CN112130529A - Force-sensing-based multi-assembly-station operation safety system and implementation method thereof - Google Patents
Force-sensing-based multi-assembly-station operation safety system and implementation method thereof Download PDFInfo
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- CN112130529A CN112130529A CN202010894535.3A CN202010894535A CN112130529A CN 112130529 A CN112130529 A CN 112130529A CN 202010894535 A CN202010894535 A CN 202010894535A CN 112130529 A CN112130529 A CN 112130529A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41805—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by assembly
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41835—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by programme execution
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/41855—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication by local area network [LAN], network structure
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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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
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention relates to the field of automatic production and assembly, in particular to a force-sensing-based multi-assembly-station operation safety system and an implementation method thereof. The method comprises the following steps: the system comprises a main controller, a rotary table servo driver, a fence system, a carrying robot and a functional robot; the turntable motor, the turntable, the carrying robot and the functional robot are all arranged in the fence area; the main controller is connected with the servo driver, the carrying robot and the functional robot through a field bus; a transfer robot and a functional robot are arranged on two sides of the rotary table, are respectively provided with a corresponding robot controller and are connected with the main controller through a hard-wire safety link; and a one-dimensional force sensor is arranged at the clamp end of the transfer robot and is connected with the robot controller. The invention has the advantages of ensuring the real-time performance and stability of communication between devices, realizing the control and monitoring of real-time position and state signals in the operation process of the main station transmission device and finishing accurate production positioning and workpiece transmission positioning.
Description
Technical Field
The invention relates to the field of automatic production and assembly, in particular to a force-sensing-based multi-assembly-station operation safety system and an implementation method thereof.
Background
In a modern automated production plant, the main production line comprises a plurality of work stations, each of which performs assembly production according to a respective task. The production process of individual stations is complex, and the situation that a person works with a robot or other automatic equipment simultaneously exists. Taking automobile welding production as an example, dozens of parts need to be accurately placed on a frame and are welded one by a robot, and the parts are transferred by a conveying line or carried to the next station by the robot after the welding is finished. Part of the stations need to be manually loaded in sequence, and a plurality of robots carry out welding one by one and integral carrying work. Because the potential safety hazard inevitably exists in the collaborative work between people and the automation equipment to when people's maloperation easily take place the robot and grab from fixed frock put the work piece in-process because the deformation and the damage of the work piece that slightly interferes between the work piece that frock and robot held, this causes the production beat for production safety and when the accident takes place, has also increased work load for the quality control of later stage product.
Disclosure of Invention
The invention aims to provide a force sensing-based multi-assembly station operation safety system and an implementation method thereof.
The technical scheme adopted by the invention for realizing the purpose is as follows: a force-aware based multi-assembly station operational safety system, comprising: the system comprises a main controller, a rotary table servo driver, a fence system, a carrying robot and a functional robot; the turntable motor, the turntable, the carrying robot and the functional robot are all arranged in the fence area;
the main controller is connected with the servo driver, the carrying robot and the functional robot through a field bus to realize data communication and state monitoring;
a carrying robot and a functional robot are arranged on two sides of the rotary table, and the carrying robot and the functional robot are respectively provided with corresponding robot controllers and are connected with a main controller through hard-wire safety links;
and the clamp end of the transfer robot is provided with a one-dimensional force sensor for measuring the pressure and the tension of the clamp, and the one-dimensional force sensor is connected with the robot controller and used for feeding back an analog signal acquired when the robot works and transmitting the analog signal back to the robot controller.
The main controller is a programmable logic controller for fault safety and is provided with safety IO modules corresponding to the number of devices, shutdown brake signals received and sent by the safety IO modules of the main controller are independently programmed in a safety logic program block in the main controller to form safety interlocking logic, and the priority is higher than collision detection and clamp end force detection feedback signals.
A safety door is arranged on the fence system, a correlation type safety grating is arranged at a workpiece inlet, and the safety grating enters and exits when the workpiece is manually loaded; the safety door and the safety grating are respectively connected with a safety IO module of the main controller.
The hard wire safety link comprises a relay K1 and a relay K2, and the relay K1 and the relay K2 both have a linkage double-contact structure with a forced guiding function; two linkage contacts of the relay are respectively connected with the emergency stop interface of the corresponding robot controller; when the moving equipment needs to be added, the number of the relays is increased, and then the hard-wire safety link is expanded.
