CN110534334B - Automatic lamination robot for transformer iron core - Google Patents
Automatic lamination robot for transformer iron core Download PDFInfo
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- CN110534334B CN110534334B CN201910960130.2A CN201910960130A CN110534334B CN 110534334 B CN110534334 B CN 110534334B CN 201910960130 A CN201910960130 A CN 201910960130A CN 110534334 B CN110534334 B CN 110534334B
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- 238000003475 lamination Methods 0.000 title claims abstract description 35
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title description 12
- 239000000463 material Substances 0.000 claims description 24
- 239000003638 chemical reducing agent Substances 0.000 claims description 23
- 230000033001 locomotion Effects 0.000 claims description 20
- 238000004891 communication Methods 0.000 claims description 13
- 230000005540 biological transmission Effects 0.000 claims description 8
- 230000008878 coupling Effects 0.000 claims description 7
- 238000010168 coupling process Methods 0.000 claims description 7
- 238000005859 coupling reaction Methods 0.000 claims description 7
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 229910000976 Electrical steel Inorganic materials 0.000 abstract description 56
- 238000000034 method Methods 0.000 abstract description 9
- 230000008569 process Effects 0.000 abstract description 7
- 238000012545 processing Methods 0.000 abstract description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 238000003384 imaging method Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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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
- B25J9/02—Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type
- B25J9/023—Cartesian coordinate type
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J15/00—Gripping heads and other end effectors
- B25J15/06—Gripping heads and other end effectors with vacuum or magnetic holding means
- B25J15/0616—Gripping heads and other end effectors with vacuum or magnetic holding means with vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/10—Programme-controlled manipulators characterised by positioning means for manipulator elements
- B25J9/102—Gears specially adapted therefor, e.g. reduction gears
- B25J9/1035—Pinion and fixed rack drivers, e.g. for rotating an upper arm support on the robot base
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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
-
- 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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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0233—Manufacturing of magnetic circuits made from sheets
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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- Engineering & Computer Science (AREA)
- Robotics (AREA)
- Mechanical Engineering (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manipulator (AREA)
Abstract
An automatic lamination robot for a transformer core can solve the technical problems of low process efficiency and high labor intensity of the existing transformer core lamination. The device comprises a main frame for supporting a large beam assembly, wherein the large beam assembly can move back and forth on the main frame, a transverse moving assembly is arranged on the large beam assembly and can move left and right, a longitudinal moving assembly is arranged on the transverse moving assembly and can move up and down, and a rotating assembly is arranged at the tail end of the longitudinal moving assembly and can rotate freely. The industrial camera arranged at the tail end of the rotating assembly can shoot an integral picture of the feeding area, the position of the silicon steel sheet to be sucked by the manipulator is determined through image processing and identification, and the position of the manipulator is adjusted to enable the manipulator to be opposite to the silicon steel sheet to be sucked, so that the truss manipulator is controlled to finish single-sheet suction of the silicon steel sheet. The invention can automatically identify the required silicon steel sheet in an image identification mode, automatically correct the position of the manipulator, grasp and place the silicon steel sheet at the appointed position of the stacking table, improve the stacking quality and efficiency and reduce the labor intensity of workers.
Description
Technical Field
The invention relates to the technical field of automatic equipment, in particular to an automatic lamination robot for a transformer core.
Background
With the rapid development of power systems in China, the number of the required transformers is continuously increased, and the transformer iron core is one of the most important components of the transformers, so that the effect of limiting a closed magnetic circuit of a main magnetic field is achieved. The large-scale transformer core is assembled by nearly ten thousand silicon steel sheets, and the specification of silicon steel sheet reaches hundred kinds in addition, and manual assembly is wasted time and energy, and the accuracy is not high. The stacking precision of the silicon steel sheets can directly influence the performance indexes such as iron loss, noise and the like of the transformer.
In China, the stacking process is finished manually, the stacking efficiency and the stacking precision of the iron cores are not guaranteed, and the iron core stacking process becomes a bottleneck for restricting the production efficiency of the transformer and improving the product quality.
Disclosure of Invention
The invention provides an automatic lamination robot for a transformer core, which can solve the technical problems of low process efficiency, low automation degree, high management cost and high labor intensity of the existing transformer core lamination.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
An automatic lamination robot for a transformer core, comprising:
The device comprises a main frame, a large cross beam assembly, a transverse moving assembly, a longitudinal moving assembly and a rotating assembly, and also comprises a control cabinet, wherein a control module is arranged in the control cabinet;
the large beam assembly is arranged above the main frame;
the transverse assembly is arranged on the large beam assembly;
The longitudinal moving assembly is arranged on the transverse moving assembly;
the rotating assembly is arranged at the bottom of the longitudinal moving assembly.
