive, and industrial robots that work using electric power can work for a long time without interruption. An industrial control computer is a general name of equipment for detecting and controlling production process, electromechanical equipment and process equipment by adopting a bus structure, is called an industrial control computer for short, comprises a computer and process input and output channels, and has important computer attributes and characteristics. The advent of industrial control computers has completed the safety and precision of manufacturing and construction industries. At present, the robot is used for replacing the manpower, and the development direction of the manufacturing industry has become a wide prospect.
With the increasing level of industrial automation, more and more devices adopt automatic control to complete all device functions, and the PLC, as a mature industrial control product, is widely used in signal control, motor control and processes due to its approved stability.
According to the traditional PLC control robot system, a PLC controls a robot to move between points through signal confirmation, fingers or vacuum parts at the front end of the robot are controlled to cooperate with the robot to finish the actions of material taking, blanking, feeding and the like, the PLC is purely used as a control device, and feedback information is not received from the robot. When using the duplex position, if when a lathe broke down, the system can't skip the operation such as unloading to another lathe of problem lathe, had reduced work efficiency.
Therefore, technical personnel in the field are dedicated to developing a control method and a control system for feeding and discharging of a double-station robot machine tool, the robot is controlled to sequentially execute feeding and discharging operations on the double-station machine tool by utilizing the PLC based on the feedback of an industrial personal computer and the robot, the working efficiency is improved, meanwhile, abnormal conditions occurring in the production process can be timely processed, and the error handling capacity of the system is enhanced.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, the technical problems to be solved by the present invention are:
(1) the PLC does not receive feedback information when controlling the robot;
(2) when the PLC control robot system is used for double stations, the PLC control robot system can not continue to use single station for operation when another machine tool stops working.
In order to achieve the aim, the invention provides a control method for feeding and discharging of a double-station robot machine tool, which comprises the following steps:
a feeding judgment step: the PLC judges the condition of the blank on the automatic loading and unloading mechanism of at least one station;
the production and processing steps are as follows: the PLC controls the robot, an automatic loading and unloading mechanism of the current station and a machine tool to finish a production and processing flow based on image processing result feedback of an industrial personal computer, feedback of the robot and state feedback of the current station;
wherein the production processing steps comprise:
taking materials: the PLC controls the robot to go to an automatic feeding and discharging mechanism of the current station to take materials based on a positioning image processing result of the industrial personal computer, and is provided with a material taking failure alarm mechanism and a priority mechanism;
loading and unloading on a machine tool: the PLC controls the robot to feed and discharge based on the feedback signal of the machine tool at the current station, and is provided with a feeding failure handling mechanism and a machine tool leaving protection mechanism;
the production and processing steps are as follows: the PLC controls the machine tool of the current station to complete a machining program based on a feedback signal of the robot;
a workpiece placing step: the PLC controls the robot to place the processed workpiece on the automatic feeding and discharging mechanism of the current station, the robot feeds back a completion signal to the PLC after the placement is completed, and the PLC starts the production and processing flow of another station;
wherein,
after initialization is completed, in the material taking step, processing and transmission of image processing data of another station are parallel;
the prioritization mechanism includes: the PLC can preferentially judge the blank feeding condition of the automatic feeding and discharging mechanism of the station in the non-production machining state; when a station is in an abnormal state or a material shortage state, the PLC can automatically skip the production and processing flow of the station;
the control method is used for one-station production processing, and the priority mechanism is not started.
Further, the material taking step comprises the following processes:
step 21: the PLC triggers an industrial personal computer to acquire images by using the coarse positioning camera of the current station, processes the images and feeds back the processing result to the PLC;
step 22: the PLC controls the robot to go to the automatic feeding and discharging mechanism of the current station to take materials;
step 23: the robot successfully takes the materials and feeds back a successful material taking signal to the PLC; the PLC controls the robot to sequentially execute the next action;
step 24: if the robot fails to take the materials, feeding back a material taking failure signal to the PLC, returning the robot to the fixed point, and executing the step 21 and the step 22 again by the PLC;
step 25: and if the material taking failure in the step 24 occurs for 3 times, stopping the operation and triggering an alarm device.
