CN112270861A

CN112270861A - Robot assembly training control system based on PLC and various bus integration

Info

Publication number: CN112270861A
Application number: CN202011229049.6A
Authority: CN
Inventors: 郭琼; 黄麟; 王海荣; 郑贞平; 姚晓宁
Original assignee: Wuxi Institute of Technology
Current assignee: Wuxi Institute of Technology
Priority date: 2020-11-06
Filing date: 2020-11-06
Publication date: 2021-01-26

Abstract

The invention discloses a robot assembly practical training control system based on PLC and various bus integration, relates to a practical training control system, and particularly relates to a practical training control system based on PLC, which adopts various field bus forms to connect various controllers in a subsystem for networking. The system comprises a vertical warehouse control subsystem, a tray production line control subsystem, an assembly production line control subsystem and an AGV trolley control subsystem; the tray production line control subsystem and the assembly production line control subsystem share a master control PLC controller. The training system has complete functions, rich training items and strong combination, and is beneficial to the learning and implementation of the training items.

Description

Robot assembly training control system based on PLC and various bus integration

Technical Field

The invention discloses a robot assembly practical training control system based on PLC and various bus integration, relates to a practical training control system, and particularly relates to a practical training control system based on PLC, which adopts various field bus communication modes and connects various controllers in a subsystem to be networked.

Background

In the existing robot assembly teaching and practical training, an independent control system is generally adopted to realize a single practical training function. With the advance of modern processes, such a mode is lagged behind, and in practical use, an integrated control system capable of integrating sub-control systems with various functions is urgently needed, so that various controllers in subsystems are connected and networked, real-time interaction of information is performed in a communication mode, the smoothness of a control flow is ensured, and the control requirements are met.

Disclosure of Invention

The invention aims to provide a robot assembly training control system based on PLC and multiple bus integration, and relates to a training control system, which integrates a vertical warehouse control subsystem, a tray pipeline control subsystem, an assembly production line control subsystem and an AGV trolley control subsystem. The control system has strong combinability and convenient operation, and is beneficial to the culture and improvement of the professional skills and the system integration capability of students.

The invention is realized by adopting the following technical scheme:

a robot assembly training control system based on PLC and multiple bus integration comprises a vertical warehouse control subsystem, a tray production line control subsystem, an assembly production line control subsystem and an AGV trolley control subsystem;

the vertical warehouse control subsystem realizes the storage function of the components to be assembled and finished products; extracting and placing the components at the specified warehouse position in the vertical warehouse to an AGV (automatic guided vehicle) by a stacker crane, or storing the components in the AGV to the specified warehouse position;

the AGV trolley control subsystem realizes the transfer and transmission of the components to be assembled or finished products between the vertical warehouse and the tray production line; conveying the components to be assembled taken out from the vertical warehouse to a production line through an AGV trolley; or transferring the assembled finished product from the tray assembly line and placing the finished product into a vertical warehouse;

the tray production line control subsystem is used for detecting element types and position information in the tray, transmitting the information to the robot, positioning, grabbing and placing the information on an assembly production line; the acquisition and processing of the element type and the position information are realized by an industrial camera; the tray and the workpiece are conveyed to a production line grabbing position in the robot operation range to wait for the robot to grab;

the assembly production line control subsystem is used for grabbing the workpiece from the robot to the grabbing position by selecting a proper clamp according to the acquired workpiece type and position information; placing the workpiece at a corresponding position of an access position of an assembly production line; when the assembly requirements are met, the robot grabs the workpiece to an assembly station, and performs assembly after secondary positioning; after completion, the robot picks the finished product and places it into the finished product warehouse station.

The system comprises a vertical library control subsystem and a vertical library control system, wherein the vertical library control subsystem comprises a vertical library PLC controller, and a body of the vertical library PLC controller is connected with a vertical library detection sensor, a master electrical appliance for external operation, a frequency converter protection and motion stroke protection element, and a digital quantity input/output element of an external AGV conveying trolley butt joint photoelectric element, an indicator light and an alarm element; the vertical warehouse PLC controller is respectively connected with an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane, a Z-axis frequency converter of the stacker crane and a vertical warehouse touch screen through an exchanger by adopting industrial Ethernet networking; and the vertical storehouse PLC controller respectively controls an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane to drive corresponding stacker crane motors to operate in a bus control mode.

The vertical warehouse detection sensor comprises a vertical warehouse position detection sensor, a horizontal direction positioning sensor, a vertical direction positioning sensor and a pallet fork positioning sensor.

The vertical warehouse control subsystem also has a frequency converter protection function, and the frequency converter protection function is realized through a fault digital quantity output terminal signal of the frequency converter; a fault digital quantity output terminal of the frequency converter is connected with the vertical warehouse PLC controller; when a corresponding fault occurs in the running process of the frequency converter, a corresponding frequency converter fault output terminal is arranged with a1 and is connected with the input end of the vertical library PLC controller; the vertical library PLC controller sends out an instruction to stop the operation of the frequency converter and display faults; after the fault is processed, the vertical library PLC controller outputs a fault reset signal and sends the fault reset signal to the frequency converter to enable the frequency converter to recover to operate; the frequency converter comprises an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane.

Travel protection elements are arranged on the running tracks of the X-axis horizontal running mechanism and the Z-axis lifting mechanism of the stacker crane for overrun detection, and when the stacker crane runs out of a normal running range, the travel protection elements act, and an X-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane stop working immediately, so that the running safety of equipment is ensured.

The stand-up PLC controller adopts a commercially available Schneider PLC programmable controller.

The tray production line control subsystem and the assembly production line control subsystem share a master control PLC controller; in the tray assembly line control subsystem, a master control PLC controller is respectively connected with an entrance photoelectric sensor, a photographing photoelectric sensor, a grabbing photoelectric sensor, an AGV receiving photoelectric sensor and an AGV transmitting photoelectric sensor; the master control PLC controller is connected with the tray production line through a tray production line driving unit; the tray production line driving unit is provided with a frequency converter for driving a tray production line motor, a first single electric control electromagnetic valve and a second single electric control electromagnetic valve; the motor drive frequency converter of the tray production line is connected with the tray production line alternating current motor of the tray production line, the first single electric control electromagnetic valve is connected with the photographing station blocking cylinder of the tray production line, and the second single electric control electromagnetic valve is connected with the grabbing station blocking cylinder of the tray production line;

the master control PLC controller is further connected with a camera controller, and the camera controller is respectively connected with the light source and the industrial camera and used for controlling the industrial camera to shoot and adjusting the brightness of the light source.

The master control PLC controller adopts a commercially available Schneider PLC programmable controller.

In the assembly production line control subsystem, a master control PLC controller is respectively connected with a master control touch screen, a master control electrical appliance, an assembly production line driving unit and a robot controller; the master control PLC controller is connected with a stepping driver of the assembly production line driving unit and an assembly production line origin switch; the stepping driver is connected with a stepping motor of the assembly production line; the master control PLC controller is respectively connected with the relays of the robot enabling end, the robot disabling end and the robot stopping end; the master control PLC controller is respectively connected with the laser pen for positioning and the switch of the guard rail door.

The master control PLC controller is connected with the robot controller by adopting an industrial Ethernet.

And the robot controller is connected with the six-axis industrial robot to control the action of the six-axis industrial robot.

The main control PLC controller body is connected with a secondary positioning cylinder for 4 workpieces, and the main control PLC controller controls the secondary positioning cylinder through a corresponding electromagnetic valve; the manual control of the electromagnetic valve is operated by an external master control electric appliance, and the interaction of the running state parameters and the data is completed by a master control touch screen.