The large beam assembly, the transverse moving assembly, the longitudinal moving assembly and the rotary assembly are respectively in communication connection with the control module and controlled to move by the control module;
the device also comprises an image acquisition module, wherein the image acquisition module is in communication connection with the control module, and the image acquisition module acquires images of the feeding area and sends the images to the control module;
Still include the material and snatch the module, the material snatchs the module setting on rotatory assembly, the material snatchs module and control module communication connection, the material snatchs the module and receives control module's control signal and realize snatching or letting out of material.
Further, the main frame includes rectangular frame body and sets up the stand as the support in the bottom, two sides that rectangular frame body wherein are opposite are provided with the guide rail cushion respectively, the used linear guide of big crossbeam frame that supplies big crossbeam assembly is installed to guide rail cushion top, and linear guide is used for the big crossbeam frame direction, and guide rail cushion side-mounting has the linear rack that supplies big crossbeam frame to use, and the linear rack is used for driving big crossbeam frame removal with the drive gear cooperation of big crossbeam frame both sides.
Further, U-shaped large beam supports are respectively arranged at two ends of the large beam frame, a first group of sliding blocks are arranged below the large beam support and used for being matched and guided with a linear guide rail above the main frame, the large beam support comprises a left beam support and a right beam support, a speed reducer support is fixed below the left beam support and used for being installed with a speed reducer, a bearing support is fixed below the right large beam support and used for being installed with a double-row bearing seat, a first planetary speed reducer fixed on the speed reducer support is provided with one input, two outputs are connected with a servo motor, the whole large beam frame is driven to move, one end of the output is directly connected with a driving gear, the driving gear is used for being matched with a linear rack arranged on the main frame, the other end of the output is firstly connected with a double-row plum coupling which is used for being connected with the main transmission shaft and the first planetary speed reducer, one side of the main transmission shaft is connected with a clamping type coupling which is used for being connected with the main transmission shaft and the bearing seat, the bearing seat is fixed on the bearing support below the large beam support on the right side, and the double-row bearing seat is connected with a driving gear, and the linear rack arranged below the main frame is matched with the main frame;
The servo motor for the large cross beam is controlled by a motion controller.
Furthermore, two groups of transverse linear guide rails and one group of transverse racks are arranged on the side face of the large cross beam frame, the transverse linear guide rails are matched with sliding blocks arranged on the transverse moving assembly for guiding, and the transverse racks are matched with driving gears arranged on the transverse moving assembly.
Further, the lateral moving assembly comprises a lateral moving main board, a servo motor and a planetary reducer II are respectively fixed on the left side and the right side of the lateral moving main board, the left lateral longitudinal moving servo motor is used for driving the longitudinal moving assembly and the rotating assembly to move up and down, the right lateral moving servo motor is used for driving the lateral moving assembly to move, two groups of sliding blocks are respectively arranged on the two sides of the right lateral moving servo motor, wherein the left sliding block is transversely arranged and is matched and guided with a transverse linear guide rail arranged on the side surface of the large beam frame, and the right sliding block is longitudinally arranged and is matched and guided with a longitudinal linear guide rail arranged on the side surface of the longitudinal moving assembly;
Wherein, sideslip servo motor and indulge and move servo motor control by control module.
Further, the tail end of the longitudinal moving assembly is connected with the rotating assembly;
The longitudinal moving assembly is arranged on a transverse moving host frame plate of the transverse moving assembly, two groups of longitudinal linear guide rails and one group of longitudinal linear racks are arranged on the side face of the longitudinal moving assembly, the longitudinal linear guide rails are matched with two groups of sliding blocks arranged on the right side of the transverse moving host board for guiding, and the longitudinal linear racks are matched with a longitudinal driving gear arranged at the output end of a speed reducer on the left side of the transverse moving host board for driving.
Further, a bottom mounting plate is arranged at the tail end of the longitudinal moving assembly and used for supporting a rotary servo motor, the rotary servo motor is arranged in hollow square steel of the longitudinal moving assembly, the output end of the rotary servo motor is connected with a harmonic reducer, and the harmonic reducer is connected with the rotary assembly;
The rotary servo motor is controlled by a control module.
Further, the material grabbing module is a sucker system.