Further, after the step 23 is completed, the PLC controls the robot to perform the following processes:
step 31: after the robot successfully takes the materials, the robot moves to the position of the accurate positioning camera of the current station;
step 32: the robot triggers an industrial personal computer to acquire and process pictures of the accurate positioning camera;
step 33: if the industrial personal computer successfully processes the picture of the current station accurate positioning camera, feeding back a successful processing signal to the robot for storage, and controlling the robot to sequentially execute the next action by the PLC;
step 34: if the industrial personal computer processes the picture of the current station accurate positioning camera in error, the PLC controls the robot to carry out material throwing processing and return to a fixed point, and the step 21, the step 22, the step 23, the step 31 and the step 32 are executed again;
step 35: and if the picture processing error in the step 34 occurs for 3 times, stopping the operation and triggering an alarm device.
Further, the loading and unloading step of the machine tool comprises the following steps:
step 41: the robot waits for a PLC instruction outside the machine tool of the current station;
step 42: after the machine tool finishes processing, feeding back a complete opening signal of an automatic door of the machine tool and a tool retracting signal of the machine tool to the PLC;
step 43: the PLC controls the robot to enter a clamping position in the machine tool;
step 44: the PLC controls the robot to execute a clamping action according to a signal of finishing the positioning of the main shaft of the machine tool, and starts a clamping step;
step 45: the PLC controls the robot to move to a loading position in the machine tool to complete loading according to a feedback signal of the robot for completing clamping;
step 46: and starting the machine tool leaving protection mechanism, and controlling the robot to leave the machine tool by the PLC.
Further, when the machined workpiece does not fall off after the machine tool clamp is loosened, the clamping step includes:
step 51: the machine tool loosens the clamp and feeds back a clamp loosening signal to the PLC;
step 52: the PLC controls the robot to clamp the processed workpiece, and the robot feeds back a clamping completion signal to the PLC after clamping completion.
Further, when the processed workpiece falls off when the machine tool clamp is released, the clamping step comprises:
step 61: the machine tool feeds back a clamp clamping signal to the PLC, and the PLC controls the robot to clamp the processed workpiece;
step 62: after the robot finishes the clamping action, feeding back a clamping finishing signal to the PLC;
and step 63: the PLC controls the machine tool to loosen the clamp, and the machine tool feeds back a clamp loosening signal to the PLC;
step 64: and the PLC controls the robot to execute the next action according to the clamp loosening signal.
Further, the step 45 further includes a feeding failure handling mechanism, which includes the following processes:
when the robot puts the blank material into the last section of the die cavity of the machine tool fixture, the robot starts a comparison process between the current position and a preset successful feeding position, and if the comparison result is inconsistent, the feeding failure is judged;
the robot skips the part not executed in said step 45, jumps to said step 46 and activates the alarm means.
Further, the step 46 includes the following processes:
step 81: when the robot does not exit the machine tool, an interference domain signal is output to prevent a program from making mistakes, so that the machine tool is started;
step 82: when the robot completely exits the machine tool, the interference domain signal is closed, and a complete exit signal is fed back to the PLC;
step 83: and the PLC controls the robot to execute the next action.
Further, the control method further comprises a material shortage reminding step, which specifically comprises the following steps:
the PLC identifies that all blank materials of one station are taken away according to the image processing result of the industrial personal computer, and triggers a single-station material shortage prompt;
if the PLC identifies that all the blank materials at the double stations are taken away, triggering double-station material shortage reminding;
the signal of the single-station material shortage reminding is inconsistent with the signal of the double-station material shortage reminding.
The invention also provides a loading and unloading system of the double-station robot machine bed, which comprises a PLC, an industrial personal computer, a robot, a material shortage reminding device and two stations; each station comprises an automatic feeding and discharging mechanism, a machine tool, a coarse positioning camera and a precise positioning camera; the PLC controls the robot, the automatic loading and unloading mechanism and the machine tool to execute actions and receives feedback control signals of the robot and the machine tool; the industrial personal computer controls the coarse positioning camera and the precise positioning camera to shoot, receives and processes the shot pictures, and feeds picture processing data back to the PLC and the robot; the robot is communicated with the industrial personal computer and used for triggering the accurate positioning camera to shoot and receiving a picture processing result shot by the industrial personal computer on the accurate positioning camera; the material shortage reminding device is used for reminding material shortage, and has different reminding modes when a certain station is in shortage or when two stations are in shortage.
