CN113714789B - Screw tightening device based on visual positioning and control method - Google Patents
Screw tightening device based on visual positioning and control method Download PDFInfo
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- CN113714789B CN113714789B CN202110968755.0A CN202110968755A CN113714789B CN 113714789 B CN113714789 B CN 113714789B CN 202110968755 A CN202110968755 A CN 202110968755A CN 113714789 B CN113714789 B CN 113714789B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/04—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes for assembling or disassembling parts
- B23P19/06—Screw or nut setting or loosening machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/001—Article feeders for assembling machines
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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]
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Abstract
The invention discloses a screw tightening device based on visual positioning and a control method, wherein the device comprises the following components: the device comprises a robot, a control system, a feeding mechanism, a vision measuring module and a tightening tool, wherein the control system is respectively in communication connection with the robot and the tightening tool, the feeding mechanism comprises a frame, a conveyor belt, a material tray, a material baffle, a blocking cylinder, a clamping cylinder and a photoelectric sensor, the conveyor belt is arranged on the frame, the material tray is arranged on the conveyor belt, the material baffle is arranged on two sides of the conveyor belt, the blocking cylinder and the clamping cylinder are arranged on the same side of the material baffle, and the photoelectric sensor is arranged on the opposite side of the blocking cylinder; the vision measurement module is installed in the frame, and the tightening tool is installed on the flange of the sixth axis of the robot, and the vision measurement module is located the top of tightening the operation area. The invention can rapidly position a plurality of bolt positions, and can program and control the tightening torque, thereby improving the screw tightening control precision and enabling the screw connection to achieve the expected tightening effect.
Description
Technical Field
The invention relates to the technical field of screw tightening assembly, in particular to a screw tightening device based on visual positioning and a control method.
Background
At present, most production enterprises still adopt hand-held electric or pneumatic tools to assemble threaded fasteners, or use special screw locking machines to realize a semi-automatic screw tightening function, and a small part adopts a tool clamp and a robot to assemble the threaded fasteners, namely, the tool clamp is used for preliminary positioning of the workpieces to be assembled, then a robot carrying the tightening tools is used for controlling movement tracks and positioning in a teaching learning mode, the screw assembling and tightening process is completed, and a guide pin in a jacking mechanism is inserted into a corresponding positioning hole of an engine tray in the application of the robot bolt tightening technology of engine assembly, such as Shanghai, so that the positioning of an engine is realized; and then the engine is processed through the compressing mechanism, so that all bolt holes are positioned on the same horizontal plane, and finally, a planned robot path program is set to realize positioning and screwing of the target bolts. In addition, there are few modes of machine vision and robot for carrying out connection treatment on threaded fasteners, namely positioning of bolts is achieved through vision, a robot is guided to carry a tightening tool for carrying out threaded connection treatment on the fasteners, as Tong Zhen, in the key technical research of machine vision-based screw locking SCARA robot, a vision system and the tightening tool can be simultaneously installed at the tail end of the SCARA robot through a design clamp, movement tracks of the robot are designed and planned to achieve photographing treatment on threaded holes at different positions, and finally the robot is guided to carry out threaded connection and assembly on LED flat lamp products.
Along with the continuous improvement of labor cost, the production cost of screw thread assembly of the fastener by adopting a handheld tool is high, and the tightening precision is greatly influenced by human factors; the special screw locking machine equipment is generally incapable of flexibly adjusting the screwing position and flexibly setting or changing the screwing moment according to the requirement so as to obtain higher screwing control precision; the fact that the robot teaching mode is used for carrying out thread assembly on the fastener has the defects that the tool fixture is complex in design and high in requirement on repeated positioning accuracy of the robot, and adjustment flexibility is poor; the mode of visual positioning and guiding by using the SCARA robot is only used for carrying a small-sized screwing tool with lighter weight, and the screwing operation is generally distributed on a plane and cannot meet the requirement of multi-azimuth or attitude screw assembly.
Meanwhile, in the screwing process of the robot, a commonly used screwing tool, namely an electric screwdriver, is generally carried, only a certain determined torque upper limit threshold value can be generally set, and rotation is stopped when the torque upper limit threshold value is reached, so that on one hand, the torque control precision is very low, on the other hand, different screwing torque values cannot be set for different threaded fasteners, and a more proper screwing process flow is planned to obtain the best assembly effect. Meanwhile, the tightening tool generally has no tightening process data feedback function, can not directly judge and warn the abnormal condition of the tightening process, and can not further trace, process and save the tightening data.
Disclosure of Invention
The invention mainly aims to provide a screw tightening device and a control method based on visual positioning, which are used for adapting to various screw assembling positions and flexibly setting tightening torque, improving screw tightening control precision and obtaining better assembling and tightening effects.
