CN109580404B - Method and device for testing abrasion and accelerated abrasion of built-in wire bundle of industrial robot - Google Patents
Method and device for testing abrasion and accelerated abrasion of built-in wire bundle of industrial robot Download PDFInfo
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Abstract
The invention discloses a method and a device for testing abrasion and accelerated abrasion of a built-in type wire bundle of an industrial robot. At present, no method and device specially aiming at the built-in wire harness of the industrial robot are available. The device mainly comprises a plurality of wire harnesses, a camera, a simulation mechanical arm, a wire harness joint motor, a camera spatial position adjusting device, a plurality of wire harness binding device, a swing motor, a mounting seat, a hoop, a swing arm, a simulation plate swing rotating device, a simulation plate moving platform, an industrial personal computer, a motor motion controller, a swing motor driver, a stepping motor driver and an image acquisition card. The invention can select a plane abrasion test or a joint constraint abrasion test, control the swinging amplitude and the swinging period of the swinging motor according to a wire harness abrasion mode or a wire harness accelerated abrasion mode, and then identify the wire harness abrasion area caused by simulation by utilizing an image identification technology, thereby realizing the intellectualization of wire harness abrasion and accelerated abrasion detection, and having simple and efficient image processing process.
Description
Technical Field
The invention belongs to the technical field of industrial robot wear testing, and particularly relates to a method and a device for testing the built-in type wire harness wear and accelerated wear reliability of an industrial robot.
Background
Industrial robots are one of the major hallmarks of contemporary industrial automation, replacing a large number of dangerous or potential safety hazards. Industrial robots are widely used in various industries. For an industrial robot of the built-in harness type, wear of the built-in harness is inevitable, and at the same time, the wear of the harness is one of the main causes of failure of such an industrial robot. Therefore, it is necessary to develop a research and development method and a device for testing the built-in wire harness abrasion of the industrial robot.
Currently, only a few industrial robots have built-in wire harness abrasion and accelerated abrasion testing methods and devices in related fields, and for example, patent application No. 201610109629.9 discloses a wire harness abrasion testing device and a testing method. The device consists of longitudinal and transverse guide rails, fixed frame connecting rods and other mechanisms. The wire harness is arranged in a designed mechanism, and moves regularly up, down, left and right under the action of the controller, so that the abrasion of the wire harness is tested. Firstly, the testing device of the invention is too large and can only measure the wire harness within a specific length range of a specific type for the tested wire harness, and the influence of the length of the wire harness on the abrasion test is not considered; secondly, the testing method mainly depends on the upper horizontal guide rail and the lower horizontal guide rail to carry out regular simple reciprocating property testing, does not carry out the abrasion testing of the wire harness aiming at the special working environment of the wire harness installed on the built-in wire harness type industrial robot, is only a universal abrasion testing of the wire harness, and ignores the complex abrasion condition of the wire harness in the joint part of the built-in wire harness type industrial robot; some industrial robot joint head ends and the arm of joint tail end can form an contained angle restraint in actual work, and at this moment the pencil can constantly rub in the structure of this contained angle restraint in industrial robot working motion, and this friction and wear process is different from plane friction and wear. Then, the testing method adopts a power-on testing method and an X-ray scanning testing method, and the wiring harness needs to be taken out of the testing device, so that better integration, intellectualization and integration cannot be realized.
Disclosure of Invention
The invention aims to provide a method and a device for testing abrasion and accelerated abrasion of a built-in wire harness of an industrial robot, aiming at the defects of the prior art, the actual abrasion of the wire harness is analyzed through the actual observation of the use environment of the wire harness of the industrial robot, and the abrasion of the wire harness is mainly the plane abrasion of the wire harness and a body structure of a joint of the industrial robot, or the abrasion between a salient point formed by two mechanical arms at a rotary swing joint of the industrial robot and the wire harness in the actual movement process. Aiming at the two wear modes, simulation is carried out through a specific simulation mechanical structure, and then the wire harness wear area caused by simulation is identified by utilizing an image identification technology, so that the wear degree of the wire harness is intelligently monitored. The invention relates to a method and a device for detecting the friction and wear of a built-in wire harness and a body structure based on low-frequency high-amplitude swinging loading; the method and the device for detecting the friction accelerated wear of the high-frequency low-amplitude swing loaded built-in wire harness and the body structure; the method and the device for testing abrasion and accelerated abrasion of the built-in wiring harness with adjustable constraint position and adjustable constraint tightness are provided; the method and the device are used for testing the abrasion and accelerated abrasion of the surface of the wire harness based on machine vision detection; the intelligent testing device integrates the functions of restraint position adjustment, variable-frequency variable-amplitude swing control and friction and wear visual detection.