The invention has the following technical effects:
1. according to the invention, by optimizing the time sequence control of the robot, when the robot loads and unloads materials on two machines, the time for the robot to wait for data is shortened, and the time required by the whole production process is saved;
2. according to the invention, the stability of the PLC control robot is improved by the technical means of visual feedback of the industrial personal computer, motion feedback of the robot and the like;
3. according to the invention, fault-tolerant processing mechanisms such as material taking failure alarm, material loading failure alarm, material shortage reminding, protection of robot entering and exiting a machine tool and the like are introduced, so that the fault-tolerant capability of the system is improved;
4. according to the invention, the two machine tools are sequentially loaded and unloaded, so that when a problem occurs in one machine tool, the robot is controlled to skip the problem machine tool, and the other machine tool is loaded and unloaded, thereby ensuring the productivity.
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
Drawings
FIG. 1 is a timing diagram illustrating the simultaneous normal operation of two stations in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic flow chart of the material taking step, starved material reminder and priority mechanism according to a preferred embodiment of the present invention;
FIG. 3 is a signal flow diagram of a preferred embodiment of the present invention for fine positioning;
FIG. 4 is a flow chart of the operation of the prioritization mechanism of a preferred embodiment of the present invention;
FIG. 5 is a flowchart of loading and unloading processes for a machine tool in which a workpiece does not fall off after the machine tool clamp is opened according to a preferred embodiment of the present invention;
FIG. 6 is a flowchart of loading and unloading processes for a machine tool in which a workpiece may fall off after the machine tool clamp is opened according to a preferred embodiment of the present invention;
FIG. 7 is a flow chart of the workpiece placement process according to a preferred embodiment of the present invention;
fig. 8 is a schematic structural diagram of a loading and unloading system of a double-station robot according to a preferred embodiment of the invention.
Detailed Description
A preferred embodiment of the present invention will be described below with reference to the accompanying drawings for clarity and understanding of the technical contents thereof. The present invention may be embodied in many different forms of embodiments and the scope of the invention is not limited to the embodiments set forth herein.
In the drawings, structurally identical elements are represented by like reference numerals, and structurally or functionally similar elements are represented by like reference numerals throughout the several views. The size and thickness of each component shown in the drawings are arbitrarily illustrated, and the present invention is not limited to the size and thickness of each component. The thickness of the components may be exaggerated where appropriate in the figures to improve clarity.
The embodiment provides a control method for controlling the robot to carry out loading and unloading on the double-station machine tool when two stations work normally.
The control method of the embodiment comprises a feeding judgment step, a production and processing step of the current station and a material shortage reminding step. In the feeding judging step, the PLC judges whether blank feeding is carried out on the first station and the second station or not, obtains the sequence of the blank feeding through judging the feedback information of the blank feeding on the first station and the second station, and carries out the sequence control of photographing. The following description is based on the operation of the first station feeding blanks and the second station feeding blanks immediately after the first station feeding blanks. It should be noted that the method of the present embodiment is not limited to the above-mentioned prior order of the feeding of the blanks, but is performed in the order recognized by the PLC.
As shown in fig. 1, the control method of this embodiment realizes that the PLC controls the robot to sequentially execute the first station and the second station. The PLC controls the robot to go to the first station to take materials according to a first station coarse positioning photo processing result fed back by the industrial personal computer, and the robot triggers the industrial personal computer to control the accurate positioning camera to take photos when passing through the first station accurate positioning camera after the materials are taken; the industrial personal computer directly transmits a processing result to the robot for storage after processing the picture shot by the accurate positioning camera; then the robot continues to execute the program, and starts the loading and unloading step of the machine tool after leaving the accurate positioning camera and before arriving at the first station machine tool; and after the loading and unloading are finished, the robot completely leaves the first station machine tool, the PLC controls the first station machine tool to perform production and processing, and simultaneously controls the robot to continuously enter the production and processing step of the second station, wherein the step is consistent with the production and processing step of the first station. The PLC controls the robot to circulate all the time, so that the first station and the second station operate in a crossed mode.