Further, the rotating assembly comprises a sucker bracket rod, wherein the sucker bracket rod is connected with a harmonic reducer at the tail end of the longitudinal moving assembly, four equidistant sucker frames and two high-definition industrial cameras are arranged below the sucker bracket rod, and a vacuum sucker is respectively arranged on the four sucker frames;
The industrial camera is directly connected with the industrial personal computer and controlled by the industrial personal computer, the vacuum chuck is controlled by the vacuum system, and the vacuum system is controlled by the industrial personal computer.
Further, the control module adopts a PLC module.
According to the technical scheme, the automatic lamination robot for the transformer core based on the machine vision aims at realizing the crossing transition from 'someone' to 'unmanned', can replace manual lamination of the transformer core, improves lamination quality and efficiency, reduces labor intensity of workers and labor cost of enterprises, and realizes unmanned operation of a transformer production workshop.
Drawings
FIG. 1 is a schematic diagram of the structure of the present invention;
FIG. 2 is a schematic view of the overall frame structure of the present invention;
FIG. 3 is a partial schematic view of the overall frame of the present invention;
FIG. 4 is a schematic elevational view of the large beam assembly of the present invention;
FIG. 5 is a schematic view of the reverse side construction of the large beam assembly of the present invention;
FIGS. 6 (a), (b), (c) are partial schematic views of a large beam assembly of the present invention;
FIG. 7 is a schematic view of a traversing assembly of the present invention;
FIGS. 8 (a), (b) are partial schematic views of traversing assemblies of the present invention;
FIG. 9 is a schematic view of the longitudinal movement assembly and rotation assembly of the present invention;
FIG. 10 is a schematic view of the longitudinal movement assembly of the present invention;
FIG. 11 is a schematic view of a rotary assembly of the present invention;
FIG. 12 is a second schematic illustration of a rotating assembly according to the present invention;
fig. 13 is an automatic operation flowchart of the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention.
As shown in fig. 1-12, the automatic lamination robot equipment for the transformer iron core based on machine vision in the embodiment comprises a main frame 1, a large beam assembly 2, a traversing assembly 3, a longitudinal moving assembly 4, a rotating assembly 5 and a control module arranged in a control cabinet;
In the main frame assembly 1, eight upright posts 6 support the whole system, two groups of guide rail cushion blocks 7 are arranged on the left side and the right side above the main frame 1 and used for fixing linear guide rails 8 and linear racks 9 on the two sides, wherein the linear guide rails 8 and the linear racks 9 are respectively matched with sliding blocks 12 and driving gears 21 of the large cross beam assembly 2.
In the large beam assembly 2, two groups of sliding blocks 12 are respectively arranged at the bottoms of two large beam brackets 11, the sliding blocks 12 are embedded on a linear guide rail 8 above a main frame 1 and used for guiding the whole large beam assembly 1, the input end of a planetary reducer 15 is connected with a servo motor 17, one end of the output end is directly connected with a driving gear 21, the output end is meshed with the large beam brackets by a linear rack 9, one end of the output end is connected with a plum blossom shaft coupling 18, the other end of the plum blossom shaft coupling 18 is connected with a main transmission shaft 19, one end of the main transmission shaft 19 is connected with a clamping type shaft coupling 20, the clamping type shaft coupling 20 is connected with a double-row bearing seat 16, the bearing seat is provided with a driving gear 21, the driving gear 21 is meshed with the linear racks 9 arranged on the main frame 1, and the gear rack mechanisms at the left end and the right end of the large beam assembly 2 realize the movement of the large beam assembly 2. Two transverse linear guide rails 22 and a transverse linear rack 23 are arranged on the side face of the large cross beam frame 10, wherein the transverse linear guide rails 22 and the transverse rack 23 are respectively matched with a transverse sliding block 28 and a transverse driving gear 30 of the transverse moving assembly 3.
In the traversing assembly 3, a traversing host frame plate 24 is taken as a core, a planetary reducer 27 and a servo motor are respectively arranged at the left side and the right side of the traversing host frame plate, the traversing servo motor 26 is used for driving transverse movement, the longitudinal movement servo motor 25 is used for driving longitudinal movement, and correspondingly, two groups of sliding blocks are also arranged at the left side and the right side of the traversing assembly, and the traversing assembly is divided into transverse and longitudinal guiding, wherein the transverse sliding blocks 28 are matched with transverse linear guide rails 22 arranged at the side surfaces of a large beam frame 9, and the longitudinal sliding blocks 29 are matched with longitudinal linear guide rails 32 arranged at the side surfaces of the longitudinal movement assembly 4.