The invention discloses a method for testing built-in type wire harness abrasion and accelerated abrasion of an industrial robot, which comprises the following specific steps:
step one, binding all wires of a plurality of wire harnesses together through a plurality of multi-wire harness binding devices; the top ends of the multiple wire harnesses are connected with the wire harness joint motor through plugs welded at the end parts, and the bottom ends of the multiple wire harnesses are fixed through a hoop; correspondingly adjusting the whole tensioning degree of the multi-wire bundle and the tight attaching degree of each wire in the multi-wire bundle according to the tensioning condition of the wire bundle in the mechanical arm of the industrial robot to be simulated; rotating the simulation plate to a vertical state, and setting the distance between a joint constraint block on the simulation plate and the multiple wire harnesses to be k in the state when performing a joint constraint abrasion test1，k1Taking values in 5-25 mm, and when carrying out plane abrasion test, not installing joint restraint block on the simulation board, setting the interval between the simulation board and the multi-wire harness to k under the state2，k2Taking the value in 5-25 mm; the swing arm is driven by the swing motor to a vertical state in which a distance between the swing arm and the plurality of harnesses is set to k3，k3Taking the value in 10-20 mm; fixing the top end of the swing arm and an adjusting groove at the bottom end of the simulation mechanical arm through bolts, and adjusting the connecting position of the adjusting groove of the simulation mechanical arm to ensure that the distance from the top end of the simulation mechanical arm to the bottom end of the swing arm is equal to the length of the mechanical arm of the industrial robot to be simulated; and then, fixing the top end of the simulation mechanical arm and a base of the wire harness joint motor. The simulation mechanical arm, the swing arm and the simulation plate jointly simulate the mechanical arm of the industrial robot, or the simulation mechanical arm, the swing arm, the simulation plate and the joint constraint block jointly simulate the mechanical arm of the industrial robot, the swing motor simulates a single-degree-of-freedom joint at the tail end of the mechanical arm of the industrial robot, and the wiring harness joint motor simulates a single-degree-of-freedom joint at the head end of the mechanical arm of the industrial robot.
Selecting a harness abrasion mode or a harness accelerated abrasion mode, and setting the oscillation amplitude of the oscillating motor in the harness abrasion mode to be
The swing amplitude of the swing motor in the accelerated wear mode of the wire harness is set as
n is 2, 3 or 4,
the value is in the range of-60 degrees to-30 degrees,
the value is within the range of 45-75 degrees; calculating the time t required by the swing motor to rotate for one circle according to the rated rotating speed of the swing motor, and then obtaining the swing period of the swing motor in the wire harness abrasion mode
The swing period of the swing motor in the accelerated wear mode of the wire harness is set to T2＝T1/n。
And step three, controlling a swing motor to swing according to the swing amplitude and the swing period set in the step two, swinging for 30min if a harness wear mode is selected in the step two, swinging for 30/n min if a harness accelerated wear mode is selected in the step two, then rotating the simulation plate for 90 degrees to enable the simulation plate to be parallel to the horizontal plane, and then horizontally moving the simulation plate to a position far away from the multiple harnesses to make a space for the camera.
And step four, if the wear traces are found on the multiple wire harnesses, the lens of the camera is sequentially aligned to each wear part, the wear image of each wear part is transmitted to the industrial personal computer after being filtered by the image acquisition card, otherwise, the simulation board is reset, and the step three is repeated.
Step five, the industrial personal computer converts the wear image of each wear part from the RGB model into the HSV model to obtain the hue and brightness digital information of the wear image of the HSV model, and then the hue distribution and brightness are used for matchingComparing, and analyzing to obtain the brightness gradient of the HSV model abrasion image, wherein the brightness of the abrasion deepest part is lowest, and the brightness of the position of the unworn pixel point is highest; the inherent depth of field of the camera is set as L, and the brightness value of the pixel point with the distance from the lens of the camera equal to the depth of field is set as I0If the brightness difference between the pixel with the highest brightness and the pixel with the lowest brightness is set as I, the wear depth H is LI/I0。
And step six, the industrial personal computer conducts binarization processing on the wear image of each wear part, then determines a wear area according to the wear image after binarization processing, and detects the edge of the wear area according to the wear area, so that the wear area detection result of the wear area is determined.
And step seven, if the wear area detection results of all the wear parts do not exceed the wear area threshold value and the wear depth detection results of all the wear parts do not exceed the wear depth threshold value, returning to the step three, otherwise, storing and displaying the wear judgment results of all the wear parts of which the wear area detection results exceed the wear area threshold value or the wear depth detection results exceed the wear depth threshold value by the industrial personal computer, wherein the wear judgment results comprise the swing amplitude, the swing period and the total swing time of the swing motor and the wear depth and the wear area of all the wear parts of which the detection results exceed the threshold value.