The AGV trolley control subsystem comprises a trolley PLC controller, and the trolley PLC controller is respectively connected with a motor driver I, a motor driver II, a conveyor belt stepping motor driver, tracking sensors and landmark sensors which are positioned at the front part and the rear part of the AGV trolley, an external master control electric appliance and an indicating element; a motor driver I and a motor driver II of the AGV trolley driving unit are respectively connected with stepping motors on the left wheel and the right wheel of the AGV trolley and are used for controlling the left wheel and the right wheel of the AGV trolley to work; the motor driver I is also called as a left driving wheel motor driver, and the motor driver II is also called as a right driving wheel motor driver; and the conveyor belt stepping motor driver is connected with the stepping motor of the tray conveyor belt and used for driving the conveyor belt motor to work.

The power supply of the AGV trolley control subsystem is provided by a storage battery, and a charging circuit and a device are arranged.

The butt joint of the trolley PLC controller with the vertical warehouse and the production line is realized through 2 groups of opposite type photoelectric switches which are respectively arranged on the vertical warehouse and the production line.

And the data communication between the trolley PLC controller and the system is realized by adopting a wireless communication mode.

The manual control mode of the AGV trolley control subsystem is operated through an external master control electric appliance, and the interaction of the running state parameters and the data is completed through an AGV touch screen.

The trolley PLC controller adopts a commercial belief PLC programmable controller.

The working principle is as follows:

according to the robot assembly training control system based on PLC and various bus integration, several subsystems can work independently and cooperatively; the vertical warehouse control subsystem can control the stacker crane to realize the functions of warehousing, ex-warehouse, moving warehouse and the like of products or parts; the storage position of the vertical warehouse can be input through a touch screen, and after receiving the storage position information, the vertical warehouse PLC operates the stacker crane to the butt joint point of the AGV conveying trolley, so that the tray is taken out of the AGV conveying trolley; and then the operation is carried out to the designated bin position and is put into a tray, and the warehousing operation is completed. The control principle of the warehouse-out and warehouse-moving operation is basically similar to that of the warehouse-in.

The AGV trolley control subsystem is mainly used for carrying and conveying workpieces in a vertical warehouse to a tray production line; the butt joint of the AGV trolley, the vertical warehouse and the tray assembly line can be realized in a wireless communication mode or a correlation type photoelectric mode; when the workpieces are delivered from the warehouse, an instruction is given, the AGV trolley walks towards the stereoscopic warehouse, the vertical warehouse executes goods taking operation after the workpieces are in place, the workpieces are taken out from the designated warehouse position through a stacker crane and placed on a conveying line at the upper part of the AGV trolley, and when the workpieces reach the designated number, a signal is given, and the AGV trolley leaves the vertical warehouse; the AGV moves along a laid magnetic track line and reaches the side of a tray assembly line to stop, a conveyor belt on the upper part of the AGV moves, and the tray with the workpieces is conveyed to the tray assembly line; if the transport needs to be continued, an instruction can be sent, and the AGV continues to return to the vertical storage along the track line for carrying again. The control principle of the warehousing operation process is basically similar to that of warehousing.

And a tray assembly line of the tray assembly line control subsystem drives a speed multiplying chain to rotate back and forth by a three-phase asynchronous motor so as to convey the tray to a designated station. An inlet photoelectric sensor, a photographing photoelectric sensor and a grabbing photoelectric sensor are respectively arranged at an inlet of the tray production line, a photographing station and a grabbing station and are used for detecting the article tray; a photographing station blocking cylinder and a grabbing station blocking cylinder are respectively arranged at the photographing station and the grabbing station and are used for positioning the tray and blocking the subsequent tray; the tray assembly line mainly comprises a workpiece butt joint station, an industrial visual detection station and a workpiece grabbing station. When the AGV conveying trolley moves to a butt joint station of the tray assembly line, the system automatically conveys trays on the AGV conveying trolley into the assembly line through a conveying roller way, and the photoelectric action of an inlet counts; when the industrial camera runs to the visual detection station, the visual station blocks the action of the air cylinder, the tray is fixed at a photographing position, and meanwhile, the industrial camera starts photographing and transmits position information processed by the camera controller to the master control PLC controller; after the completion of the retraction of the vision station blocking cylinder, the tray continues to run to a workpiece grabbing station, and after the tray is in place, the grabbing station blocks the action of the cylinder to prohibit a subsequent tray from entering the grabbing station; and meanwhile, waiting for the industrial robot to select a proper tool to grasp the workpiece according to the coordinate and the type of the grasped workpiece given by the master control PLC controller.

The robot assembly system matched with the assembly production line control subsystem consists of a sucker tool, a paw cylinder, a vacuum generator, a digital pressure switch and other mechanisms; the sucker tool and the paw cylinder are switched by robot control; the sucking disc tool is used for sucking the workpiece to assemble and empty the tray to a tray recovery position; the paw cylinder tool is used for grabbing the base. The vacuum generator is arranged on the robot body and is controlled by the robot; the assembly line adopts a plate link chain structure and is responsible for assembly and transmission of the modules; the assembly line is provided with 3 stations which are respectively an assembly station, a base spare part warehouse and finished product warehouse location and a spare part warehouse location; after the robot grabs the workpiece, the robot can place the workpiece after waiting for the assembly line to move to a working station and entering the operation range of the robot; the robot selects a proper clamp according to the type and position information of the workpiece sent by the master control PLC controller, and grabs the workpiece at the grabbing position of the tray assembly line; placing the workpiece in a workpiece access position of an assembly production line; when the assembly requirements are met, the robot installs and assembles the sequence, grabs the corresponding workpiece to an assembly position, and carries out assembly operation after secondary positioning by the positioning cylinder; and after the assembly is finished, grabbing the finished product and placing the finished product into a finished product warehouse.

The system of the invention has perfect function, rich training items and strong combination, is beneficial to the learning and implementation of training items, and the formed subsystem has the following advantages:

1) the control function of the vertical warehouse control subsystem is complete, and multiple functions of warehousing, ex-warehouse and moving of products or parts can be realized; through the cooperation of the PLC, the frequency converter and the human-computer interface HMI, the automation degree of the equipment is high, the rotating speed of the motor can be flexibly adjusted in a communication mode, and the working efficiency of the equipment is improved; the movement is positioned by adopting a high-precision worm gear speed reducer and 3 sensors, the storage position is accurately positioned, and the quantity of the storage positions can be flexibly expanded; the system has clear structure and can accurately control each component part;

2) the AGV trolley control subsystem has complete control function and can realize the task of reciprocating workpiece taking and conveying between the stereoscopic warehouse and the production line; the AGV trolley is driven by two stepping motors, the deviation degree of the AGV trolley is detected by a tracking sensor, and the differential adjustment of the driving motors is carried out in a PID control mode, so that the AGV trolley has the characteristics of rapid deviation correction, stable operation, high working efficiency and the like; the system can also realize warehousing operation, namely finished products to be assembled are conveyed to a vertical warehouse through a tray assembly line by an AGV trolley, and warehousing operation is carried out by a stacker crane;

3) the control function of the tray assembly line control subsystem is complete, and the automatic butt joint with an AGV conveying trolley, the visual detection of workpieces in the tray, the data processing of the types and the position coordinates of the workpieces by a PLC and the dispatching of a robot can be realized; the automation degree of the equipment is high through the cooperation of the PLC, the industrial camera, the frequency converter and the human-computer interface HMI; the type and the position coordinates of the workpiece are detected through the industrial camera, manual operation is reduced, and the detection precision is high; each unit in the system can be independently operated, has strong combinability and is beneficial to the learning and implementation of training projects;

4) the control function of the control subsystem of the assembly production line is complete, and the robot can automatically select proper tools and accurately grab workpieces to be grabbed in the tray; accurately adjusting and positioning the working position of an assembly production line; secondary positioning of a workpiece to be assembled; assembling the finished product correctly according to the assembling sequence; warehousing finished products and the like; all internal units of the subsystem can be independently operated, the combination is strong, and the training program is beneficial to learning and implementation.