As shown in fig. 2, after the PLC recognizes that the blank material has been loaded on the automatic loading and unloading mechanism at the first station, the material taking step is started: after the initialization is carried out, the PLC triggers the industrial personal computer by changing the value of a certain register appointed by the industrial personal computer, so that the industrial personal computer controls the coarse positioning camera of the first station to carry out image acquisition; the industrial personal computer receives and processes the image and feeds back a processing result to the PLC; the PLC controls the robot to go to an automatic loading and unloading mechanism of the first station to take materials according to the feedback result; the PLC controls the next action of the robot according to the feedback of the robot on the material taking state: if the material taking is successful, the PLC controls the robot to execute the next action; if the material taking fails, a material taking failure alarm mechanism is started. The industrial personal computer is set to be in a state of continuously scanning the registers, and once the value of a certain register is changed, the industrial personal computer enters a corresponding program. The working process of the material taking failure alarm mechanism is as follows: if the material taking fails, the robot returns to the fixed point and feeds back a material taking failure signal to the PLC; the PLC triggers the industrial personal computer to carry out the processes of rough positioning camera photographing, image processing and the like again, and controls the robot to go to take materials again; and if the situation of material taking failure occurs for three times continuously, starting the alarm device, stopping the operation, and waiting for the recovery of the treatment after the reason is checked by the technical personnel.
Generally, the probability of failure when a rough positioning camera performs identification under the condition of material is very small, however, if the processing fails, the register returned by an industrial personal computer is used for judging, if a value 1 indicates that a target workpiece is successfully identified, a value 2 indicates that the image processing is successful, but no workpiece is identified, and a value 3 indicates that the processing fails. And when the register value returned by the industrial personal computer is 3, the PLC triggers the industrial personal computer again to perform image recognition of the coarse positioning camera, then gives a result, and triggers an alarm if the failure occurs for three times continuously.
As shown in fig. 3, when the robot successfully takes the material, the PLC controls the robot to continue to execute, and when the robot moves to the position of the first station precise positioning camera, the robot directly interacts with the industrial personal computer, and the sent appointed character string is used to trigger the industrial personal computer to control the first station precise positioning camera to perform image acquisition and processing, and the industrial personal computer directly transmits the processed image data to the robot. The robot and the industrial personal computer receive data through Socket communication, the received data are a string of character strings, the robot carries out coding analysis after receiving the data, if information of successful image processing is obtained through agreed zone bit analysis, the information is stored for standby application, and next action is executed. If the image processing reports wrong, the robot throws materials and returns to a fixed point, and the robot takes materials again and takes pictures in a precise positioning mode at the first station. If the accurate positioning image processing fails for three times, starting a system to alarm, stopping operation, and processing and recovering after a technician checks the reason.
As shown in fig. 4, in order to improve the production efficiency, the robot executes a priority mechanism at the time of cross-operation. When the PLC controls the robot to operate at the first station, the robot leaves the accurate positioning position and continues to operate outside the machine tool at the first station after the accurate positioning is finished. After the robot leaves the accurate positioning position, a leaving signal is fed back to the PLC, the PLC triggers the industrial personal computer to take pictures and process images of the coarse positioning camera of the second station by changing the register value, the blank feeding condition of the second station is preferentially judged according to the processing result, and if no blank is found in the second station, the operation returns to carry out station switching; and if the image processing is successful, the industrial personal computer transmits the data to the robot. Through such a priority mechanism, the robot can directly execute the material taking action of the second station after the robot executes the production and processing of the first station, and the process of transmitting the rough positioning image processing data by the PLC is reduced. Although theoretically, the interaction time between the PLC and the robot is short, in practical application, one-time interaction is reduced, and the time for the robot to acquire data outside the machine tool can be shortened, so that the machine tools such as the robot and the like can be used as much as possible, and the working efficiency can be improved.