Further, step eight, establishing a wear limit of the multi-wire bundle in a wire bundle wear mode and a wear limit N in a wire bundle accelerated wear modemaxThe relationship between them is as follows:
in the formula, N0、N1Values of the multi-wire bundle wear limit obtained by carrying out a plane wear test in a wire bundle wear mode and the multi-wire bundle wear limit obtained by carrying out a joint constraint wear test are two times of the ratio of the total swing time to the swing period in the corresponding wear judgment result; alpha (k)1 2，k3 2) Is k1、k3The two variables act togetherThe lower influence coefficient on the wear limit of the wire harness in the accelerated wear mode; beta (. DELTA.k, k)2 2，k3 2) Is k2、k3And delta k is an influence factor of the wear limit under the combined action of the three variables of the simulated plate and the delta k, wherein the delta k represents an influence factor after the joint restraint block is installed on the simulated plate. Alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) The values of (A) are as follows: selecting more than ten groups of k1、k2And k3Each group k1、k2And k3Taking the lower N in sequence as 2, 3 and 4, and respectively carrying out plane abrasion test in a wire harness abrasion mode to obtain a plurality of N0Respectively carrying out joint constraint abrasion test in a wire harness abrasion mode to obtain a plurality of N1Respectively carrying out plane abrasion test and joint constraint abrasion test in a wire harness accelerated abrasion mode to obtain a plurality of Nmax(ii) a Each N is0Corresponding to NmaxSubstituting into formula (1) to obtain N in each group0And NmaxCorresponding alpha (k)1 2，k3 2) Each N is1Corresponding to NmaxSubstituting into formula (2) to obtain N in each group1And NmaxCorresponding beta (. DELTA.k, k)2 2，k3 2) (ii) a By alpha (k)1 2，k3 2) As a function, k1And k3Fitting a function to the independent variable, with β (Δ k, k)2 2，k3 2) As a function, k2And k3Fitting another function to the independent variable, thus according to arbitrary k1、k2And k3All values can obtain corresponding alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) And then only need to test to obtain N0Or N1Then, N can be obtained from the formula (1) or (2)maxOr only need to test to obtain NmaxThen, N can be obtained from the formula (1)0Or obtaining N from the formula (2)1。
The invention relates to a built-in type wire harness abrasion and accelerated abrasion testing device of an industrial robot, which mainly comprises a plurality of wire harnesses, a camera, a simulation mechanical arm, a wire harness joint motor, a camera space position adjusting device, a plurality of wire harness binding devices, a swing motor, a mounting seat, a hoop, a swing arm, a simulation plate swing rotating device, a simulation plate moving platform, an industrial personal computer, a motor motion controller, a swing motor driver, a stepping motor driver and an image acquisition card.
The simulation board swinging and rotating device comprises a swinging angle motor and a connecting board; an output shaft of the swing angle motor is fixed with the bottom end of the simulation plate; a base of the swing angle motor is fixed on a sliding table of the simulation board moving platform through a connecting plate; the base body of the simulation board moving platform is fixed on the mounting base; the camera space adjusting device adjusts the position of the camera.
The base of the swing motor is fixed with the mounting seat through a screw, and an output shaft of the swing motor is fixed with the bottom end of the swing arm; the top end of the swing arm and an adjusting groove at the bottom end of the simulation mechanical arm are fixed through bolts; the top end of the simulation mechanical arm is fixed with a base of the wire harness joint motor.
Each wire of the multiple wire harnesses is bound together through a plurality of multiple wire harness binding devices; the top end of the multi-wire harness is connected with the wire harness joint motor through a plug welded at the end part, and the bottom end of the multi-wire harness is fixed through a hoop. Under the condition that the simulation plate and the swing arm are both in a vertical state, the distance between the swing arm and the multi-wire harness is set to be k3，k3Taking a value in 10-20 mm, and setting the distance between the joint restraint block and the multi-wire harness to k when the joint restraint block is installed on the simulation board1，k1Taking a value in 5-25 mm, and setting the distance between the simulation board and the multi-wire harness to be k when the joint restraint block is not installed on the simulation board2，k2Taking the value in 5-25 mm.
The signal input end of the motor motion controller is connected with the industrial personal computer, and the signal output end of the motor motion controller is connected with the swing motor driver and the stepping motor driver; the swing motor driver drives the swing motor; the two stepping motor drivers respectively drive the swing angle motor and the simulation board moving platform; the signal output end of the camera is connected with the image acquisition card, and the image output end of the image acquisition card is connected with the industrial personal computer.
The camera space adjusting device comprises an adjusting block and two cylindrical guide rails; the adjusting block and the two guide rails are fixed through screws, one guide rail is horizontally arranged, and the other guide rail is vertically arranged. The bottom end of the vertical guide rail is fixed on the mounting seat; the base body of the camera is fixed on the horizontal guide rail.