In the vertical moving assembly 4, two vertical moving linear guide rails 32 and a vertical moving rack 33 are installed on the side surfaces, a rotary servo motor 35 and a harmonic reducer 36 are installed on the bottom installation plate 34 for realizing the rotation movement, the rotary servo motor 35 is connected with the rotary assembly 5 through a sucker bracket rod 37, a sucker bracket 38 and an industrial camera 39 are installed on the sucker bracket rod 37, and a vacuum sucker 40 is installed on the sucker bracket 38.
The control module comprises an upper computer control module and a lower computer control module.
The upper computer control module comprises an industrial camera control module, a database module and an industrial tablet computer module, and the lower computer control module comprises a programmable logic controller, a driver module, a sensor module and a pneumatic loop module.
The driving mechanisms of the transverse moving assembly, the longitudinal moving assembly and the rotating assembly are respectively connected with the programmable logic controller; the sensor module is directly connected with the programmable logic controller;
the industrial camera assembly and the programmable logic controller are connected with the industrial tablet personal computer;
The sensor assembly is used for measuring the distance between the four-axis truss manipulator and the sheet to be taken, and sending the distance to the industrial tablet personal computer, so that the truss manipulator is controlled to move downwards for a fixed distance to finish the sucking operation;
The industrial camera assembly is used for shooting unordered silicon steel sheet pictures in the feeding area and sending the pictures to the industrial tablet personal computer, the industrial tablet personal computer performs image processing and analysis on the pictures, and calculates a distance difference value between the truss manipulator and the silicon steel sheet to be taken, so that the truss manipulator is controlled to be positioned right above the silicon steel sheet to be taken.
The pneumatic loop assembly comprises a filtering pressure reducing valve, a vacuum generator, a vacuum supply valve, a vacuum breaking valve and a vacuum chuck 40, wherein the vacuum chuck 40 is arranged at the tail part of the truss manipulator and used as a medium for sucking the silicon steel sheet, and when the truss manipulator reaches the position right above the silicon steel sheet to be picked up according to an image recognition result and moves downwards to the position, which is fed back by the displacement sensor, of the vacuum chuck to contact the material sheet, the vacuum generator starts to generate vacuum at the moment, and the silicon steel sheet can be sucked.
The motor also comprises a pulse generator, namely an electronic hand wheel, which is directly connected with the programmable logic controller, the pulse generator can simultaneously control the movement of four shafts, the multiplying power can be selected, and the motor can be conveniently debugged.
Further, the sensor assembly includes a proximity switch.
The proximity switch assembly is mounted at the extreme positions of movement of the respective shafts.
The proximity switch assembly is directly connected with the programmable logic controller.
Based on above-mentioned automatic lamination robot control system of transformer core, include the following step:
After the system is electrified, the industrial personal computer is communicated with the controller and is connected with the servo system, and the industrial personal computer is communicated with the industrial camera and is connected with the industrial camera.
And the industrial personal computer reads a register with servo motor position information stored in the motion controller to obtain the position information of the truss robot after the system is electrified, and then executes the original point returning operation to reset the whole servo system.
The user selects the specification of the stacked transformer, and different databases are called for matching according to different specifications selected by the user, wherein the databases comprise the specific size of the silicon steel sheet of a certain type of transformer and the path information of automatic stacking operation.
Then, the truss robot moves to the upper part of the feeding area, a position photo of the feeding area is shot through the industrial camera assembly and is sent to the industrial personal computer, the industrial personal computer performs image processing and analysis on the photo, and the distance difference between the truss manipulator and the silicon steel sheet to be taken is calculated, wherein the specific conversion process is as follows:
Because each time the truss manipulator is moved to a fixed position above the bin, only the Z-axis direction changes according to the value of the displacement sensor, the actual coordinates corresponding to the center point of the photograph after each industrial camera imaging can be determined.
According to the deflection angle of the upper edge line of the silicon steel sheet and the horizontal line, the deflection amount required by the rotation shaft of the truss manipulator can be calculated, after the circle center coordinates of the circle on the silicon steel sheet are calculated, the deviation dx and dy (taking pixels as units) of the coordinates of the center point of the photo can be calculated, and because the actual distance of each pixel is fixed, the actual offset distance can be calculated according to the offset pixels, and the distance is the offset amount required to be moved by the X axis and the Y axis of the truss manipulator, so that the position of the silicon steel sheet under the world coordinate system is obtained.