A two-way circuit is arranged between the main controller and the robot controller; the two-way circuit is two loops with normally closed contacts.
The rotary table is provided with a plurality of pneumatic fixtures and a plurality of sensors, and the electromagnetic valves and the sensors for controlling the pneumatic fixtures are connected to a field module which is arranged on the rotary table and used for collecting data transmitted by the electromagnetic valves and the sensors, and then are connected to the main controller through a field bus for communication; proximity switches on the turntable for defining the position and orientation of the turntable are individually hard-wired to the IO modules of the main controller.
The implementation method of the multi-assembly-station operation safety system based on force perception is characterized by comprising the following steps of:
1) the workpiece is loaded on the rotary table in a manual carrying mode or a carrying robot carrying mode, the rotary table clamp clamps the workpiece, the main controller controls the rotary table motor to drive the rotary table to rotate through the servo driver, so that the workpiece is stopped at one side of the functional robot, and the robot carries out workpiece assembling work;
2) the servo driver transmits real-time angular velocity, position and alarm information of the rotary table to the main controller in real time to monitor and receive a control command, when the rotary table stops and an error exists or a rotary table limit proximity switch is triggered, the main controller gives an alarm and interrupts a program flow, and meanwhile, the rotary table is braked so that the robot does not continuously cooperate with the rotary table to perform subsequent assembly work;
3) in the working process, when a robot or a servo driver suddenly stops and brakes, a safety door is opened, a grating passes through the safety grating without manual request, and any condition of a shielding signal is detected to occur, the main controller controls the input of the safety IO module to disappear, a safety logic program block in the main controller takes effect, and closes a safety output to brake equipment connected with the main controller through a hard-wire safety link;
4) after the functional robot finishes working, the rotary table is rotated to one side of an upper part, the carrying robot grabs an integrated workpiece to leave a rotary area of the rotary table at a speed lower than a set speed and then moves to the next rotary table at a running speed, in the process, when an analog signal acquired by a one-dimensional force sensor on a carrying robot clamp exceeds a set threshold value, the workpiece is indicated to be interfered with the rotary table clamp, the carrying robot and the functional robot are controlled by the robot controller to enter a pause state, the analog signal acquired by the one-dimensional force sensor is uploaded to the main controller through the robot controller to be recorded, and equipment connected with the main controller through a hard-wire safety link is recovered after manual inspection;
the step 3) is specifically as follows:
when the safety grating at the workpiece loading position of the station is shielded, the safety grating feeds back to an IO input module of the main controller to enable a normally closed signal of a double-circuit to disappear, an independent safety logic program block in the main controller stops high level output of a safety output port, so that coils of the relay K1 and the relay K2 are powered off, contacts corresponding to the relay K1 and the relay K2 are disconnected, and accordingly, the carrying and functional robot is triggered to emergently stop through a carrying and functional robot emergency stop interface, and the carrying robot and the functional robot enter an emergency stop state; before the assembly station operation safety system enters the operation state again, a grating double-hand reset button used for restarting in the peripheral area of the fence needs to be pressed manually, so that the main controller recovers the high-level output of the safety output port.
The equipment connected with the main controller through the hard-wire safety link comprises a rotary table motor, a rotary table, a safety door, a carrying robot and a functional robot.
The invention has the following beneficial effects and advantages:
1. the invention ensures the real-time performance and stability of communication between devices, realizes the control and monitoring of real-time position and state signals in the operation process of the main station transmission device, and completes accurate production positioning and workpiece transmission positioning so as to meet the requirements of production application.
2. When various standard automation equipment works in a man-machine cooperation mode, the safety link of a hard wire double loop formed by the fail-safe programmable controller and the safety component can realize normal operation of a station on the premise of ensuring personal safety.
3. The robot with the force sensor has a force sensing function, the robot controller can independently judge whether the working state is abnormal or not according to a preset force feedback threshold value and serves as a co-controller, the abnormal working state is distinguished as alarming or prompting and reported to the main controller through a field bus, and at the moment, the robot is in a pause mode and cannot cause the whole-line shutdown of a production line.