The invention has the beneficial effects that:
1. the invention provides a high-frequency low-amplitude and low-frequency high-amplitude motion simulation scheme based on the analysis of the motion rule of the mechanical arm of the actual industrial robot, and the determination of the motion simulation scheme is based on the sorting and analysis of the actual working condition of the industrial robot. The workpieces processed by the industrial robot can be roughly divided into two types, i.e., a workpiece with a large curvature change and a complex structure and a workpiece with a small curvature change and a simple structure. Corresponding to a workpiece with large curvature change, in the processing process of the industrial robot, the action of a joint mechanical arm of the industrial robot is mainly formed by high-frequency small-amplitude swinging, and a high-frequency low-amplitude motion simulation scheme is determined according to the point; corresponding to a workpiece with small curvature change, the action of the joint mechanical arm mainly comprises low-frequency large-amplitude swing, and a low-frequency high-amplitude motion simulation scheme is determined according to the point; the industrial personal computer is communicated with the swing motor (servo motor), and the control of different motion states of the swing motor is realized through pulse signals and direction signals, so that the detection of the friction wear or accelerated wear of the wire harness and the body structure under different motion modes is realized; the abrasion of the detection wire harness is more effectively and truly simulated for simulating different joint structures of the industrial robot.
2. The simulation plate simulates the slow friction of the wire harness with the plane of the body mechanism in the cavity of the industrial robot, and the abrasion between the wire harness and the uneven position of the protrusion of the wire harness in the cavity of the joint of the industrial robot is simulated by the additional joint restraint block.
3. The invention designs a swing arm length adjusting structure which is used for adjusting the restraint position and the restraint tightness of a wire harness.
4. The invention realizes the intellectualization and high precision of the wire harness abrasion and accelerated abrasion detection through the machine vision detection, and the image processing process is simple and efficient.
5. According to the invention, only one of the wear limit in the wire harness wear mode or the wear limit in the wire harness accelerated wear mode needs to be obtained through testing, so that the other one can be obtained, and the wear testing efficiency is improved.
6. The invention can provide powerful data support for the design of the service life detection and quality safety monitoring of the wire harness of the industrial robot.
Drawings
FIG. 1 is a side view of the device of the present invention.
Fig. 2 is another side view of the device of the present invention.
FIG. 3 is a schematic diagram of the testing principle of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
As shown in fig. 1, 2 and 3, the built-in type wire harness abrasion and accelerated abrasion testing device of the industrial robot mainly comprises a multi-wire harness 1, a camera 2, a simulation mechanical arm 3, a wire harness joint motor 4, a camera space position adjusting device 5, a multi-wire harness binding device 6, a swing motor 7, a mounting seat 8, a hoop 9, a swing arm 10, a simulation plate 11, a simulation plate swing rotating device 12, a simulation plate moving platform 13, an industrial personal computer 15, a motor motion controller 16, a swing motor driver 19, a stepping motor driver 18 and an image acquisition card 17.
The simulation board swinging and rotating device 12 comprises a swinging angle motor and a connecting board; an output shaft of the swing angle motor is fixed with the bottom end of the simulation plate 11, and if the interior of a mechanical arm of the industrial robot to be simulated is not smooth, two joint restraint blocks 14 which are arranged at intervals are fixed on the simulation plate 11 through screws; the base of the swing angle motor is fixed on the sliding table of the simulation board moving platform 13 through a connecting plate; the sliding table of the simulation board moving platform 13 can horizontally move along the direction vertical to the simulation board 11; the base body of the simulation board moving platform 13 is fixed on the mounting base 8; the camera space adjusting device 5 comprises an adjusting block and two cylindrical guide rails; the adjusting block and the two guide rails are fixed through screws, one guide rail is horizontally arranged, and the other guide rail is vertically arranged. The bottom end of the vertical guide rail is fixed on the mounting base 8; the base body of the camera 2 is fixed on the horizontal guide rail, and the desired spatial position is reached through the adjustment of the camera spatial position adjusting device 5, so that the worn image is identified.
The base of the swing motor 7 is fixed with the mounting seat 8 through screws, and the output shaft of the swing motor 7 is fixed with the bottom end of the swing arm 10; the top end of the swing arm 10 and an adjusting groove at the bottom end of the simulation mechanical arm 3 are fixed through bolts, and the height of the simulation mechanical arm 3 can be adjusted by adjusting the connecting position of the adjusting groove of the simulation mechanical arm 3; the top end of the simulation mechanical arm 3 is fixed with the base of the wire harness joint motor 4.