As shown in fig. 5 and 6, after the robot succeeds in accurate positioning, the robot starts to perform the loading and unloading steps of the machine tool, including that the robot enters the machine tool, the robot finishes clamping, the robot performs loading operation, and the robot exits the machine tool.
After the machine tool is machined, in order to ensure that a path for the robot to enter the machine tool is not interfered, the machine tool feeds back a signal for completely opening the automatic door and a machine tool retracting completion signal to the PLC, and the PLC controls the robot to enter the machine tool according to the two signals which are simultaneously obtained.
Due to the design of the machine tool clamp, a part of workpieces may not fall off after the clamp is loosened after machining is completed, and a part of workpieces may fall off into the machine tool when the clamp is loosened due to the deviation of the size center, so that different operation controls for taking the workpieces by robots are needed to be designed for the two situations respectively. Fig. 5 shows a process diagram of loading and unloading when a workpiece does not fall after the machining fixture is loosened, and fig. 6 shows a process diagram of loading and unloading when a workpiece falls after the machining fixture is loosened.
As shown in fig. 5, after the robot enters the machine tool, the machine tool feeds back the clamp to the PLC as a loose state, the PLC sends a signal for taking the workpiece to the robot, and the robot immediately takes the workpiece.
As shown in fig. 6, after the robot enters the machine tool, the machine tool feeds back the clamp to the PLC as a clamping state, and the PLC sends a workpiece-fetching signal to the robot; the robot clamps the workpiece immediately, then feeds back a clamped workpiece signal, and the PLC controls the machine tool clamp to loosen.
Compared with the mode of clamping the workpiece by adopting the clamp clamping state only, the time is saved by adopting the mode of distinguishing two situations that the workpiece is clamped by the machine tool in the clamp clamping state and the workpiece is clamped in the clamp loosening state. The feeding and discharging actions of the clamp in a directly loosened state are at least 0.6 second faster than those of the clamp in a clamped state due to the response and interaction of signals, the reaction time of the clamp actions and the like.
And after the robot finishes clamping the workpiece, the robot moves to a non-interference position to change the position, and moves to a loading position to perform loading operation. In order to ensure safe production, a processing mechanism for material loading failure is designed in this embodiment: if the feeding fails, the robot judges a limit signal in the last section of the stroke of putting the blank material into the cavity of the clamp, and when the feeding is successful, the limit signal cannot be triggered, and the program is executed downwards; when the limit signal is triggered, the robot compares the current loading position with a preset position numerical value of successful loading, if a certain numerical value is compared, the difference value exceeds a certain range, the loading is considered to be failed, the robot can perform squeezing operation, namely, a part which is not executed in the last stroke during the loading is skipped, a jump program after judgment is executed downwards, the program can jump to a step of exiting the machine tool and then exits the machine tool to reach a completely safe position, an alarm signal is sent to the PLC, when the PLC receives the alarm signal, the PLC immediately alarms, and technicians are required to check reasons and recover.
After the normal feeding of the robot is finished, a feeding completion signal is sent to the PLC, the PLC controls the machine tool clamp to clamp, the machine tool feeds back that the PLC clamp is clamped, and then the PLC controls the robot to leave the machine tool.
The robot leaves the lathe is a process, in order to guarantee that the robot can start the lathe to process after leaving the lathe completely, designed the robot in this embodiment and left the lathe protection mechanism: by utilizing the interference domain function of the robot, when the robot is in the machine tool, the interference domain signal is output to prevent a program from making mistakes and starting the machine tool downwards, when the robot leaves the interior of the machine tool, the interference domain signal is closed, the PLC is fed back immediately to completely leave the machine tool signal, and the PLC controls the machine tool to be started for machining.
As shown in fig. 7, after the robot leaves the machine tool, the PLC controls the robot to perform an operation of placing the processed workpiece, and then the robot feeds back a signal that the PLC can perform processing at the second station after returning to the fixed point. The PLC controls the robot to take the materials at the second station, if the materials are taken unsuccessfully, the robot returns to the fixed position, the materials taking operation is repeated, and if the materials are taken unsuccessfully for three times, the whole system gives an alarm. If the image processing fails, the whole system gives an alarm. And when the image processing at the accurate positioning position is successful, the robot feeds back a signal that the PLC robot leaves the accurate positioning camera when the robot leaves.