4. The main controller can obtain the state information of the automation equipment in the station in real time, and when personnel illegally enter the station, reliable safety braking is carried out on the complex large-scale movement equipment, personal safety and equipment safety are guaranteed, and meanwhile, the time for fault diagnosis is shortened.
Drawings
FIG. 1 is a hardware architecture framework of the present invention;
FIG. 2 is a schematic layout of the present invention;
fig. 3 is a schematic diagram of the hard-wired secure link connection of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
As shown in fig. 1 and 2, the force-sensing-based multi-assembly-station operation safety system includes: the system comprises a main controller, a rotary table servo driver, a fence system, a carrying robot and a functional robot;
the turntable motor, the turntable, the carrying robot and the functional robot are all arranged in the fence area;
the main controller is connected with the servo driver, the carrying robot and the functional robot through a field bus to realize data communication and state monitoring; the turntable servo motor is driven by a servo driver, the servo driver and a main controller form a closed-loop control structure through bus communication, and the start and stop operation of the servo motor is controlled by the main controller.
The turntable is used as a core transmission device for each station, the state of the turntable is judged by the main controller before the robot and the robot work, and safety signals of safety devices such as a grating and a safety door are judged, so that accidents caused by misoperation of the large turntable are prevented. A transfer robot and a functional robot are arranged on two sides of the rotary table and used for welding and carrying, and the transfer robot and the functional robot are respectively connected with the corresponding robot controllers and are connected with the main controller through hard-wire safety links;
and a one-dimensional force sensor for measuring the pressure and the tension of the clamp is arranged at the clamp end of the transfer robot and is connected with the robot controller, and an analog signal acquired when the robot works is fed back to the robot controller.
The workpieces are placed on the rotary table controlled to rotate one by one in a manual or transfer robot transfer mode, the rotary table is loaded at a specific position and then clamped by the rotary table clamp and rotated 180 degrees, one face, provided with the workpieces, of the rotary table is rotated to one side where a functional robot for welding work is located, and the workpieces are fastened and assembled by another robot far away from the manual workpiece loading position. After the workpieces are fastened, the rotary table rotates to one side of the upper workpiece, and the workpieces which are integrally connected are integrally conveyed to the next rotary table by the conveying robot. All the robot controllers are additionally provided with Profibus bus gateway modules which communicate with the main controller and receive control of the main controller. The turntable motor is driven by a servo driver, the servo driver selects a Profibus communication card to communicate with the main controller, and an electric element on the turntable uses an SMC field IO module to communicate with the main controller through a Prifibus bus.
The station number of each bus device in the production line subnet is unique, the main controller is a programmable logic controller for fault safety, is provided with safety IO modules with the number corresponding to the number of the devices, and is provided with at least eight safety input ports and two safety output ports. The shutdown brake signal received and sent by the safety IO module of the main controller is independently programmed in a safety logic program block in the main controller to form a safety interlocking logic, and the priority is higher than the collision detection and clamp end force detection feedback signal. The robot controller safety interface should have, but not be limited to, emergency stop and emergency stop feedback functions, and should comply with ISO 10218 standard. The turntable servo driver has an STO function, and the main controller safety IO module is independent of a field bus and independently leads out a turntable emergency stop line to an STO function interface of the turntable servo driver.
A fence system for preventing people from passing through is arranged in the station working area, a safety door is arranged on the fence system, a correlation type safety grating is arranged at a workpiece inlet, and the safety grating enters and exits when the workpieces are loaded manually; the safety door and the safety grating are respectively connected with a safety IO module of the main controller. The safety door lock of the safety door needs to have a double contact structure.
Fig. 3 is a schematic diagram of the hard-wired secure link wiring of the present invention. The way the servo turntable is connected in the loop is not shown in detail. However, the present invention is not limited to the above-described embodiments, and various changes can be made without departing from the spirit of the present invention within the knowledge of those skilled in the art.
As shown in fig. 3, the hard-wired safety link includes a relay K1 and a relay K2, and the relay K1 and the relay K2 both have a linkage double-contact structure with a forced guiding function; two linkage contacts of the relay are respectively connected with the emergency stop interface of the corresponding robot controller; when the moving equipment needs to be added, the number of the relays is increased, and then the hard-wire safety link is expanded.