Under the condition that the world coordinates of the silicon steel sheet to be taken are calculated, the industrial personal computer controls the manipulator to move to the position right above the silicon steel sheet, and as the distance sensor can ensure the vertical distance of the manipulator on the Z axis, the industrial personal computer controls the manipulator to descend according to the value of the distance sensor, and after the vacuum chuck contacts the material sheet, the vacuum chuck is required to generate negative pressure at the moment, so that the silicon steel sheet is sucked, namely, the industrial personal computer controls the vacuum generator to generate vacuum through controlling the electromagnetic valve of the pneumatic loop, so that the vacuum chuck can suck the silicon steel sheet.
Because the path of the placement area is fixed, each piece is planned in advance in the placement position, the truss manipulator sucks the silicon steel sheet and then moves to the fixed position of the placement area, no other positioning calculation is needed at this time, only path information which is set in advance is needed to be read out from a database, after the truss manipulator moves to the fixed discharging area, the Z axis of the truss manipulator descends by a proper distance, then the industrial personal computer breaks the negative pressure of the vacuum chuck through controlling the vacuum breaking valve of the pneumatic circuit, and the vacuum chuck can release the silicon steel sheet, so that the stacking of one piece is completed.
The iron cores of a transformer are stacked together, a layer of five iron cores are respectively a left column, a middle column, a right column, an upper yoke and a lower yoke, and truss manipulators sequentially identify and grasp the iron cores in the five groups of silicon steel sheets until the stacking of the whole transformer is completed.
A description will now be made of a database of the truss robot moving path:
In order to improve the stacking efficiency of the whole system, the positions of five groups of silicon steel sheets in a feeding area are relatively orderly, the left column material sheets are placed on the left side of the stacking table, the middle column material sheets are placed in the middle, the right column material sheets are placed on the rightmost side, the upper yoke material sheets and the lower yoke material sheets are placed on the upper side and the lower side of the stacking table, because the visual field of an industrial camera is limited, only a few local information can be shot each time, truss manipulators are required to move to different positions in the feeding area when different material sheets are grabbed, based on the fact, a database when the material sheets are grabbed is arranged, five groups of path information are stored in the database, the positions of the five groups of material sheets in actual coordinates correspond to pulse quantities required to be moved by the four shafts respectively, and each time the truss manipulators can move to the upper side of the corresponding material sheets in the feeding area after reading the path information in the database, so that the industrial camera can take photos at the moment, and therefore the information can be identified and grabbed.
After each time the silicon steel sheet is grabbed, the placement position of the silicon steel sheet is fixed, the database also comprises a group of placement paths, and as each layer of the transformer iron core is provided with five silicon steel sheets, five groups of path information are shared in the placement path database and are in one-to-one correspondence with the path information in the grabbing database, and the truss manipulator can place the silicon steel sheet to the designated position after reading the path information in the placement database.
Correspondingly, an explanation will be made on the identification of the silicon steel sheet by the industrial camera:
The silicon steel sheet is placed in a static manner in a feeding area, the dimension of the longest silicon steel sheet is about 1280x250x0.2mm (length x width x thickness), and two center holes and one edge of the silicon steel sheet are selected as positioning features. The visual field range of the industrial camera is fixed at 500mm, each pixel is about 0.125mm, the precision requirement is met, and the distance between two central holes of the silicon steel sheet with the length of 1280mm is 700mm, so that two industrial cameras are required to be arranged, one is in charge of a left hole, and the other is in charge of a right hole and a right edge line.
The deflection angle between the upper edge line of the silicon steel sheet and the horizontal line is found, the deflection required by the rotation shaft of the truss manipulator can be calculated, and after the center coordinates of the center circle of the silicon steel sheet are found, the deviation dx and dy (taking pixels as units) of the center point coordinates of the picture can be calculated.
Because the silicon steel sheets have a plurality of different types and the silicon steel sheets of different types have different lengths and widths, whether the types are correct or not needs to be determined before the truss manipulator grabs the silicon steel sheets.
In the upper graph, the width of the silicon steel sheet can be calculated according to the distance from the center of a circle to the upper edge line, the world coordinate of the left hole can be calculated in an imaging photo of a left industrial camera, the length of the silicon steel sheet can be obtained according to the coordinates of the left hole and the right hole, and the model of the silicon steel sheet can be determined after the length and the width of the silicon steel sheet are obtained.
The control module described above may be further explained as follows:
The control system of the automatic lamination machine mainly comprises an upper computer system and a lower computer system, wherein the lower computer system realizes the control of each motion axis of the rectangular coordinate robot, and the communication with the upper computer and the processing of alarm signals, and the upper computer system mainly comprises a man-machine interaction interface, a communication module, an initialization, an image acquisition, an automatic module, an alarm module, a manual module, a database and other program modules, and the functions of each module are firstly explained.