And receiving a signal that the robot leaves the accurate positioning camera, preferentially controlling the industrial personal computer by the PLC to carry out coarse positioning photographing of the first station, carrying out image processing, transmitting robot data and feeding back a PLC station 1 data receiving completion signal. At this time, the robot has arrived outside the station 2 machine tool 2 and waits for the PLC signal to control to enter the machine tool, when the PLC controls the robot to enter the machine tool 2, the robot can perform the feeding and discharging actions and the signal interaction as described in [0025], when the robot completely leaves the machine tool, the PLC immediately feeds back that one robot completely leaves the machine tool 2, and the PLC immediately starts the machine tool 2 for processing. When the robot completely leaves the machine tool 2, the PLC controls the robot to place the workpiece processed by the machine tool 2, and when the workpiece is placed completely, the robot returns to the fixed post-feedback PLC to perform the next sequential flow signal.
As shown in fig. 2, when the robot takes the material, there is a material shortage reminding step. When the industrial personal computer identifies that all blank materials in the field of view of the first station coarse positioning camera are taken away in the image processing, the PLC immediately controls the industrial personal computer to take pictures and process the images of the second station coarse positioning camera and transmit data, and if all blank materials in the field of view of the second positioning coarse positioning camera are identified to be taken away at the moment, a double-station material shortage reminding signal is sent. If the industrial personal computer successfully takes pictures and processes images of the second positioning coarse positioning camera and transmits data, the robot only carries out loading and unloading on the second station before blank loading is carried out on the first station. After the blank feeding is carried out on the first station, due to a priority mechanism of cross operation, once the first station is judged to be in a state of blank feeding completion, the judgment after the accurate positioning position at this time is that after the machine tool loading and unloading flow is completed on the second station, the machine tool loading and unloading are carried out on the first station instead of only continuously executing the machine tool loading and unloading on the second station. Similarly, if the second station is in the material shortage state, the robot only carries out the production and processing flow of the first station until the station state is changed, and then the robot runs in a crossed mode. When a certain station is in a material shortage state, a single-station material shortage reminding signal is sent out.
When only one station is needed to work, the other station can be closed on the PLC interface, all the steps can be carried out only in the station needing to work at present, and after the accurate positioning is completed, the priority mechanism is cancelled, only the current station state is judged, and the alarm is carried out when the station is circularly worked to the material shortage state.
In the embodiment, a feeding and discharging system of a double-station robot machine bed is further provided, and comprises a PLC (not shown in the figure), an industrial personal computer (not shown in the figure), a robot 3, a material shortage indicator lamp 6, a buzzer 7, a protective fence 8, a first station and a second station; the first station comprises a first station machine tool 1, a first station automatic loading and unloading mechanism 2, a first station coarse positioning camera (not shown in the figure) and a first station precise positioning camera (not shown in the figure); the second station comprises a second station machine tool 4, a second station automatic loading and unloading mechanism 5, a second station coarse positioning camera (not shown in the figure) and a second station accurate positioning camera (not shown in the figure).
The PLC is used as a main control device and is used for controlling the robot 3, the first station automatic feeding and discharging mechanism 2, the first station machine tool 1, the second station machine tool 4 and the second station automatic feeding and discharging mechanism 5 to execute actions, and the PLC can receive control signals fed back by the robot 3, the first station machine tool 1 and the second station machine tool 4.
The industrial personal computer controls the first station coarse positioning camera, the first station precise positioning camera, the second station coarse positioning camera and the second station precise positioning camera to shoot, receives and processes the shot pictures, and feeds picture processing data back to the PLC or the robot 3; the robot 3 is communicated with an industrial personal computer and is used for triggering the first station accurate positioning camera or the second station accurate positioning camera to shoot and receiving a picture processing result shot by the industrial personal computer on the first station accurate positioning camera or the second station accurate positioning camera; the material shortage indicator lamp 6 is used for single-station material shortage reminding, and when a certain station is in short of material, the material shortage indicator lamp 6 flickers; the buzzer 7 is used for double-station material shortage reminding, and when two stations lack materials, the buzzer 7 gives an alarm.