The individual wires of the multi-wire bundle 1 are bound together by a plurality of multi-wire bundle binding devices 6 (e.g., using ties); the tightness between the lines can be simulated by adjusting the different lengths of the lines between the adjacent multi-line bundle binding devices 6. The top end of the multi-wire harness 1 is connected with the wire harness joint motor 4 through a plug welded at the end part, the bottom end of the multi-wire harness 1 is fixed through the hoop 9, and the integral tensioning degree of the multi-wire harness 1 can be adjusted by adjusting the length of the multi-wire harness 1 between the hoop 9 and the wire harness joint motor 4. The distance k between the swing arm 10 and the multi-line bundle 1 in the state where the dummy plate 11 and the swing arm 10 are both vertical315mm, and the spacing k between the joint restraint block 14 and the multi-wire harness 1 when the joint restraint block 14 is installed on the simulation plate 11110mm, otherwise the spacing k of the plate 11 from the multi-strand bundle 1 is simulated2＝10mm。
The signal input end of the motor motion controller 16 is connected with the industrial personal computer 15, and the signal output end is connected with the swing motor driver 19 and the stepping motor driver 18; the swing motor driver 19 drives the swing motor 7; two stepping motor drivers 18 respectively drive the swing angle motor and the simulation board moving platform 13; the signal output end of the camera 2 is connected with the image acquisition card 17, and the image output end of the image acquisition card 17 is connected with the industrial personal computer 15.
The method for testing the abrasion and accelerated abrasion of the built-in type wire bundle of the industrial robot comprises the following specific steps:
step one, binding all the wires of the multi-wire bundle 1 together through a plurality of multi-wire bundle binding devices 6; the top end of the multi-wire harness 1 is welded on a plug at the end part and a wire harness joint motor4, the bottom ends are fixed through a hoop 9; correspondingly adjusting the whole tensioning degree of the multi-wire harness 1 and the tight attaching degree of each wire in the multi-wire harness 1 according to the tensioning condition of the wire harness in the mechanical arm of the industrial robot to be simulated; rotating the simulation plate 11 to a vertical state, and carrying out a joint constraint abrasion test, wherein the distance k between the joint constraint block 14 on the simulation plate 11 and the multi-wire harness 1 is in the state1When the plane wear test is performed at 10mm, the joint restraint block 14 is not attached to the dummy plate 11, and the distance k between the dummy plate 11 and the multi-wire harness 1 is set in this state2The method comprises the following steps that (1) plane abrasion or joint constraint abrasion testing is conducted according to the smoothness degree of the inner portion of a mechanical arm of the industrial robot to be simulated, wherein the plane abrasion or joint constraint abrasion testing is 10 mm; the swing arm 10 is driven by the swing motor 7 to a vertical state in which the pitch k of the swing arm 10 from the multi-line beam 1315 mm; fixing the top end of the swing arm 10 and an adjusting groove at the bottom end of the simulation mechanical arm 3 through bolts, and adjusting the connecting position of the adjusting groove of the simulation mechanical arm 3 to ensure that the distance from the top end of the simulation mechanical arm 3 to the bottom end of the swing arm 10 is equal to the length of the mechanical arm of the industrial robot to be simulated (the invention is only suitable for arm structures with single degree of freedom at head and tail joints); then, the top end of the simulation mechanical arm 3 is fixed with the base of the wire harness joint motor 4. The simulation mechanical arm 3, the swing arm 10 and the simulation plate 11 jointly simulate the mechanical arm of the industrial robot, or the simulation mechanical arm 3, the swing arm 10, the simulation plate 11 and the joint constraint block 14 jointly simulate the mechanical arm of the industrial robot, the swing motor 7 simulates a single-degree-of-freedom joint at the tail end of the mechanical arm of the industrial robot, and the wiring harness joint motor 4 simulates a single-degree-of-freedom joint at the head end of the mechanical arm of the industrial robot;
selecting a wire harness wear mode or a wire harness accelerated wear mode, and carrying out two tests of the wire harness wear mode and the wire harness accelerated wear mode because workpieces processed by the industrial robot are divided into workpieces with different curvature change sizes, for the workpieces with larger curvature change, the industrial robot mainly swings in a high-frequency small-amplitude mode in the processing process, and the swinging amplitude of the swinging motor 7 in the wire harness accelerated wear mode is set to be
n＝2，
For a workpiece with small curvature change, the action of the mechanical arm is mainly low-frequency and large-amplitude swing, and the swing amplitude of the swing motor 7 under the wire harness wear mode is set to be
The time t required for the oscillating motor to rotate for one revolution is determined from the rated speed of the oscillating motor (in this example, t is 0.34s), and the oscillating period of the oscillating motor in the harness wear mode is determined
The swing period of the swing motor in the accelerated wear mode of the wire harness is set to T2＝T1/n。
And step three, controlling the swing motor 7 to swing according to the swing amplitude and the swing period set in the step two, after swinging for 30min if the harness wear mode is selected in the step two, swinging for 30/n min if the harness accelerated wear mode is selected in the step two, then rotating the simulation plate 11 for 90 degrees to enable the simulation plate 11 to be parallel to the horizontal plane, and then horizontally moving the simulation plate 11 to a position far away from the multi-harness 1 to make room for the camera 2.