(1) And the image acquisition module is used for acquiring pictures by mainly utilizing two industrial cameras on each manipulator. Firstly, an industrial camera shoots a feeding area, the photos are stored in a path appointed by an upper computer, the upper computer processes and identifies images, a required silicon steel sheet is found, and actual coordinate values are stored.
(2) And the communication module is used for mainly establishing the contact of the whole system. The system comprises two industrial personal computers, wherein the two industrial personal computers are in communication with each other, the industrial personal computers are in communication with the controller, and the industrial personal computers are in communication with the industrial camera. When the system is started, the left industrial personal computer starts lamination, the right industrial personal computer is in a standby state, when the lamination of the left industrial personal computer is completed, a corresponding instruction is sent to the right industrial personal computer, the left industrial personal computer is in a stop standby state, the right industrial personal computer starts lamination, and the two industrial personal computers perform lamination work in a reciprocating manner. The communication between the industrial personal computer and the controller is based on the expansion memobus protocol of TCP, and the motion control of the motor is realized by sending an instruction to the MP3300 controller, setting a motion mode and the like. The industrial personal computer communicates with the industrial camera through a network interface, and photographing, storage and other actions are completed by calling an API function of the camera.
(3) And the database module considers that the types of different transformers are different, and the required specifications of the silicon steel sheets are different, so that a set of database is designed for the transformers with different types, the database stores the information of the silicon steel sheets with corresponding types, the types of the transformers are selected before lamination, and then the system matches the information obtained after the photo is processed with the information in the corresponding database. Considering the flexibility of lamination paths, when one lamination machine breaks down, the other lamination machine needs to independently complete lamination work, so that different paths are needed to meet the demands of users, a plurality of sets of different paths are planned for each lamination machine and stored in a database, and users can select proper paths to complete lamination work according to own demands.
(4) The manual operation module is provided with manual operation functions in consideration of early debugging and later maintenance, and in a manual mode, each function can be independently tested, and a user can realize the functions of photographing of an industrial camera, opening and closing of an electromagnetic valve, click-through of a motor, fast forward of the motor and the like through buttons on a touch screen.
(5) And the automatic operation module is used for automatically stacking the system after the user selects the type information and the path information of the transformer, and the specific flow chart is shown in fig. 6. After the system is electrified, the left industrial personal computer and the right industrial personal computer are communicated with the MP3300 controllers respectively, the control system reads a register of the position information of the servo motor stored in the MP3300 controllers to obtain the position information of the servo motor after the system is electrified, then the servo system is reset by executing the original point operation, then the control system operates a path in a database according to path information selected by a user and model information of a transformer, when the system operates above a feeding area, the system controls an industrial camera to photograph, processes a photo and matches with the model of a silicon steel sheet in the database, if the silicon steel sheet is needed, the position information is automatically compensated and grasped, if the silicon steel sheet is not needed, a voice alarm is sent out, after the manipulator grasps the needed silicon steel sheet, the servo motor is placed at a designated position according to the information in the path database, after the left industrial personal computer completes the stacking of three sheets, the right industrial personal computer sends an instruction, the right industrial personal computer starts to operate the right industrial personal computer to complete the operation of the left industrial personal computer after the left industrial personal computer completes the stacking of the three sheets according to the mode, and the whole transformer stacking system is completed until the whole transformer stacking platform is completed.
Referring to fig. 13, the specific working procedure of the automatic lamination robot for the transformer core based on machine vision of the invention is as follows:
The first step: after the system is powered on, the large beam assembly 2 moves above the loading table, and an industrial camera 39 mounted on the rotating assembly 5 photographs the loading area.
And a second step of: the industrial personal computer in the control cabinet performs image processing on the pictures returned by the industrial camera 39, calculates the actual position of the silicon steel sheet, and calculates the compensation amount required to move for each axis.
And a third step of: the controller sends pulse signals corresponding to four servo motors for controlling the large beam assembly 2, the transverse moving assembly 3, the longitudinal moving assembly 4 and the rotating assembly 5, the four servo motors start to act simultaneously, and after the corresponding pulse signals are walked, the rotating assembly 5 moves to the position right above the silicon steel sheet.
And a third step of: the vertical moving assembly 4 starts to drive the rotating assembly 5 to descend according to the value of the distance sensor, when the value of the distance sensor is 0, at the moment, the vacuum sucking disc 40 is contacted with the material sheet, the vacuum system starts to generate vacuum, negative pressure is formed inside the sucking disc 40, and the controller controls the vertical moving assembly 4 to ascend, and at the moment, the silicon steel sheet is sucked up.