The protective fence 8 is used to isolate a safe production area.
PLC receives the coarse positioning camera picture processing result of industrial computer feedback, has realized getting material control to robot 3 to realized lacking the material and reminded the function, and when a station lacked the material, lacked material pilot lamp 6 and glimmered, when two stations all lacked the material, bee calling organ 7 reported to the police.
The PLC receives an automatic door opening signal, a tool retracting completion signal and the like of the first station machine tool or the second station machine tool, determines that a traveling path of the robot 3 is not obstructed, and ensures that the robot 3 safely enters the machine tool; the PLC receives a clamping signal or a loosening signal of the clamp, and the control of the blanking action of the robot 3 under the two conditions that a machined workpiece can fall or cannot fall after the clamp is loosened is realized.
When the robot 3 completes one action, the signal is fed back to the PLC to complete the execution, so that the whole system has better stability.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. A control method for feeding and discharging of a double-station robot machine tool is characterized by comprising the following steps:
a feeding judgment step: the PLC judges the condition of the blank on the automatic loading and unloading mechanism of at least one station;
the production and processing steps are as follows: the PLC controls the robot, an automatic loading and unloading mechanism of the current station and a machine tool to finish a production and processing flow based on image processing result feedback of an industrial personal computer, feedback of the robot and state feedback of the current station;
wherein the production processing steps comprise:
taking materials: the PLC controls the robot to go to an automatic feeding and discharging mechanism of the current station to take materials based on a positioning image processing result of the industrial personal computer, and is provided with a material taking failure alarm mechanism and a priority mechanism;
loading and unloading on a machine tool: the PLC controls the robot to feed and discharge based on the feedback signal of the machine tool at the current station, and is provided with a feeding failure handling mechanism and a machine tool leaving protection mechanism;
the production and processing steps are as follows: the PLC controls the machine tool of the current station to complete a machining program based on a feedback signal of the robot;
a workpiece placing step: the PLC controls the robot to place the processed workpiece on the automatic feeding and discharging mechanism of the current station, the robot feeds back a completion signal to the PLC after the placement is completed, and the PLC starts the production and processing flow of another station;
wherein,
after initialization is completed, in the material taking step, processing and transmission of image processing data of another station are parallel;
the prioritization mechanism includes: the PLC can preferentially judge the blank feeding condition of the automatic feeding and discharging mechanism of the station in the non-production machining state; when a station is in an abnormal state or a material shortage state, the PLC can automatically skip the production and processing flow of the station;
the control method is used for one-station production processing, and the priority mechanism is not started.
2. The control method as set forth in claim 1, wherein said material taking step includes the process of:
step 21: the PLC triggers an industrial personal computer to acquire images by using the coarse positioning camera of the current station, processes the images and feeds back the processing result to the PLC;
step 22: the PLC controls the robot to go to the automatic feeding and discharging mechanism of the current station to take materials;
step 23: the robot successfully takes the materials and feeds back a successful material taking signal to the PLC; the PLC controls the robot to sequentially execute the next action;
step 24: if the robot fails to take the materials, feeding back a material taking failure signal to the PLC, returning the robot to the fixed point, and executing the step 21 and the step 22 again by the PLC;
step 25: and if the material taking failure in the step 24 occurs for 3 times, stopping the operation and triggering an alarm device.
3. The control method according to claim 2, wherein after the step 23 is performed, the PLC controls the robot to perform the following process:
step 31: after the robot successfully takes the materials, the robot moves to the position of the accurate positioning camera of the current station;
step 32: the robot triggers an industrial personal computer to acquire and process pictures of the accurate positioning camera;
step 33: if the industrial personal computer successfully processes the picture of the current station accurate positioning camera, feeding back a successful processing signal to the robot for storage, and controlling the robot to sequentially execute the next action by the PLC;
step 34: if the industrial personal computer processes the picture of the current station accurate positioning camera in error, the PLC controls the robot to carry out material throwing processing and return to a fixed point, and the step 21, the step 22, the step 23, the step 31 and the step 32 are executed again;
step 35: and if the picture processing error in the step 34 occurs for 3 times, stopping the operation and triggering an alarm device.