And step four, if the abrasion traces exist on the multi-wire harness 1, the lens of the camera 2 is sequentially aligned to each abrasion part, the abrasion images of each abrasion part are transmitted to the industrial personal computer 15 after being filtered by the image acquisition card 17, otherwise, the simulation board 11 is reset, and the step three is repeated.
Step five, the industrial personal computer 15 converts the wear image of each wear part from an RGB model into an HSV model to obtain hue and brightness digital information of the wear image of the HSV model, and then analyzes and obtains the brightness gradient of the wear image of the HSV model through hue distribution and brightness contrast, wherein the brightness of the deepest wear part is lowest, and the brightness of the position where an unworn pixel point is located is highest; the inherent depth of field of the camera 2 is set as L, and the brightness value of the pixel point with the distance from the lens of the camera 2 equal to the depth of field is set as I0Pixel point with highest brightness and pixel point with lowest brightnessWhen the brightness difference is I, the abrasion depth H is LI/I0。
And step six, the industrial personal computer 15 conducts binarization processing on the wear image of each wear part, then determines a wear area according to the wear image after binarization processing, and detects the edge of the wear area according to the wear area, so as to determine the wear area detection result of the wear area.
Step seven, if the detection results of the wear areas of all the wear parts do not exceed the wear area threshold (in this embodiment, 30cm is taken)2) And if the wear depth detection results of all the wear parts do not exceed the wear depth threshold (40% of the radius of the wiring harness in the embodiment), returning to the step three, otherwise, storing and displaying the wear judgment results of the wear parts of which the wear area detection results exceed the wear area threshold or the wear depth detection results exceed the wear depth threshold by the industrial personal computer 15, wherein the wear judgment results comprise the swing amplitude, the swing period and the total swing time of the swing motor and the wear depth and the wear area of the wear parts of which the detection results exceed the threshold.
Step eight, establishing a wear limit of the multi-wire bundle in a wire bundle wear mode and a wear limit N in a wire bundle accelerated wear modemaxThe relationship between them is as follows:
in the formula, N0、N1Values of the multi-wire bundle wear limit obtained by carrying out a plane wear test in a wire bundle wear mode and the multi-wire bundle wear limit obtained by carrying out a joint constraint wear test are two times of the ratio of the total swing time to the swing period in the corresponding wear judgment result (the number of times of friction when the wear area or the wear depth reaches a threshold value after the test); alpha (k)1 2，k3 2) Is k1、k3The influence coefficient of the wear limit of the wire harness in an accelerated wear mode under the combined action of the two variables; beta (. DELTA.k, k)2 2，k3 2) Is k2、k3Three variables of, Δ kAnd the influence coefficient on the wear limit of the wire harness in an accelerated wear mode under the combined action, wherein delta k represents the influence factor after the joint restraint block is installed on the simulation board. Alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) The values of (A) are as follows: selecting more than ten groups of k1、k2And k3Each group k1、k2And k3Taking the lower N in sequence as 2, 3 and 4, and respectively carrying out plane abrasion test in a wire harness abrasion mode to obtain a plurality of N0Respectively carrying out joint constraint abrasion test in a wire harness abrasion mode to obtain a plurality of N1Respectively carrying out plane abrasion test and joint constraint abrasion test in a wire harness accelerated abrasion mode to obtain a plurality of Nmax(ii) a Each N is0Corresponding to NmaxSubstituting into formula (1) to obtain N in each group0And NmaxCorresponding alpha (k)1 2，k3 2) Each N is1Corresponding to NmaxSubstituting into formula (2) to obtain N in each group1And NmaxCorresponding beta (. DELTA.k, k)2 2，k3 2) (ii) a By alpha (k)1 2，k3 2) As a function, k1And k3Fitting a function to the independent variable, with β (Δ k, k)2 2，k3 2) As a function, k2And k3Fitting another function to the independent variable, thus according to arbitrary k1、k2And k3All values can obtain corresponding alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) And then only need to test to obtain N0Or N1Then, N can be obtained from the formula (1) or (2)maxOr only need to test to obtain NmaxThen, N can be obtained from the formula (1)0Or obtaining N from the formula (2)1。
Claims (4)
1. The built-in type wire harness abrasion and accelerated abrasion testing method of the industrial robot is characterized by comprising the following steps: the method comprises the following specific steps:
step (ii) ofFirstly, binding all wires of a plurality of wire harnesses together through a plurality of multi-wire harness binding devices; the top ends of the multiple wire harnesses are connected with the wire harness joint motor through plugs welded at the end parts, and the bottom ends of the multiple wire harnesses are fixed through a hoop; correspondingly adjusting the whole tensioning degree of the multi-wire bundle and the tight attaching degree of each wire in the multi-wire bundle according to the tensioning condition of the wire bundle in the mechanical arm of the industrial robot to be simulated; rotating the simulation plate to a vertical state, and setting the distance between the joint constraint block on the simulation plate and the multi-wire harness as k when performing joint constraint abrasion test1，k1Taking values in 5-25 mm, and when carrying out plane abrasion test, not installing joint restraint block on the simulation board, setting the distance between the simulation board and the multiple wire harnesses to be k2，k2Taking the value in 5-25 mm; the swing arm is driven by the swing motor to a vertical state in which a distance between the swing arm and the plurality of harnesses is set to k3，k3Taking the value in 10-20 mm; fixing the top end of the swing arm and an adjusting groove at the bottom end of the simulation mechanical arm through bolts, and adjusting the connecting position of the adjusting groove of the simulation mechanical arm to ensure that the distance from the top end of the simulation mechanical arm to the bottom end of the swing arm is equal to the length of the mechanical arm of the industrial robot to be simulated; then, fixing the top end of the simulation mechanical arm and a base of the wire harness joint motor; the simulation mechanical arm, the swing arm and the simulation plate jointly simulate the mechanical arm of the industrial robot, or the simulation mechanical arm, the swing arm, the simulation plate and the joint constraint block jointly simulate the mechanical arm of the industrial robot, the swing motor simulates a single-degree-of-freedom joint at the tail end of the mechanical arm of the industrial robot, and the wiring harness joint motor simulates a single-degree-of-freedom joint at the head end of the mechanical arm of the industrial robot;
selecting a harness abrasion mode or a harness accelerated abrasion mode, and setting the oscillation amplitude of the oscillating motor in the harness abrasion mode to be
The swing amplitude of the swing motor in the accelerated wear mode of the wire harness is set as
n is 2, 3 or 4,
the value is in the range of-60 degrees to-30 degrees,
the value is within the range of 45-75 degrees; calculating the time t required by the swing motor to rotate for one circle according to the rated rotating speed of the swing motor, and then obtaining the swing period of the swing motor in the wire harness abrasion mode
The swing period of the swing motor in the accelerated wear mode of the wire harness is set to T2＝T1/n；
Step three, controlling a swing motor to swing according to the swing amplitude and the swing period set in the step two, swinging for 30min if a harness wear mode is selected in the step two, swinging for 30/n min if a harness accelerated wear mode is selected in the step two, then rotating the simulation plate for 90 degrees to enable the simulation plate to be parallel to the horizontal plane, and then horizontally moving the simulation plate to a position far away from multiple harnesses to make a space for the camera;
if the wear traces are found on the multiple wire harnesses, the lens of the camera is sequentially aligned to each wear part, the wear image of each wear part is filtered by an image acquisition card and then transmitted to an industrial personal computer, otherwise, the simulation board is reset, and the third step is repeated;
the industrial personal computer converts the wear image of each wear part from an RGB model into an HSV model to obtain hue and brightness digital information of the wear image of the HSV model, and then the brightness gradient of the wear image of the HSV model is obtained through hue distribution and brightness comparison in an analyzing mode, wherein the brightness of the deepest wear part is lowest, and the brightness of the position where an unworn pixel point is located is highest; the inherent depth of field of the camera is set as L, and the brightness value of the pixel point with the distance from the lens of the camera equal to the depth of field is set as I0If the brightness difference between the pixel with the highest brightness and the pixel with the lowest brightness is set as I, the abrasion depth is increasedDegree H ═ LI/I0；
The industrial personal computer conducts binarization processing on the wear image of each wear part, then determines a wear area according to the wear image after binarization processing, and detects the edge of the wear area according to the wear area, so that the wear area detection result of the wear area is determined;
and step seven, if the wear area detection results of all the wear parts do not exceed the wear area threshold value and the wear depth detection results of all the wear parts do not exceed the wear depth threshold value, returning to the step three, otherwise, storing and displaying the wear judgment results of all the wear parts of which the wear area detection results exceed the wear area threshold value or the wear depth detection results exceed the wear depth threshold value by the industrial personal computer, wherein the wear judgment results comprise the swing amplitude, the swing period and the total swing time of the swing motor and the wear depth and the wear area of all the wear parts of which the detection results exceed the threshold value.