Fourth step: after the upper computer reads the information of the placement path in the database, the compensation quantity of each shaft is sent to the motion controller, and after the motion controller receives the information, the motion controller simultaneously sends corresponding pulse quantity to the four servo motors to control the four shafts to synchronously move to the corresponding positions above the stacking table.
Fifth step: the longitudinal moving servo motor 25 arranged on the transverse moving assembly 3 drives the longitudinal moving assembly 4 to descend, when the rotating assembly 5 descends to a proper distance, the vacuum breaking valve starts to act to break the vacuum in the vacuum chuck 40, at the moment, the silicon steel sheet can be put down, and thus, the stacking of one sheet is finished.
Sixth step: repeating the steps one to five until the whole transformer is stacked.
The embodiment of the invention realizes the crossing transition from 'someone' to 'no person', and the introduction of the automatic lamination technology improves the lamination precision and the production efficiency of factories in the period of alternating new and old management systems and methods in the power industry, shortens the production period of products and reduces the labor cost.
The above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (7)
1. The utility model provides an automatic lamination robot of transformer core, includes main frame (1), big crossbeam assembly (2), sideslip assembly (3), indulges and moves assembly (4), rotatory assembly (5), its characterized in that: the control cabinet is internally provided with a control module;
the large cross beam assembly (2) is arranged above the main frame (1);
the transverse moving assembly (3) is arranged on the large cross beam assembly (2);
The longitudinal moving assembly (4) is arranged on the transverse moving assembly (3);
The rotating assembly (5) is arranged at the bottom of the longitudinal moving assembly (4);
The large beam assembly (2), the transverse moving assembly (3), the longitudinal moving assembly (4) and the rotary assembly (5) are respectively in communication connection with the control module and controlled to move by the control module;
the device also comprises an image acquisition module, wherein the image acquisition module is in communication connection with the control module, and the image acquisition module acquires images of the feeding area and sends the images to the control module;
The material grabbing device comprises a rotating assembly (5), a material grabbing module and a control module, wherein the material grabbing module is arranged on the rotating assembly and is in communication connection with the control module, and the material grabbing module receives a control signal of the control module to grab or release materials;
The rotary assembly (5) comprises a sucker bracket rod (37), wherein the sucker bracket rod (37) is connected with a harmonic reducer (36) at the tail end of the longitudinal movement assembly (4), four equidistant sucker brackets (38) are arranged below the sucker bracket rod (37), and two high-definition industrial cameras (39), wherein one vacuum sucker (40) is respectively arranged on the four sucker brackets (38);
The industrial camera (39) is directly connected with the industrial personal computer and controlled by the industrial personal computer, the vacuum sucker (40) is controlled by a vacuum system, and the vacuum system is controlled by the industrial personal computer;
The main frame (1) comprises a rectangular frame body and upright posts (6) which are arranged at the bottom and used as supports, guide rail cushion blocks (7) are respectively arranged on two opposite side edges of the rectangular frame body, a linear guide rail (8) used for a large beam frame (10) of the large beam assembly (2) is arranged above the guide rail cushion blocks, the linear guide rail (8) is used for guiding the large beam frame (10), a linear rack (9) used for the large beam frame (10) is arranged on the side surface of the guide rail cushion blocks (7), and the linear rack (9) is used for being matched with driving gears on two sides of the large beam frame (10) to drive the large beam frame to move;
The two ends of the large beam frame (10) are respectively provided with a U-shaped large beam frame (11), two groups of first sliding blocks (12) are arranged below the large beam frame and used for guiding the large beam frame in a matched manner with a linear guide rail (8) arranged above the main frame (1), the large beam frame (11) comprises a left beam frame and a right beam frame, a speed reducer bracket (13) is fixed below the left beam frame and used for installing a speed reducer, a bearing bracket (14) is fixed below the right large beam frame and used for installing a double-row bearing seat (16), a planetary speed reducer I (15) fixed on the speed reducer bracket (13) is provided with one input, two outputs are connected with a servo motor (17) and used for driving the whole large beam frame (10) to move, one end of the output is directly connected with a driving gear (21), the driving gear (21) is used for being matched with a linear rack (9) arranged on the main frame (1), the other end of the output is firstly connected with a plum blossom coupling (18) which is used for connecting the main transmission shaft (19) with the first planetary speed reducer (15), one side of the main transmission shaft (19) is connected with a bearing seat (16), one side of the main transmission shaft (19) is connected with the bearing seat (16) which is fixedly connected with the bearing seat (16) on the side of the main frame (16), which is matched with a linear rack (9) arranged below the main frame (1);
the large beam assembly (2) is controlled by a motion controller through a servo motor (17).