4. The control method as claimed in claim 1, wherein the loading and unloading step of the machine tool comprises the following processes:
step 41: the robot waits for a PLC instruction outside the machine tool of the current station;
step 42: after the machine tool finishes processing, feeding back a complete opening signal of an automatic door of the machine tool and a tool retracting signal of the machine tool to the PLC;
step 43: the PLC controls the robot to enter a clamping position in the machine tool;
step 44: the PLC controls the robot to execute a clamping action according to a signal of finishing the positioning of the main shaft of the machine tool, and starts a clamping step;
step 45: the PLC controls the robot to move to a loading position in the machine tool to complete loading according to a feedback signal of the robot for completing clamping;
step 46: and starting the machine tool leaving protection mechanism, and controlling the robot to leave the machine tool by the PLC.
5. The control method according to claim 4, wherein when the machined workpiece does not fall off after the machine tool chuck is released, the gripping step comprises:
step 51: the machine tool loosens the clamp and feeds back a clamp loosening signal to the PLC;
step 52: the PLC controls the robot to clamp the processed workpiece, and the robot feeds back a clamping completion signal to the PLC after clamping completion.
6. The control method of claim 4, wherein when the machined workpiece falls off when the machine tool clamp is released, the clamping step comprises:
step 61: the machine tool feeds back a clamp clamping signal to the PLC, and the PLC controls the robot to clamp the processed workpiece;
step 62: after the robot finishes the clamping action, feeding back a clamping finishing signal to the PLC;
and step 63: the PLC controls the machine tool to loosen the clamp, and the machine tool feeds back a clamp loosening signal to the PLC;
step 64: and the PLC controls the robot to execute the next action according to the clamp loosening signal.
7. The control method of claim 4, wherein the step 45 further comprises a feeding failure handling mechanism comprising the following processes:
when the robot puts the blank material into the last section of the die cavity of the machine tool fixture, the robot starts a comparison process between the current position and a preset successful feeding position, and if the comparison result is inconsistent, the feeding failure is judged;
the robot skips the part not executed in said step 45, jumps to said step 46 and activates the alarm means.
8. The control method according to claim 4, wherein said step 46 includes the process of:
step 81: when the robot does not exit the machine tool, an interference domain signal is output to prevent a program from making mistakes, so that the machine tool is started;
step 82: when the robot completely exits the machine tool, the interference domain signal is closed, and a complete exit signal is fed back to the PLC;
step 83: and the PLC controls the robot to execute the next action.
9. The control method according to claim 1, further comprising a starved material reminding step, specifically:
the PLC identifies that all blank materials of one station are taken away according to the image processing result of the industrial personal computer, and triggers a single-station material shortage prompt;
if the PLC identifies that all the blank materials at the double stations are taken away, triggering double-station material shortage reminding;
the signal of the single-station material shortage reminding is inconsistent with the signal of the double-station material shortage reminding.
10. The double-station robot machine tool feeding and discharging system using the control method according to any one of claims 1 to 9 is characterized by comprising a PLC (programmable logic controller), an industrial personal computer, a robot, a material shortage reminding device and two stations; each station comprises an automatic feeding and discharging mechanism, a machine tool, a coarse positioning camera and a precise positioning camera; the PLC controls the robot, the automatic loading and unloading mechanism and the machine tool to execute actions and receives feedback control signals of the robot and the machine tool; the industrial personal computer controls the coarse positioning camera and the precise positioning camera to shoot, receives and processes the shot pictures, and feeds picture processing data back to the PLC and the robot; the robot is communicated with the industrial personal computer and used for triggering the accurate positioning camera to shoot and receiving a picture processing result shot by the industrial personal computer on the accurate positioning camera; the material shortage reminding device is used for reminding material shortage, and has different reminding modes when a certain station is in shortage or when two stations are in shortage.
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