A two-way circuit is arranged between the main controller and the robot controller; the two-way circuit is two return circuits with normally closed contacts, and the relay is adopted in the embodiment.
As shown in fig. 2, the turntable is provided with a plurality of pneumatic clamps and a plurality of sensors, and the solenoid valves and the sensors for controlling the pneumatic clamps are connected to a field module for collecting data transmitted by the solenoid valves and the sensors, and then are connected to a main controller for communication through a field bus; proximity switches on the turntable for defining the position and orientation of the turntable are individually hard-wired to the IO modules of the main controller. When the transfer robot takes the workpiece away from the rotary table, the transfer robot needs to open and close the pneumatic clamp for fixing the workpiece to be assembled on the rotary table and the pneumatic element on the robot clamp according to a fixed time sequence.
And electrical elements such as a plurality of pneumatic clamps, a plurality of sensors and proximity switches on the rotary table are connected to the Prifibus field module and are used as slave stations parallel to the robot to which the station belongs to and connected to the master control PLC through a bus. The main control coordinates the robot and the rotary table and carries out logic control inside the station according to the manual intervention condition, the main control cabinet is provided with a Siemens TP1200 touch screen, a human-computer interface provides a graphical interface to monitor the state of each device, and the touch screen is used for carrying out independent manual operation on the devices in the station after the authority authentication under the special condition.
As shown in fig. 1 to 3, the method for implementing the multi-assembly-station operation safety system based on force sensing includes the following steps:
1) the workpiece is loaded on the rotary table in a manual carrying mode or a carrying robot carrying mode, the rotary table clamp clamps the workpiece, the main controller controls the rotary table motor to drive the rotary table to rotate through the servo driver, so that the workpiece is stopped at one side of the functional robot, and the robot carries out workpiece assembling work;
2) the servo driver transmits the real-time angular velocity, the position and the alarm information of the rotary table to the main controller in real time to monitor and receive a control command, the rotary table is a double-sided rotary table, a mechanical positioning label of the double-sided rotary table during initial assembly is set to be zero, and working position calibration is carried out through robot matching. The position and speed information of the turntable during operation are transmitted to the main controller through the servo driver via the bus: when an error exists when the rotary table stops or the rotary table limit proximity switch is triggered, the main controller gives an alarm and interrupts the program flow, and meanwhile, the rotary table is braked so that the robot does not continuously cooperate with the rotary table to perform subsequent assembly work;
the running states of the speed, the position and the like of the turntable motor are obtained by a servo driver, the states of execution mechanisms, such as various air cylinder valve blocks and various proximity switches, arranged on the turntable and related to production are gathered to a field module on the turntable and then transmitted to a main controller through a field bus for monitoring, and the main controller is used as a master station and is simultaneously responsible for monitoring other devices of the production line and for flow scheduling tasks during automatic running of the production line. The real-time position of the rotary table motor end encoder is transmitted to the main controller through the bus, the positioning precision and the real-time performance of rotary table motion control are greatly improved, the repeated positioning precision of the tail end of the rotary table is within 1mm, and the rotary table motor end encoder can be matched with the repeated precision of a robot to carry out production.
When a person enters the working radius of the robot or works on the turntable to place a workpiece, the safety grating at the unique workpiece loading position of each station transmits a blocking signal to the safety input port of the main controller, and a braking signal is sent to the turntable, the carrying robot and the functional robot in the station after being processed by the safety program of the main controller.