Drawings

The invention will be further explained with reference to the drawings, in which:

FIG. 1 is a schematic diagram of a system plant layout of the control system of the present invention;

FIG. 2 is a system network topology diagram of the control system of the present invention;

FIG. 3 is a schematic diagram of the overall layout of the control system of the present invention;

FIG. 4 is a control schematic block diagram of the riser control subsystem of the control system of the present invention;

FIG. 5 is a PLC controller wiring diagram of the riser control subsystem of the control system of the present invention;

FIG. 6 is an electrical schematic of the power supply loop of the riser control subsystem of the control system of the present invention;

FIG. 7 is a stacker frequency drive schematic (stacker X-axis) of the riser control subsystem of the control system of the present invention;

FIG. 8 is a stacker frequency drive schematic (stacker Y-axis) of the riser control subsystem of the control system of the present invention;

FIG. 9 is a stacker frequency drive schematic (stacker Z-axis) of the riser control subsystem of the control system of the present invention;

FIG. 10 is a control schematic block diagram of the tray pipeline control subsystem of the control system of the present invention;

FIG. 11 is a master PLC controller wiring diagram of the pallet pipeline control subsystem of the control system of the present invention;

FIG. 12 is an electrical schematic of the power supply loop of the tray pipeline control subsystem of the control system of the present invention;

FIG. 13 is a schematic diagram of the drive circuit of the tray flow line control subsystem of the control system of the present invention;

FIG. 14 is a camera control circuit schematic of the tray pipeline control subsystem of the control system of the present invention;

FIG. 15 is a control schematic block diagram of the assembly line control subsystem of the control system of the present invention;

FIG. 16 is a drawing of a master PLC controller of the assembly line control subsystem of the control system of the present invention as shown in FIG. 1;

FIG. 17 is a drawing of a master PLC controller of the assembly line control subsystem of the control system of the present invention depicted in FIG. 2;

FIG. 18 is an electrical schematic of the power supply circuit of the assembly line control subsystem of the control system of the present invention;

FIG. 19 is a schematic diagram of the drive circuitry of the assembly line control subsystem of the control system of the present invention;

FIG. 20 is a control schematic block diagram of an AGV cart control subsystem of the control system of the present invention;

FIG. 21 is a PLC controller wiring diagram of the AGV cart control subsystem of the control system of the present invention FIG. 1;

FIG. 22 is a PLC controller wiring diagram of the AGV cart control subsystem of the control system of the present invention 2;

FIG. 23 is a schematic diagram of a correlation signal circuit for the AGV cart control subsystem of the control system of the present invention;

FIG. 24 is a schematic diagram of the drive circuit for the AGV car control subsystem of the control system of the present invention.

Detailed Description

The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

Referring to the attached drawings 1-3, the robot assembly training control system based on PLC and various bus integration comprises a vertical warehouse control subsystem, a tray pipeline control subsystem, an assembly production line control subsystem and an AGV trolley control subsystem; the vertical warehouse control subsystem realizes the storage function of the components to be assembled and finished products; extracting and placing the components at the specified warehouse position in the vertical warehouse to an AGV (automatic guided vehicle) by a stacker crane, or storing the components in the AGV to the specified warehouse position; the AGV trolley control subsystem realizes the transfer and transmission of the components to be assembled or finished products between the vertical warehouse and the tray production line; conveying the components to be assembled taken out from the vertical warehouse to a production line through an AGV trolley; or transferring the assembled finished product from the tray assembly line and placing the finished product into a vertical warehouse; the tray production line control subsystem is used for detecting element types and position information in the tray, transmitting the information to the robot, positioning, grabbing and placing the information on an assembly production line; the acquisition and processing of the element type and the position information are realized by an industrial camera; the tray and the workpiece are conveyed to a production line grabbing position in the robot operation range to wait for the robot to grab; the assembly production line control subsystem is used for grabbing the workpiece from the robot to the grabbing position by selecting a proper clamp according to the acquired workpiece type and position information; placing the workpiece at a corresponding position of an access position of an assembly production line; when the assembly requirements are met, the robot grabs the workpiece to an assembly station, and performs assembly after secondary positioning; after completion, the robot picks the finished product and places it into the finished product warehouse station.

Referring to the attached figure 4, the vertical warehouse control subsystem comprises a vertical warehouse PLC controller, wherein a vertical warehouse detection sensor, a horizontal direction positioning sensor, a vertical direction positioning sensor, a fork positioning sensor, a master control electric appliance for external operation, a frequency converter protection and motion stroke protection element, an external AGV conveying trolley butt joint photoelectric element, an indicator light, an alarm element and other digital IO (input/output) elements are connected to the body of the vertical warehouse PLC controller.

The vertical warehouse PLC controller is respectively connected with an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane, a Z-axis frequency converter of the stacker crane and a vertical warehouse touch screen (HMI) through an exchanger by adopting industrial Ethernet networking; the vertical storehouse PLC controller respectively controls three frequency converters in a bus control mode, namely an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane, so as to drive a motor of the stacker crane to operate.

Fig. 5 is a PLC controller wiring diagram of the riser control subsystem. In this embodiment, a commercially available schneider PLC programmable controller TM241CEC24R is used as the library PLC controller. An L, N, PE terminal (a phase line, a neutral line and a protective grounding line) of the vertical library PLC is connected with an external power supply; a Q0.0 terminal of the vertical warehouse PLC is connected with a buzzer HB1, and the buzzer HB1 gives an alarm when the stacker crane fails; a Q0.1 terminal of the vertical warehouse PLC controller is connected with an operation indicator lamp HL 2; a Q0.2 terminal of the vertical warehouse PLC controller is connected with an AGV conveying trolley butt-joint photoelectric switch, and when the Q0.2 terminal outputs a signal of 1, the AGV conveying trolley is driven to leave the vertical warehouse; the I0.0, I0.1 and I0.2 terminals of the PLC are respectively connected with an emergency stop button, a start button and a stop button; the I0.3 and I0.4 terminals of the vertical storehouse PLC controller are respectively connected with a left limit switch and a right limit switch of an X-axis motor of the stacker crane; i0.5 and I0.6 terminals of the vertical storehouse PLC controller are respectively connected with an upper limit switch and a lower limit switch of a Z-axis motor of the stacker crane; i0.7, I1.0 and I1.1 terminals of the vertical storehouse PLC controller are respectively connected with a fork goods taking, original point and a fork goods delivering position switch operated by a Y-axis motor of the stacker crane; an I1.2 terminal of the vertical warehouse PLC controller is connected with an AGV conveying trolley butt joint photoelectric switch, and when the output value of the I1.2 terminal is 1, the AGV conveying trolley can be confirmed to run to the vertical warehouse; the I1.3, I1.4 and I1.5 terminals of the vertical library PLC controller are respectively connected with fault output signal ends of an X-axis frequency converter, a Y-axis frequency converter and a Z-axis frequency converter of the stacker crane.

Fig. 6 is an electrical schematic diagram of a power supply circuit of a vertical library control subsystem, in this embodiment, L1, L2, L3, and PE of a main power supply inlet are external power supply inlet terminals, and a three-phase load switch QF0 is used as a main power supply switch of a system; l1, L2 and L3 respectively represent three phase lines of a three-phase power supply, and PE represents a protective grounding line; 380V power indicator lamps are connected to the L1 and the L2 phase lines behind the three-phase load switch QF0, and the power indicator lamps are lightened after the system is powered on; the rear of the two-phase air switch QF4 is connected with a 380V/220V isolation transformer, so that the safety of power utilization is ensured, and meanwhile, a power supply is provided for the power utilization equipment of the system AC 220V; the two-phase air switch QF6 controls the cooling fan motor in the cabinet; the two-phase air switch QF5 provides power to the PLC controller, the three motor brakes, the in-cabinet socket, the DC24V switching power supply, and the DC5V switching power supply.

FIGS. 7 to 9 are wiring diagrams of an X-axis frequency converter, a Y-axis frequency converter and a Z-axis frequency converter of the stacker crane, and the three frequency converters are similar in wiring.