2. The automatic lamination robot for transformer cores of claim 1, wherein: two groups of transverse linear guide rails (22) and a group of transverse racks (23) are arranged on the side face of the large cross beam frame (10), the transverse linear guide rails (22) are matched with sliding blocks arranged on the transverse moving assembly (3) for guiding, and the transverse racks (23) are matched with driving gears arranged on the transverse moving assembly (3).
3. The automatic lamination robot for transformer cores of claim 2, wherein: the transverse moving assembly (3) comprises a transverse moving main board (24), a servo motor and a planetary reducer II (27) are respectively fixed on the left side and the right side of the transverse moving main board (24), the left side longitudinal moving servo motor (25) is used for driving the longitudinal moving assembly (4) and the rotating assembly (5) to move up and down, the right side transverse moving servo motor (26) is used for driving the transverse moving assembly (3) to move, two groups of sliding blocks are respectively arranged on the two sides of the transverse moving assembly, wherein the left side sliding block (28) is transversely arranged and matched with a transverse linear guide rail (22) arranged on the side face of the large beam frame (10) for guiding, and the right side sliding block (29) is longitudinally arranged and matched with a longitudinal linear guide rail (32) arranged on the side face of the longitudinal moving assembly (4) for guiding;
wherein, sideslip servo motor (26) and indulge and move servo motor (25) and control the module.
4. The automatic lamination robot for transformer cores of claim 3, wherein:
the tail end of the longitudinal moving assembly (4) is connected with the rotating assembly (5);
The longitudinal moving assembly (4) is arranged on a transverse moving host frame plate of the transverse moving assembly (3), two groups of longitudinal linear guide rails (32) and one group of longitudinal linear racks (33) are arranged on the side face of the longitudinal moving assembly (4), the longitudinal linear guide rails (32) are matched with two groups of sliding blocks (29) arranged on the right side of the transverse moving host board (24) for guiding, and the longitudinal linear racks (33) are matched with a longitudinal driving gear (31) arranged at the output end of a speed reducer on the left side of the transverse moving host board (24) for driving.
5. The automatic lamination robot for transformer cores of claim 4, wherein:
A bottom mounting plate (34) is arranged at the tail end of the longitudinal moving assembly (4) and is used for supporting a rotary servo motor (35), the rotary servo motor (35) is arranged in hollow square steel of the longitudinal moving assembly (4), the output end of the rotary servo motor (35) is connected with a harmonic reducer (36), and the harmonic reducer (36) is connected with the rotary assembly (5);
the rotary servo motor (35) is controlled by a control module.
6. The automatic lamination robot for transformer cores of claim 1, wherein:
The material grabbing module is a sucker system.
7. The automatic lamination robot for transformer cores according to any one of claims 1-6, wherein: the control module adopts a PLC module.
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| TWI754914B (en) * | 2020-04-10 | 2022-02-11 | 張志陸 | Horizontal picking device for automatic storage system |
| CN112103063B (en) * | 2020-08-07 | 2021-12-31 | 山东电力设备有限公司 | Full-automatic bonding device and process method for magnetic shielding of transformer |
| CN112071622B (en) * | 2020-09-12 | 2022-07-12 | 哈尔滨理工大学 | Transformer core silicon steel sheet laminating device and method |
| CN112489978B (en) * | 2020-12-03 | 2025-04-11 | 浙江江山变压器股份有限公司 | A transformer silicon steel sheet reverse transfer mechanism and center column lamination device |
| CN112719888A (en) * | 2020-12-25 | 2021-04-30 | 滁州博格韦尔电气有限公司 | Clamping piece assembling equipment for iron core stacking of reactor for rail transit |
| CN113070655A (en) * | 2021-04-02 | 2021-07-06 | 深圳市众铭安科技有限公司 | Automatic feeding and discharging device of backlight assembling machine |
| CN114472993A (en) * | 2021-12-29 | 2022-05-13 | 江苏隆宝重工科技有限公司 | Truss automatic control mechanism of edge milling machine |
| CN114473696B (en) * | 2022-01-20 | 2023-01-13 | 合肥元贞电力科技股份有限公司 | Automatic system for high-speed lamination of transformer core |
| CN115091446A (en) * | 2022-07-12 | 2022-09-23 | 西安航空学院 | A Mechatronics Industrial Robot Automation Control System |
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| CN105643605B (en) * | 2016-03-30 | 2017-07-07 | 中国科学院沈阳自动化研究所 | A kind of transformer core lamination manipulator |
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