3) The main controller is of a fault safety model, and is used for mounting a safety door lock mechanical linkage double contact, a robot emergency stop interface, a turntable servo driver emergency stop interface, a grating signal and a feedback interface thereof, wherein the fault safety type IO module is in hard-line connection with all stations;
4) after the functional robot finishes working, the rotary table is rotated to one side of an upper workpiece, the carrying robot grabs an integrated workpiece to leave a rotary area of the rotary table at a speed lower than a set speed and then moves to the next rotary table at a running speed, in the process, when the working position change caused by analog signals collected by a one-dimensional force sensor on a clamp of the carrying robot or any other reasons exceeds a set threshold value, the interference between the workpiece and the clamp of the rotary table is indicated, the robot controller controls the carrying robot and the functional robot to enter a pause state, and simultaneously reports the processing number to a main controller through a field bus to report to a main controller of a production line for recording, so that quality inspection processes after an assembly part is off-line are conveniently inspected, and meanwhile, equipment connected with the main controller through a hard-line safety link is recovered after manual inspection;
and 3) when the robot is used as multifunctional automation equipment and enters an emergency stop state through local operation of a control cabinet or a demonstrator, the robot feeds back a double-circuit signal through a safety interface, or when a safety grating at the workpiece loading position of a station is shielded, the double-circuit signal is detected by a safety input port of the fail-safe programmable logic controller in a 1oo2 mode, and when the fail-safe main controller detects that the two-circuit signal is switched from normal close to disconnection, the main controller judges that a person enters a robot and a turntable operation area and emergently stops the respective automation equipment. The personal safety during manual intervention and the equipment safety during automatic production are ensured. The turntable feeds back state information, speed, position and alarm information to the main controller through the bus in real time during operation, a stop block and a contact switch are arranged at the tail end of the base of each station turntable to serve as mechanical limit, and when serious error conditions such as overtravel or rotation direction errors occur to the turntable, the turntable feeds back signals to the main controller through hard wires in time to give an alarm and locks and brake the turntable and peripheral equipment.
The working principle is as follows: an independent safety logic program block in the main controller enables coils of the relay K1 and the relay K2 to be powered off by stopping high level output of the safety output port, contacts corresponding to the relay K1 and the relay K2 are disconnected, and accordingly, the carrying and functional robot is triggered to emergently stop through a carrying and functional robot emergency stop interface, and the carrying robot and the functional robot enter an emergency stop state; before the assembly station operation safety system enters the operation state again, the grating double-hand reset button used for restarting in the peripheral area of the fence needs to be pressed manually at the same time, so that the main controller recovers the high-level output function of the safety output port. The overall loop safety can reach SIL3 level.
The equipment connected with the main controller through a hard-wire safety link comprises a rotary table motor, a rotary table, a safety door, a carrying robot and a functional robot.
The safety door is designed and used as a basic safety device door lock according to the principle of 1oo 2. The safety grating is not blocked and needs to be reset by double buttons to restore the automatic running state of the system, and when the transfer robot enters the transfer state and needs to reasonably enter a grating protection area, Bypass function statements are written in a program of a corresponding flow of the main controller to prevent the grating from braking the whole station.
According to the complexity of station assembly work, the automation equipment which can be contained in the loop is not limited to two robots and a servo turntable, when the number of the robots is increased according to the station process requirements, the safe input and output points of the main controller can be correspondingly increased to conveniently expand and upgrade the station control system, and the safety level of the system cannot be reduced.
The embodiments of the present invention have been described above with reference to one drawing, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art according to the level of security required in the application without departing from the gist of the present invention.
Claims (9)
1. A force-sensing-based multi-assembly-station operation safety system is characterized by comprising: the system comprises a main controller, a rotary table servo driver, a fence system, a carrying robot and a functional robot; the turntable motor, the turntable, the carrying robot and the functional robot are all arranged in the fence area;
the main controller is connected with the servo driver, the carrying robot and the functional robot through a field bus to realize data communication and state monitoring;
a carrying robot and a functional robot are arranged on two sides of the rotary table, and the carrying robot and the functional robot are respectively provided with corresponding robot controllers and are connected with a main controller through hard-wire safety links;
and the clamp end of the transfer robot is provided with a one-dimensional force sensor for measuring the pressure and the tension of the clamp, and the one-dimensional force sensor is connected with the robot controller and used for feeding back an analog signal acquired when the robot works and transmitting the analog signal back to the robot controller.
2. The force-aware-based multi-assembly-station operation safety system according to claim 1, wherein the main controller is a programmable logic controller for fail safety, and is provided with safety IO modules corresponding to the number of devices, and shutdown brake signals received and transmitted by the safety IO modules of the main controller are independently programmed in a safety logic program block in the main controller to form safety interlock logic, and the priority is higher than the collision detection and clamp end force detection feedback signals.