In FIG. 7, a three-phase air switch QF1 provides power for the X-axis inverter of the palletizer; the frequency converter control contactor KM1 is connected to a frequency converter power supply terminal R, S, T and controls the running state of the X-axis frequency converter; the output terminal U, V, W of the main circuit of the frequency converter is directly connected to the connecting terminal of the X-axis drive motor M1, and the motor shell needs to be connected with a protective grounding PE terminal; control terminals LI1, LI2 and LI3 of the frequency converter are respectively connected with forward rotation and reverse rotation control signals output by the vertical library PLC controller and fault reset control signals of the frequency converter; the frequency converter fault output signal is connected to the stand-up PLC controller through a relay terminal R2B and a relay terminal R2C; the relay terminal R1B and the relay terminal R1C are connected with an intermediate relay KA1 and used for controlling the X-axis driving motor M1 to brake rapidly.

In FIG. 8, a three-phase air switch QF2 provides power for the Y-axis inverter of the palletizer; the frequency converter control contactor KM2 is connected to a frequency converter power supply terminal R, S, T and controls the running state of the Y-axis frequency converter; the output terminal U, V, W of the main circuit of the frequency converter is directly connected to a connecting terminal of a Y-axis drive motor M2, and the motor shell needs to be connected with a protective grounding PE terminal; control terminals LI1, LI2 and LI3 of the frequency converter are respectively connected with forward rotation and reverse rotation control signals output by the vertical library PLC controller and fault reset control signals of the frequency converter; the frequency converter fault output signal is connected to the stand-up PLC controller through a relay terminal R2B and a relay terminal R2C; the relay terminal R1B and the relay terminal R1C are connected with an intermediate relay KA2 and used for controlling the Y-axis driving motor M2 to brake rapidly.

In FIG. 9, a three-phase air switch QF3 provides power to the Z-axis inverter of the palletizer; the frequency converter control contactor KM3 is connected to a frequency converter power supply terminal R, S, T and controls the running state of the Z-axis frequency converter; the output terminal U, V, W of the main circuit of the frequency converter is directly connected to a connecting terminal of a Z-axis drive motor M3, and a motor shell needs to be connected with a protective grounding PE terminal; control terminals LI1, LI2 and LI3 of the frequency converter are respectively connected with forward rotation and reverse rotation control signals output by the vertical library PLC controller and fault reset control signals of the frequency converter; the frequency converter fault output signal is connected to the stand-up PLC controller through a relay terminal R2B and a relay terminal R2C; the relay terminal R1B and the relay terminal R1C are connected with an intermediate relay KA3 and used for controlling the Z-axis driving motor M3 to brake rapidly.

Referring to fig. 10, the tray pipeline control subsystem includes a master PLC controller, which is respectively connected to the entrance photoelectric sensor, the photographing photoelectric sensor, the grasping photoelectric sensor, the AGV receiving photoelectric sensor, and the AGV transmitting photoelectric sensor; the master control PLC controller is connected with the tray production line through a tray production line driving unit; the tray production line driving unit is provided with a frequency converter for driving a tray production line motor, a first single electric control electromagnetic valve and a second single electric control electromagnetic valve; the motor drive frequency converter of the tray production line is connected with the tray production line alternating current motor of the tray production line, the first single electric control electromagnetic valve is connected with the photographing station blocking cylinder of the tray production line, and the second single electric control electromagnetic valve is connected with the grabbing station blocking cylinder of the tray production line;

In the embodiment, the butt joint of the AGV conveying trolley and the tray assembly line is realized by 2 pairs of counter photoelectric sensors; when the AGV conveying trolley arrives at the tray assembly line side, the transmitting end photoelectric conduction of the side face of the AGV conveying trolley is conducted, the assembly line receiving end receives the signal, the tray assembly line starts to run, the gas baffle on the AGV trolley descends, the belt runs in the same direction, and the tray is conveyed to the assembly line unit.

When the tray is powered off through the inlet of the production line, counting operation is carried out; when photo-electricity is taken, the photographing air baffle acts to fix the tray at a photographing position, an industrial camera is used for photographing a workpiece picture in the tray, and the workpiece type and position information are transmitted to the master control PLC controller through the bus after being processed by the camera controller; meanwhile, the photographing gas block resets to wait for the next tray.

The photographed tray is continuously transferred to a grabbing station through a production line, and when the photographed tray passes through the grabbing station and is photoelectric, a grabbing position gas shield acts to fix the tray at the grabbing position; waiting for the master control PLC controller to drive the robot to perform grabbing action. And after the workpieces are grabbed, the robot grabs the empty tray into the empty tray recovery frame.

The driving motor of the tray assembly line is controlled by a frequency converter; the master control PLC controller controls the frequency converter to realize speed regulation operation in an analog quantity control mode.

The manual control of the tray assembly line is operated by an external master control electric appliance, and the interaction of the running state parameters and the data is completed by a touch screen.

FIG. 11 is a PLC controller wiring diagram of the tray pipeline control subsystem. In this embodiment, the master PLC controller is a schneider PLC programmable controller TM241CEC24R that is commercially available. An L, N, PE terminal (a phase line, a neutral line and a protective grounding line) of the master control PLC is connected with an external power supply; a Q0.3 terminal of the master control PLC is connected with the intermediate relay KA2, and when an output signal of the Q0.3 terminal is 1, a contact of the intermediate relay KA2 drives a photographing station to block an air cylinder to act; a Q0.4 terminal of the master control PLC controller is connected with an intermediate relay KA3 coil for the grabbing station blocking cylinder; a Q0.5 terminal of the master control PLC is connected with the intermediate relay KA4, and when an output signal of the Q0.5 terminal is 1, a contact of the master control PLC triggers the camera to take a picture; a Q0.6 terminal of the PLC is connected with a buzzer, and an alarm is given when the assembly line fails; a Q0.7 terminal of the PLC is connected with the operation indicator lamp; and a Q1.0 terminal of the PLC is connected with the photoelectric switch for butting the AGV conveying trolley, and when the output signal of the Q1.0 terminal is 1, the AGV conveying trolley is driven to leave the tray assembly line. The I0.0, I0.1 and I0.2 terminals of the master control PLC controller are respectively connected with the emergency stop button, the start button and the stop button; an I0.3 terminal of the master control PLC controller is connected with a photographing completion signal output end of the camera controller; the I0.4, I0.5 and I0.6 terminals of the master control PLC controller are respectively connected with an inlet photoelectric sensor, a photographing broadcast and television sensor and a grabbing photoelectric sensor on the tray production line; an I0.7 terminal of the master control PLC controller is connected with an AGV conveying trolley butt joint photoelectric switch, and when a signal of the I0.7 terminal is 1, the AGV conveying trolley can be confirmed to run to an assembly line butt joint position; and an I1.1 terminal of the master control PLC is connected with a fault output signal end of the frequency converter.

FIG. 12 is an electrical schematic diagram of a power supply circuit of the tray pipeline control subsystem, wherein L1, L2, L3 and PE are external power supply inlet terminals, and a three-phase load switch QF0 is used as a system main power switch; l1, L2 and L3 respectively represent three phase lines of a three-phase power supply, and PE represents a protective grounding line; a 380V power indicator HL1 is connected to the phase lines L1 and L2 behind the three-phase load switch QF0, and when the system is powered on, the power indicator HL1 is lightened; the three-phase air switch QF1 provides a power supply for the industrial robot; the two-phase air switch QF3 is connected with a 380V/220V isolation transformer, so that the electricity safety is ensured, and meanwhile, a power supply is provided for the electric equipment of the system AC 220V; the two-phase air switch QF4 provides power for the computer socket; the two-phase air switch QF5 provides power for the socket in the cabinet and the illumination; the two-phase air switch QF6 is connected with a cooling fan motor in the control cabinet; the two-phase air switch QF7 provides power for the main control PLC controller, the industrial camera and the DC24V switch power supply; the two-phase air switch QF8 provides power for the camera controller; the filter is connected in series in the power supply loop and used for suppressing higher harmonics and external interference.