2. The method for testing built-in type wire harness abrasion and accelerated abrasion of the industrial robot according to claim 1, characterized in that: step eight, establishing a wear limit of the multi-wire bundle in a wire bundle wear mode and a wear limit N in a wire bundle accelerated wear modemaxThe relationship between them is as follows:
in the formula, N0、N1Values of the multi-wire bundle wear limit obtained by carrying out a plane wear test in a wire bundle wear mode and the multi-wire bundle wear limit obtained by carrying out a joint constraint wear test are two times of the ratio of the total swing time to the swing period in the corresponding wear judgment result; alpha (k)1 2，k3 2) Is k1、k3The influence coefficient of the wear limit of the wire harness in an accelerated wear mode under the combined action of the two variables; beta (. DELTA.k, k)2 2，k3 2) Is k2、k3Three variables of, Δ kInfluence coefficients of the wear limit under the combined action on the accelerated wear mode of the wire harness, wherein delta k represents influence factors after the joint restraint block is installed on the simulation board; alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) The values of (A) are as follows: selecting more than ten groups of k1、k2And k3Each group k1、k2And k3Taking the lower N in sequence as 2, 3 and 4, and respectively carrying out plane abrasion test in a wire harness abrasion mode to obtain a plurality of N0Respectively carrying out joint constraint abrasion test in a wire harness abrasion mode to obtain a plurality of N1Respectively carrying out plane abrasion test and joint constraint abrasion test in a wire harness accelerated abrasion mode to obtain a plurality of Nmax(ii) a Each N is0Corresponding to NmaxSubstituting into formula (1) to obtain N in each group0And NmaxCorresponding alpha (k)1 2，k3 2) Each N is1Corresponding to NmaxSubstituting into formula (2) to obtain N in each group1And NmaxCorresponding beta (. DELTA.k, k)2 2，k3 2) (ii) a By alpha (k)1 2，k3 2) As a function, k1And k3Fitting a function to the independent variable, with β (Δ k, k)2 2，k3 2) As a function, k2And k3Fitting another function to the independent variable, thus according to arbitrary k1、k2And k3All values can obtain corresponding alpha (k)1 2，k3 2) And β (Δ k, k)2 2，k3 2) And then only need to test to obtain N0Or N1Then, N can be obtained from the formula (1) or (2)maxOr only need to test to obtain NmaxThen, N can be obtained from the formula (1)0Or obtaining N from the formula (2)1。
3. Built-in type wire harness wearing and tearing testing arrangement with higher speed of industrial robot mainly comprises pencil, camera, simulation arm, pencil joint motor, camera spatial position adjusting device, the device is binded to pencil, swing motor, mount pad, staple bolt, sways the arm, the simulation board, simulation board swing rotary device, simulation board moving platform, industrial computer, motor motion control ware, swing motor driver, step motor driver and image acquisition card, its characterized in that:
the simulation board swinging and rotating device comprises a swinging angle motor and a connecting board; an output shaft of the swing angle motor is fixed with the bottom end of the simulation plate; a base of the swing angle motor is fixed on a sliding table of the simulation board moving platform through a connecting plate; the base body of the simulation board moving platform is fixed on the mounting base; the camera spatial position adjusting device adjusts the position of the camera;
the base of the swing motor is fixed with the mounting seat through a screw, and an output shaft of the swing motor is fixed with the bottom end of the swing arm; the top end of the swing arm and an adjusting groove at the bottom end of the simulation mechanical arm are fixed through bolts; the top end of the simulation mechanical arm is fixed with a base of the wire harness joint motor;
each wire of the multiple wire harnesses is bound together through a plurality of multiple wire harness binding devices; the top ends of the multiple wire harnesses are connected with the wire harness joint motor through plugs welded at the end parts, and the bottom ends of the multiple wire harnesses are fixed through a hoop; under the condition that the simulation plate and the swing arm are both in a vertical state, the distance between the swing arm and the multi-wire harness is set to be k3，k3Taking a value in 10-20 mm, and setting the distance between the joint restraint block and the multi-wire harness to k when the joint restraint block is installed on the simulation board1，k1Taking a value in 5-25 mm, and setting the distance between the simulation board and the multi-wire harness to be k when the joint restraint block is not installed on the simulation board2，k2Taking the value in 5-25 mm;
the signal input end of the motor motion controller is connected with the industrial personal computer, and the signal output end of the motor motion controller is connected with the swing motor driver and the stepping motor driver; the swing motor driver drives the swing motor; the two stepping motor drivers respectively drive the swing angle motor and the simulation board moving platform; the signal output end of the camera is connected with the image acquisition card, and the image output end of the image acquisition card is connected with the industrial personal computer.
4. The industrial robot built-in type wire harness abrasion and accelerated abrasion testing device according to claim 3, characterized in that: the camera spatial position adjusting device comprises an adjusting block and two cylindrical guide rails; the adjusting block and the two guide rails are fixed through screws, one guide rail is horizontally arranged, and the other guide rail is vertically arranged; the bottom end of the vertical guide rail is fixed on the mounting seat; the base body of the camera is fixed on the horizontal guide rail.
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| CN111238981B (en) * | 2020-02-22 | 2022-05-06 | 杭州电子科技大学 | Method and device for testing abrasion of cable of industrial robot under composite motion |
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