3. The force-sensing-based multi-assembly-station operation safety system is characterized in that a safety door is arranged on the fence system, a correlation type safety grating is arranged at a workpiece inlet, and the safety grating enters and exits when workpieces are loaded manually; the safety door and the safety grating are respectively connected with a safety IO module of the main controller.
4. The force-aware based multi-assembly-station operational safety system of claim 1, wherein the hard-wired safety link includes relay K1 and relay K2, relay K1 and relay K2 each having a ganged dual-contact structure with a forced guidance function; two linkage contacts of the relay are respectively connected with the emergency stop interface of the corresponding robot controller; when the moving equipment needs to be added, the number of the relays is increased, and then the hard-wire safety link is expanded.
5. The force-aware based multi-assembly-station operational safety system of claim 1, wherein a two-way circuit is provided between the master controller and the robot controller; the two-way circuit is two loops with normally closed contacts.
6. The force sensing-based multi-assembly-station operation safety system according to claim 1, wherein the turntable is provided with a plurality of pneumatic clamps and a plurality of sensors, and the solenoid valves and the sensors for controlling the pneumatic clamps are connected to a field module for collecting data transmitted by the solenoid valves and the sensors, which is disposed on the turntable, and then are connected to the main controller for communication through a field bus; proximity switches on the turntable for defining the position and orientation of the turntable are individually hard-wired to the IO modules of the main controller.
7. The implementation method of the multi-assembly-station operation safety system based on force perception is characterized by comprising the following steps of:
1) the workpiece is loaded on the rotary table in a manual carrying mode or a carrying robot carrying mode, the rotary table clamp clamps the workpiece, the main controller controls the rotary table motor to drive the rotary table to rotate through the servo driver, so that the workpiece is stopped at one side of the functional robot, and the robot carries out workpiece assembling work;
2) the servo driver transmits real-time angular velocity, position and alarm information of the rotary table to the main controller in real time to monitor and receive a control command, when the rotary table stops and an error exists or a rotary table limit proximity switch is triggered, the main controller gives an alarm and interrupts a program flow, and meanwhile, the rotary table is braked so that the robot does not continuously cooperate with the rotary table to perform subsequent assembly work;
3) in the working process, when a robot or a servo driver suddenly stops and brakes, a safety door is opened, a grating passes through the safety grating without manual request, and any condition of a shielding signal is detected to occur, the main controller controls the input of the safety IO module to disappear, a safety logic program block in the main controller takes effect, and closes a safety output to brake equipment connected with the main controller through a hard-wire safety link;
4) after the functional robot finishes working, the rotary table is rotated to one side of the upper part, the carrying robot grabs an integrated workpiece to leave a rotary area of the rotary table at a speed lower than a set speed and then moves to the next rotary table at an operation speed, in the process, when an analog signal acquired by a one-dimensional force sensor on a carrying robot clamp exceeds a set threshold value, the workpiece is indicated to be interfered with the rotary table clamp, the carrying robot and the functional robot are controlled by the robot controller to enter a pause state, the analog signal acquired by the one-dimensional force sensor is uploaded to the main controller through the robot controller to be recorded, and equipment connected with the main controller through a hard-wire safety link is recovered after manual inspection.
8. The force-aware-based multi-assembly-station operational safety system according to claim 7, wherein the step 3) is embodied as:
when the safety grating at the workpiece loading position of the station is shielded, the safety grating feeds back to an IO input module of the main controller to enable a normally closed signal of a double-circuit to disappear, a safety logic program block in the main controller stops high level output of a safety output port, and further enables coils of a relay K1 and a relay K2 to lose power, contacts corresponding to the relay K1 and the relay K2 are disconnected, and accordingly, the handling and functional robot is triggered to emergently stop through a handling and functional robot emergency stop interface, and the handling robot and the functional robot enter an emergency stop state; before the assembly station operation safety system enters the operation state again, a grating double-hand reset button used for restarting in the peripheral area of the fence needs to be pressed manually, so that the main controller recovers the high-level output of the safety output port.
9. The force-aware based multi-assembly-station operational safety system according to claim 7 or 8, wherein the devices connected to the main controller via a hard-wired safety link include a turntable motor, a turntable, a safety gate, a handling robot and a functional robot.
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Application publication date: 20201225 |