Fig. 13 is a tray pipeline driving circuit. In the embodiment, the three-phase air switch QF2 provides power for the frequency converter; the frequency converter control contactor KM1 is connected with a frequency converter power supply terminal R, S, T and controls the running state of the frequency converter; the output terminal U, V, W of the main circuit of the frequency converter is directly connected to the assembly line drive motor M1, and the motor shell is connected with a protective grounding PE terminal; control terminals LI1, LI2 and LI3 of the frequency converter are respectively connected with forward rotation and reverse rotation control signals output by the main control PLC controller and fault reset control signals of the frequency converter; and a relay terminal R1B and a relay terminal R1C of a fault output signal of the frequency converter are connected to an I1.1 terminal of a master PLC controller.

FIG. 14 is a camera control circuit, in this embodiment, a camera controller is placed in a transfer box located on the pallet track; in the figure, the L, N terminal of the camera controller is connected with an external alternating current 220V power supply, and the 24V and 0V terminals of the camera controller are connected with a direct current 24V power supply introduced by a power supply loop switch power supply V1; the X0 terminal of the camera controller is connected with a photographing trigger signal, and when the photographing trigger signal is 1, the camera controller triggers the camera to start photographing; the Y0 terminal of the camera controller is connected to the I0.3 terminal of the PLC controller to provide a camera photographing completion signal; the A, B terminal of the camera controller is a communication terminal and is connected to a communication module of the master PLC controller by using a twin-core shielded twisted pair.

Referring to fig. 15, the assembly line control subsystem and the tray assembly line control subsystem share a master PLC controller, and the master PLC controller is respectively connected to a master touch screen (HMI human-machine interface), a master electrical appliance, an assembly line drive unit, and a robot controller; the master control PLC controller is connected with a stepping driver of the assembly production line driving unit and an assembly production line origin switch; the stepping driver is connected with a stepping motor of the assembly production line; the master control PLC controller is respectively connected with the relays of the robot enabling end, the robot disabling end and the robot stopping end; the master control PLC controller is respectively connected with the laser pen for positioning and the switch of the guard rail door.

Fig. 16 and 17 are wiring diagrams of PLC controllers of the assembly line control subsystem. An L, N, PE terminal of the master control PLC controller is connected with an external power supply, wherein L, N, PE respectively refers to a phase line, a neutral line and a protective grounding line; the Q0.0 and Q0.1 terminals of the master control PLC controller are connected with a stepping driver, and a stepping motor is driven by high-speed pulses, wherein the Q0.0 terminal corresponds to a high-speed pulse output, and the Q0.1 terminal corresponds to a direction control terminal; a Q0.7 terminal of the master control PLC controller is connected with a system operation indicator lamp; the Q1.1 terminal is connected with a positioning laser pen on a tool at the tail end of the robot and used for determining the relative positions of the robot and a peripheral tray production line and an assembly production line; the I0.0, I0.1 and I0.2 terminals of the master control PLC controller are respectively connected with an emergency stop button, a starting button and a stop button of the practical training device; an I1.0 terminal of the master control PLC controller is connected with an original point switch of an assembly production line and used for determining an assembly original point; and the Q2.0, Q2.1 and Q2.2 terminals on the TM3DM 8R on the digital quantity expansion module are respectively connected with a robot reset relay, a robot enabling release relay and a robot enabling relay coil, and the calling of corresponding functions is realized by connecting the contact points of the relay to a robot controller.

Fig. 18 is an electrical schematic diagram of a power supply circuit of the assembly line control subsystem, in this embodiment, L1, L2, L3 and PE are external power input terminals, and the three-phase load switch QF0 is used as a system main power switch; l1, L2 and L3 respectively represent three phase lines of a three-phase power supply, and PE represents a protective grounding line; a 380V power indicator HL1 is connected to the phase lines L1 and L2 behind the three-phase load switch QF0, and when the system is powered on, the power indicator HL1 is lightened; a R, S, T terminal behind the three-phase load switch QF0 is directly connected into a control cabinet of the industrial robot to provide power for the robot; the two-phase air switch QF2 is connected with a 380V/220V isolation transformer, so that the electricity safety is ensured, and meanwhile, a power supply is provided for the electric equipment of the system AC 220V; the two-phase air switch QF4 provides power for a DC24V switching power supply, a DC48V switching power supply special for the stepping motor and an industrial camera controller; an emergency stop switch is connected in series in a primary power supply loop of the power supply loop, and when an emergency stop button is pressed, a DC48V power supply is cut off, and the operation of a stepping motor is stopped; the power supply loop is also connected with a filter L4 in series for suppressing higher harmonics and external interference.

FIG. 19 is a schematic diagram of the drive circuitry of the assembly line control subsystem; the inlet end of the two-phase air switch QF5 is connected with a DC48V power supply, and the outlet end of the two-phase air switch QF5 is connected with power supply terminals R and S of the stepping driver; the A +, A-, B + and B-terminals on the step driver are connected to a step motor M2; a control terminal CP + on the stepping driver is connected to an I0.0 terminal of the master control PLC controller, receives high-speed pulses output by the master control PLC controller, and controls the rotating speed and the position of the stepping motor; the CW + on the step driver is connected to the I0.1 terminal of the master PLC controller and is used as a direction control signal to control the rotation direction of the step motor; and CP and CW terminals on the stepping driver are connected with the cathode of the direct-current 24V power supply after being interconnected. The driver drive current and the fine stepping can be determined on an actual basis.

In the embodiment, the assembly production line adopts a plate link chain structure to finish the storage, the taking and the assembly of the workpieces; the production line is provided with 3 stations which are respectively an assembly station, a base spare part warehouse and a finished product warehouse and a spare part warehouse (a motor, a speed reducer and an output flange spare part warehouse). When the robot needs to grab or place a certain workpiece, the assembly line motor is driven by the master control PLC controller, and the corresponding station is moved into the robot working area. During the initial operation, the operation of returning to the original point is needed.

The workpieces to be assembled comprise a base, a motor, a speed reducer and an output flange; the assembly sequence is base → motor → reducer → output flange; and obtaining a finished product after assembly, and placing the finished product into a product warehouse.

The operation flow is as follows: the master control PLC controller transmits the type and position information of the workpiece at the grabbing position of the pallet assembly line to the robot, and the robot selects a suitable clamp and moves to the grabbing position to grab the workpiece; the robot places the workpiece to the corresponding position of the access position; when the types of the workpieces placed in the access positions can meet the assembly requirements, the workpieces are assembled according to the assembly sequence; the robot sequentially grabs the workpieces to an assembly station; after the workpiece is prevented, the cylinder is driven to perform secondary positioning so as to ensure the assembly precision; when the assembly is complete, the robot picks the finished product and places it into a finished product warehouse station.

The robot end tool consists of a double suction disc, a paw cylinder, a vacuum generator, a digital pressure switch and other mechanisms; the sucker tool and the paw cylinder are switched through robot control. The sucking disc tool is used for sucking workpieces to assemble and recycling empty pallets. The paw cylinder tool is used for grabbing the base. The vacuum generator is arranged on the robot body and is controlled by the robot. The digital pressure switch is arranged on the base of the robot body and used for detecting the state of the sucking disc tool sucking the workpiece; the robot tail end tool is provided with a laser pen for positioning, and is used for determining the relative positions of the robot and a peripheral tray production line and an assembly production line, so that the accurate positioning of the production line and the assembly requirements of products are ensured; the manual control of the assembly production line is operated by an external master control electric appliance, and the interaction of the running state parameters and the data is completed by a touch screen.

Referring to fig. 20, the AGV dolly control subsystem includes a dolly PLC controller, which is respectively connected to a motor driver I, a motor driver II, a conveyor belt stepping motor driver, tracking sensors and landmark sensors located at the front and rear of the AGV dolly, an external master control electrical appliance and an indicating element of the AGV dolly driving unit; a motor driver I and a motor driver II of the AGV trolley driving unit are respectively connected with stepping motors on the left wheel and the right wheel of the AGV trolley and are used for controlling the left wheel and the right wheel of the AGV trolley to work; the motor driver I is also called as a left driving wheel motor driver, and the motor driver II is also called as a right driving wheel motor driver; and the conveyor belt stepping motor driver is connected with the stepping motor of the tray conveyor belt and used for driving the conveyor belt motor to work.

The power supply of the AGV trolley control subsystem is provided by a storage battery, and a charging circuit and a device are arranged. In the embodiment, the power supply of the AGV trolley is formed by connecting two 24V storage batteries in series; the AGV trolley consists of a lower frame and an upper conveying device, and an electric control board is arranged in the middle drawer, so that the AGV trolley is convenient to install and maintain. The lower frame consists of a motor, a driving wheel, an auxiliary wheel, a battery and a frame.

The AGV trolley is driven by two stepping motors, and differential driving is carried out through two corresponding stepping motor drivers so as to ensure that the trolley runs forwards and backwards according to the laid magnetic stripe tracks. The stepping motor enable (EN-), the high-speed pulse (CP-), and the direction (CW-) control end are connected with the output terminal of the trolley PLC controller, and the motor rotating speed is regulated and controlled by the high-speed pulse frequency of the trolley PLC controller.

The deviation degree between the AGV trolley and the magnetic stripe track is detected through a tracking sensor in the corresponding direction, and quick deviation correction is realized; through deviation detection, the differential speed of motors of left and right wheels of the AGV is calculated by adopting a PID algorithm, and the AGV is adjusted to return to the middle position of a magnetic track. The speed reduction and parking control of the trolley are realized by detecting magnetic strip signals transversely arranged on the ground through a landmark sensor.

The conveying device at the upper part of the AGV trolley is driven by a stepping motor; a maximum of 3 trays can be placed on the tray; an electromagnet blocking mechanism is arranged at the tail end of the conveyor belt and used for fixing the tray and preventing the tray from falling; and 1 photoelectric switch is respectively installed at two ends of the bottom of the conveying belt and used for limiting the position of the tray and realizing the counting of the tray.

The butt joint of the AGV trolley, the vertical warehouse and the tray assembly line can be realized by adopting two modes of correlation type photoelectric or wireless communication; in a correlation photoelectric mode, when the AGV arrives at a vertical warehouse or a production line, the emitted photoelectric signals on the AGV are received by the opposite side and are transmitted to the controller in a photoelectric receiving mode, and a goods taking or tray conveying process is executed; after the task is completed, the AGV trolley is driven to move away by the controller after receiving photoelectric reception by the emitting photoelectric action on the vertical warehouse or the production line; and the wireless communication mode is used for carrying out wireless communication with a controller in a network by installing a wireless communication module.

The butt joint of the trolley PLC controller and the vertical warehouse and the tray production line is realized by 2 groups of opposite type photoelectric switches (transmitting light and receiving light) which are respectively arranged on the vertical warehouse and the production line.

And the data communication between the PLC of the trolley and the AGV trolley control subsystem is realized by adopting a wireless communication mode.

The manual control mode of the AGV trolley control subsystem is operated through an external master control electric appliance, and the interaction of the running state parameters and the data is completed through an AGV touch screen HMI.

FIG. 21 is a PLC controller wiring diagram of the AGV car control subsystem of FIG. 1. In the embodiment, the trolley PLC adopts a commercially available agile PLC XC 5-E32T-C. X0 and X1 terminals of the trolley PLC controller are respectively connected with limit photoelectric switches at the front and rear parts of the tray position and are used for limiting the tray position and counting; an X5 terminal of the PLC controller of the AGV is connected with an emergency stop button of the AGV and a series normally closed contact of a collision switch, and when collision or manual emergency stop occurs during operation, the AGV stops operating; the X10-X13 terminals of the trolley PLC controller are connected with a landmark sensor at the front end of the AGV trolley, and the X14-X17 terminals of the trolley PLC controller are connected with a landmark sensor at the rear end of the AGV trolley and are used for detecting magnetic strip signals transversely arranged on the ground, so that the AGV trolley is decelerated and stopped, and is controlled to accurately stop at a vertical warehouse or a production line butt joint position; X30-X37 terminals on the digital input expansion module XC-E16X are connected with an 8-bit front tracking sensor, X40-X47 terminals of the digital input expansion module XC-E16X are connected with an 8-bit rear tracking sensor and are used for detecting magnetic stripes on an advancing track of the AGV trolley and carrying out deviation detection and calculation, so that the differential speed of motors of left and right wheels of the AGV trolley is adjusted, and the AGV trolley is ensured to advance along the magnetic track; x20 and X21 terminals of the trolley PLC controller are respectively connected with the receiving photoelectricity of the docking photoelectricity of the garage side and the assembly line side.

FIG. 22 is a PLC wiring diagram of the AGV cart control subsystem of FIG. 2, in which the Y0, Y6, Y11 terminals on the cart PLC are connected to the high speed pulse, direction and enable terminals of the AGV cart left drive wheel motor driver to control the speed and direction of the cart left wheel; y1, Y7 and Y12 terminals on the PLC controller of the AGV are connected with high-speed pulse, direction and enabling terminals of a motor driver of a driving wheel on the right side of the AGV, so that the speed and direction of the right wheel of the AGV are controlled; y2, Y10 and Y13 terminals on the PLC controller of the AGV are connected with high-speed pulse, direction and enabling terminals of a motor driver of the conveyor belt on the upper part of the AGV, so that the speed and the direction of the conveyor belt of the AGV are controlled;

a Y3 terminal on the trolley PLC is connected with an intermediate relay KA1, and a contact of the intermediate relay KA1 controls an operation indicator lamp; a Y4 terminal on the PLC is connected with an intermediate relay KA2, and a contact of the intermediate relay KA2 controls a brake coil to realize mechanical braking of the AGV; a Y5 terminal on the trolley PLC is connected with an intermediate relay KA3, and a contact of the intermediate relay KA3 controls a jacking electromagnet and is used for locking the position of the tray; y14 and Y15 terminals on the trolley PLC controller are respectively connected with the vertical warehouse side and the assembly line side for butting photoelectric emitting photoelectricity.

FIG. 23 is a schematic diagram of a correlation signal circuit; the AGV trolley adopts 2 groups of correlation type photoelectric switches arranged on the vertical warehouse and the assembly line through a trolley PLC controller to realize the butt joint of the AGV trolley, the vertical warehouse and the assembly line; the AGV trolley is provided with 2 opposite-emitting photoelectric switches towards the direction of a vertical garage, wherein each opposite-emitting photoelectric switch comprises a three-wire photoelectric sensor SA12 and a three-wire photoelectric sensor SA 11; wherein the three-wire photosensor SA12 is a receiving photosensor, paired with an emitting photosensor S11 (a garage-side mounted emitting photosensor); the three-wire photosensor SA11 is an emitting photo, paired with a receiving photo S12 (receiving photo mounted on the garage side); wherein the brown lines of the three-wire photosensor SA12 and the three-wire photosensor SA11 are connected to the DC24V power supply positive electrode, the blue line of the three-wire photosensor SA12 is connected to the 0V power supply negative electrode, and the black line of the three-wire photosensor SA12 is connected to the X21 terminal of the cart PLC controller; the blue line of the three-wire photosensor SA11 was connected to the Y15 terminal of the cart PLC controller.

The AGV trolley is provided with 2 pairs of opposite-emitting photoelectric switches towards the direction of the tray assembly line, and each opposite-emitting photoelectric switch comprises a three-wire photoelectric sensor SA21 and a three-wire photoelectric sensor SA 22; the three-wire photosensor SA21 is an emitting photo, paired with a receiving photo S22 (receiving photo mounted on the production line side of the tray); the three-wire photosensor SA22 is a receiving photo, paired with an emitting photo S21 (emitting photo mounted on the wire production side of the tray); wherein the brown lines of the three-wire photosensor SA21 and the three-wire photosensor SA22 are connected to the DC24V power supply positive electrode, the blue line of the three-wire photosensor SA22 is connected to the 0V power supply negative electrode, and the blue line of the three-wire photosensor SA21 is connected to the Y14 terminal of the cart PLC controller; the black line of the three-wire photosensor SA22 is connected to the X20 terminal of the cart PLC controller.

FIG. 24 is a schematic diagram of a driving circuit, in which P24 is the positive pole of DC24V power supply, P48 is the positive pole of DC48V power supply (two batteries are connected in series), and 0V is the negative pole of power supply; u1 and U2 are respectively a left driving wheel motor driver and a right driving wheel motor driver of the AGV; u3 is the stepper motor drive for the conveyor belt on the upper portion of the AGV.

A power supply terminal VCC on the left driving wheel motor driver U1 is connected with a DC48V power supply anode P48 terminal, and a GND terminal is connected with 0V; the A +, A-, B + and B-terminals of the left driving wheel motor driver U1 are connected to the stepping motor on the left wheel; a control terminal CP-of the left driving wheel motor driver U1 is connected to a Y0 terminal of the trolley PLC controller, receives high-speed pulses output by the trolley PLC controller, and controls the rotating speed and the position of the stepping motor on the left wheel; the CW-terminal of the left driving wheel motor driver U1 is connected to the Y6 terminal of the trolley PLC controller and used as a direction control signal to control the rotation direction of the stepping motor on the left wheel; the EN-terminal of the left driving wheel motor driver U1 is connected to the Y11 terminal of the trolley PLC controller to be used as an enabling control signal; and the P +, CW + and EN + terminals of the C left driving wheel motor driver U1 are interconnected and then connected to the positive power supply P24 terminal of the DC 24V.

A power supply terminal VCC on the right driving wheel motor driver U2 is connected with a DC48V power supply anode P48 terminal, and a GND terminal is connected with 0V; the A +, A-, B + and B-terminals of the right driving wheel motor driver U2 are connected to the stepping motor on the right wheel; a control terminal CP-on a right driving wheel motor driver U2 is connected to a Y1 terminal of the trolley PLC controller, receives high-speed pulses output by the trolley PLC controller and controls the rotating speed and the position of a stepping motor on a right wheel; a CW-terminal of a right driving wheel motor driver U2 is connected to a Y7 terminal of a trolley PLC controller and used as a direction control signal to control the rotation direction of a stepping motor on a right wheel; the EN-terminal of the right driving wheel motor driver U2 is connected to the Y12 terminal of the trolley PLC controller to be used as an enabling control signal; the CP +, CW +, EN + terminals of the right driving wheel motor driver U2 are interconnected and then connected to the positive power supply P24 terminal of DC 24V.

A power supply terminal VCC on the stepping motor driver U3 is connected with a positive pole P48 terminal of a DC48V power supply, and a GND terminal is connected with 0V; a +, A-, B + and B-terminals on a stepping motor driver U3 are connected to a conveying line stepping motor on the upper part of the AGV; a control terminal CP-on the stepping motor driver U3 is connected to a Y2 terminal of the trolley PLC controller, receives high-speed pulses output by the trolley PLC controller and controls the rotating speed and the position of the conveyor belt stepping motor; a CW-terminal on the stepping motor driver U3 is connected to a Y10 terminal of the trolley PLC controller and used as a direction control signal to control the rotation direction of the conveyor belt stepping motor; an EN-on the stepping motor driver U3 is connected to a Y13 terminal of the trolley PLC controller to be used as an enabling control signal; the CP +, CW +, EN + terminals of the stepping motor driver U3 are interconnected and then connected to the positive P24 terminal of the DC24V power supply.

Claims

1. The utility model provides a real control system that instructs of robot assembly based on PLC and multiple bus are integrated which characterized in that: the system comprises a vertical warehouse control subsystem, a tray production line control subsystem, an assembly production line control subsystem and an AGV trolley control subsystem; the tray production line control subsystem and the assembly production line control subsystem share a master control PLC controller;

2. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 1, wherein: the system comprises a vertical library control subsystem and a vertical library control system, wherein the vertical library control subsystem comprises a vertical library PLC controller, and a body of the vertical library PLC controller is connected with a vertical library detection sensor, a master electrical appliance for external operation, a frequency converter protection and motion stroke protection element, and a digital quantity input/output element of an external AGV conveying trolley butt joint photoelectric element, an indicator light and an alarm element; the vertical warehouse PLC controller is respectively connected with an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane, a Z-axis frequency converter of the stacker crane and a vertical warehouse touch screen through an exchanger by adopting industrial Ethernet networking; the vertical storehouse PLC controller respectively controls an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane to drive corresponding stacker crane motors to operate in a bus control mode;

3. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 2, wherein: the vertical warehouse control subsystem also has a frequency converter protection function, and the frequency converter protection function is realized through a fault digital quantity output terminal signal of the frequency converter; a fault digital quantity output terminal of the frequency converter is connected with the vertical warehouse PLC controller; when a corresponding fault occurs in the running process of the frequency converter, a corresponding frequency converter fault output terminal is arranged with a1 and is connected with the input end of the vertical library PLC controller; the vertical library PLC controller sends out an instruction to stop the operation of the frequency converter and display faults; after the fault is processed, the vertical library PLC controller outputs a fault reset signal and sends the fault reset signal to the frequency converter to enable the frequency converter to recover to operate; the frequency converters comprise an X-axis frequency converter of the stacker crane, a Y-axis frequency converter of the stacker crane and a Z-axis frequency converter of the stacker crane;

4. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 1, wherein: in the tray assembly line control subsystem, a master control PLC controller is respectively connected with an entrance photoelectric sensor, a photographing photoelectric sensor, a grabbing photoelectric sensor, an AGV receiving photoelectric sensor and an AGV transmitting photoelectric sensor; the master control PLC controller is connected with the tray production line through a tray production line driving unit; the tray production line driving unit is provided with a frequency converter for driving a tray production line motor, a first single electric control electromagnetic valve and a second single electric control electromagnetic valve; the motor drive frequency converter of the tray production line is connected with the tray production line alternating current motor of the tray production line, the first single electric control electromagnetic valve is connected with the photographing station blocking cylinder of the tray production line, and the second single electric control electromagnetic valve is connected with the grabbing station blocking cylinder of the tray production line;

5. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 1, wherein: in the assembly production line control subsystem, a master control PLC controller is respectively connected with a master control touch screen, a master control electrical appliance, an assembly production line driving unit and a robot controller; the master control PLC controller is connected with a stepping driver of the assembly production line driving unit and an assembly production line origin switch; the stepping driver is connected with a stepping motor of the assembly production line; the master control PLC controller is respectively connected with the relays of the robot enabling end, the robot disabling end and the robot stopping end; the master control PLC controller is respectively connected with the laser pen for positioning and the switch of the guard rail door; the master control PLC controller is connected with the robot controller by adopting an industrial Ethernet; the robot controller is connected with the six-axis industrial robot and controls the action of the six-axis industrial robot; the main control PLC controller body is connected with a secondary positioning cylinder for 4 workpieces, and the main control PLC controller controls the secondary positioning cylinder through a corresponding electromagnetic valve; the manual control of the electromagnetic valve is operated by an external master control electric appliance, and the interaction of the running state parameters and the data is completed by a master control touch screen.

6. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 1, wherein: the AGV trolley control subsystem comprises a trolley PLC controller, and the trolley PLC controller is respectively connected with a motor driver I, a motor driver II, a conveyor belt stepping motor driver, tracking sensors and landmark sensors which are positioned at the front part and the rear part of the AGV trolley, an external master control electric appliance and an indicating element; a motor driver I and a motor driver II of the AGV trolley driving unit are respectively connected with stepping motors on the left wheel and the right wheel of the AGV trolley and are used for controlling the left wheel and the right wheel of the AGV trolley to work; the motor driver I is also called as a left driving wheel motor driver, and the motor driver II is also called as a right driving wheel motor driver; the conveyor belt stepping motor driver is connected with a stepping motor of the tray conveyor belt and used for driving the conveyor belt motor to work; the power supply of the AGV trolley control subsystem is provided by a storage battery, and a charging circuit and a device are arranged; the butt joint of the trolley PLC controller with the vertical warehouse and the production line is realized by 2 groups of opposite photoelectric switches which are respectively arranged on the vertical warehouse and the production line; the data communication between the trolley PLC controller and the system is realized by adopting a wireless communication mode; the manual control mode of the AGV trolley control subsystem is operated through an external master control electric appliance, and the interaction of the running state parameters and the data is completed through an AGV touch screen.

7. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 3, wherein: the garage PLC controller adopts a Schneider PLC programmable controller, an L, N, PE terminal of the garage PLC controller is connected with an external power supply, and the L, N, PE terminals are a phase line, a neutral line and a protective grounding line respectively; a Q0.0 terminal of the vertical warehouse PLC is connected with a buzzer HB1, and the buzzer HB1 gives an alarm when the stacker crane fails; a Q0.1 terminal of the vertical warehouse PLC controller is connected with an operation indicator lamp HL 2; a Q0.2 terminal of the vertical warehouse PLC controller is connected with an AGV conveying trolley butt-joint photoelectric switch, and when the Q0.2 terminal outputs a signal of 1, the AGV conveying trolley is driven to leave the vertical warehouse; the I0.0, I0.1 and I0.2 terminals of the PLC are respectively connected with an emergency stop button, a start button and a stop button; the I0.3 and I0.4 terminals of the vertical storehouse PLC controller are respectively connected with a left limit switch and a right limit switch of an X-axis motor of the stacker crane; i0.5 and I0.6 terminals of the vertical storehouse PLC controller are respectively connected with an upper limit switch and a lower limit switch of a Z-axis motor of the stacker crane; i0.7, I1.0 and I1.1 terminals of the vertical storehouse PLC controller are respectively connected with a fork goods taking, original point and a fork goods delivering position switch operated by a Y-axis motor of the stacker crane; an I1.2 terminal of the vertical warehouse PLC controller is connected with an AGV conveying trolley butt joint photoelectric switch, and when the output value of the I1.2 terminal is 1, the AGV conveying trolley can be confirmed to run to the vertical warehouse; the I1.3, I1.4 and I1.5 terminals of the vertical library PLC controller are respectively connected with fault output signal ends of an X-axis frequency converter, a Y-axis frequency converter and a Z-axis frequency converter of the stacker crane.

8. The PLC and multi-bus integration based robot assembly training control system according to claim 4, wherein: the master control PLC controller adopts a Schneider PLC programmable controller, and an L, N, PE terminal of the master control PLC controller is connected with an external power supply; l, N, PE, the phase line, the neutral line and the protective grounding line are respectively; a Q0.3 terminal of the master control PLC is connected with the intermediate relay KA2, and when an output signal of the Q0.3 terminal is 1, a contact of the intermediate relay KA2 drives a photographing station to block an air cylinder to act; a Q0.4 terminal of the master control PLC controller is connected with an intermediate relay KA3 coil for the grabbing station blocking cylinder; a Q0.5 terminal of the master control PLC is connected with the intermediate relay KA4, and when an output signal of the Q0.5 terminal is 1, a contact of the master control PLC triggers the camera to take a picture; a Q0.6 terminal of the master control PLC controller is connected with a buzzer, and an alarm is given when the assembly line fails; a Q0.7 terminal of the master control PLC controller is connected with the operation indicator lamp; a Q1.0 terminal of the master control PLC controller is connected with an AGV conveying trolley butt-joint photoelectric switch, and when the output signal of the Q1.0 terminal is 1, the AGV conveying trolley is driven to leave the tray assembly line; the I0.0, I0.1 and I0.2 terminals of the master control PLC controller are respectively connected with the emergency stop button, the start button and the stop button; an I0.3 terminal of the master control PLC controller is connected with a photographing completion signal output end of the camera controller; the I0.4, I0.5 and I0.6 terminals of the master control PLC controller are respectively connected with an inlet photoelectric sensor, a photographing broadcast and television sensor and a grabbing photoelectric sensor on the tray production line; an I0.7 terminal of the master control PLC controller is connected with an AGV conveying trolley butt joint photoelectric switch, and when a signal of the I0.7 terminal is 1, the AGV conveying trolley is confirmed to run to an assembly line butt joint position; and an I1.1 terminal of the PLC is connected with a fault output signal end of the frequency converter.

9. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 5, wherein: the master control PLC controller is a Schneider PLC programmable controller, an L, N, PE terminal of the master control PLC controller is connected with an external power supply, wherein L, N, PE respectively refers to a phase line, a neutral line and a protective grounding line; the Q0.0 and Q0.1 terminals of the master control PLC controller are connected with a stepping driver, and a stepping motor is driven by high-speed pulses, wherein the Q0.0 terminal corresponds to a high-speed pulse output, and the Q0.1 terminal corresponds to a direction control terminal; a Q0.7 terminal of the master control PLC controller is connected with a system operation indicator lamp; a Q1.1 terminal of the master control PLC controller is connected with a positioning laser pen on a tool at the tail end of the robot and is used for determining the relative positions of the robot and a peripheral tray production line and an assembly production line; the I0.0, I0.1 and I0.2 terminals of the master control PLC controller are respectively connected with an emergency stop button, a starting button and a stop button of the practical training device; an I1.0 terminal of the master control PLC controller is connected with an original point switch of an assembly production line and used for determining an assembly original point; and the Q2.0, Q2.1 and Q2.2 terminals on the TM3DM 8R on the digital quantity expansion module are respectively connected with a robot reset relay, a robot enabling release relay and a robot enabling relay coil, and the calling of corresponding functions is realized by connecting the contact points of the relay to a robot controller.

10. The PLC and multi-bus integration based robot assembly training control system as claimed in claim 6, wherein: the trolley PLC controller adopts a signal PLC programmable controller, and X0 and X1 terminals of the trolley PLC controller are respectively connected with limit photoelectric switches at the front part and the rear part of the tray position and are used for limiting the tray position and counting; an X5 terminal of the PLC controller of the AGV is connected with an emergency stop button of the AGV and a series normally closed contact of a collision switch, and when collision or manual emergency stop occurs during operation, the AGV stops operating; the X10-X13 terminals of the trolley PLC controller are connected with a landmark sensor at the front end of the AGV trolley, and the X14-X17 terminals of the trolley PLC controller are connected with a landmark sensor at the rear end of the AGV trolley and are used for detecting magnetic strip signals transversely arranged on the ground, so that the AGV trolley is decelerated and stopped, and is controlled to accurately stop at a vertical warehouse or a production line butt joint position; X30-X37 terminals on the digital input expansion module XC-E16X are connected with an 8-bit front tracking sensor, X40-X47 terminals of the digital input expansion module XC-E16X are connected with an 8-bit rear tracking sensor and are used for detecting magnetic stripes on an advancing track of the AGV trolley and carrying out deviation detection and calculation, so that the differential speed of motors of left and right wheels of the AGV trolley is adjusted, and the AGV trolley is ensured to advance along the magnetic track; x20 and X21 terminals of the trolley PLC controller are respectively connected with a vertical warehouse side and a pipeline side for butt-joint photoelectric receiving;

y0, Y6 and Y11 terminals on the PLC controller of the AGV are connected with a high-speed pulse, direction and enabling terminal of a motor driver of a left driving wheel of the AGV, so that the speed and direction of the left wheel of the AGV are controlled; y1, Y7 and Y12 terminals on the PLC controller of the AGV are connected with high-speed pulse, direction and enabling terminals of a motor driver of a driving wheel on the right side of the AGV, so that the speed and direction of the right wheel of the AGV are controlled; y2, Y10 and Y13 terminals on the PLC controller of the AGV are connected with high-speed pulse, direction and enabling terminals of a motor driver of the conveyor belt on the upper part of the AGV, so that the speed and the direction of the conveyor belt of the AGV are controlled;