In order to achieve the above object, the present invention provides a screw tightening device based on visual positioning, comprising: the device comprises a robot, a control system, a feeding mechanism for conveying a module to be screwed up, a vision measurement module for photographing and positioning the module to be screwed up, and a screwing tool for screwing up the module to be screwed up according to the photographing result of the vision measurement module, wherein the control system is respectively in communication connection with the robot and the screwing tool, the feeding mechanism comprises a frame, a conveyor belt, a tray, a material baffle, a blocking cylinder, a clamping cylinder and a photoelectric sensor, the conveyor belt is mounted on the frame, the tray is placed on the conveyor belt, the material baffle is mounted on two sides of the conveyor belt, the blocking cylinder and the clamping cylinder are mounted on the same side of the material baffle and are sequentially arranged in front of and behind the running direction of the conveyor belt, and the photoelectric sensor is mounted on the opposite side of the blocking cylinder and is positioned at a position slightly behind the running direction of the conveyor belt. The visual measurement module is installed on the frame, the tightening tool is installed on the robot, and the visual measurement module is located above the tightening operation area.
The tightening tool comprises a tightening shaft connected with the robot and a tightening shaft controller connected with the tightening shaft, wherein the tightening shaft controller is positioned at the tail end of the tightening shaft and connected with the tightening shaft.
The tightening shaft comprises a tightening head, an end cover, a coupler, a torque sensor, a speed reducer, a servo motor and an encoder, wherein the end cover is arranged at the front end of the tightening shaft, the coupler is respectively arranged between the end cover and the torque sensor, between the torque sensor and the speed reducer, the speed reducer is connected with the servo motor, and the encoder is arranged at the tail end of the servo motor.
The visual measurement module comprises a visual measurement assembly and an installation support, wherein the top of the installation support is L-shaped, the bottom of the installation support is installed on the frame, and the visual measurement assembly is installed on the top of the installation support through an L-shaped installation plate.
The visual assembly comprises a camera, an optical lens and an annular light source which are coaxially arranged in sequence from top to bottom, wherein the camera is arranged on the L-shaped mounting plate through a camera mounting plate, the optical lens is in threaded connection with a C interface of the camera, and the annular light source is arranged on the L-shaped mounting plate through an annular light source mounting plate.
According to a further technical scheme, the material tray comprises a supporting plate and upright posts symmetrically arranged at two ends of the bottom of the supporting plate.
According to the technical scheme, the module to be screwed comprises a screwed motor, a screwed motor mounting plate and mounting bolts, and a plurality of connecting bolts are arranged on the screwed motor to be screwed.
The control system comprises a computer, a switch, a robot control cabinet and a demonstrator, wherein the switch is respectively connected with the vision measurement module, the robot control cabinet and the computer, and the robot control cabinet is connected with the robot.
In order to achieve the above object, the present invention also provides a method for controlling a screw tightening device based on visual positioning, the method being applied to the screw tightening device based on visual positioning as described above, the method comprising the steps of:
when the photoelectric sensor detects the material tray, the blocking cylinder carries out blocking treatment on the material tray, the clamping cylinder carries out clamping treatment on the material tray, and a clamping signal is sent to a computer in the control system;
the computer in the control system controls the vision measurement module to take a picture of the module to be screwed up according to the clamping signal, and sends the position information of the bolt on the module to be screwed up to the robot;
The robot drives the tightening tool to tighten the bolt and sends tightening information to a computer in the control system;
and drawing a tightening process curve according to the tightening information by a computer in the control system, and displaying and storing a tightening result.
The invention further adopts the technical scheme that the computer in the control system draws a tightening process curve according to the tightening information, and the step of displaying and storing the tightening result further comprises the following steps:
the computer in the control system judges whether the expected tightening requirement is met according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the bolts which are subjected to tightening processing to judge whether all the bolt tightening tasks to be tightened are completed, if the tightening tasks of all the bolts are completed, the robot performs zero-return point movement, the camera measurement module stops photographing, and the process is finished;
if the expected tightening requirement is not met, judging whether a screw tightening defect exists or not;
if the tightening defect does not exist, a computer in the control system controls the tightening tool to realize secondary tightening treatment on the screw;
If the screw tightening defect exists, the computer in the control system displays and records abnormal tightening information.
The visual positioning-based thread tightening device and method have the beneficial effects that:
1. aiming at the problems of high production cost and large influence of human factors on the tightening precision of the handheld tightening tool, the invention adopts a mode of carrying the tightening tool on a robot to rapidly tighten the bolt, thereby being beneficial to improving the production efficiency, reducing the production cost and improving the automation degree of screw thread assembly;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to the needs when special screw locking machine equipment and a robot teaching mode are assembled, the invention adopts vision to take photos and position threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; the method comprises the steps of carrying out a first treatment on the surface of the
3. Aiming at the problems of the tightening assembly direction and load limitation of the SCARA robot, the invention adopts a six-axis industrial robot + vision scheme matched with the load, and solves the problems of the limitation of the robot activity space and the assembly overload of the robot due to the degree of freedom of the robot;
4. Aiming at the problems that a common electric batch carried by a robot cannot be provided with different tightening technologies according to different threaded fasteners in the tightening process, the torque control precision is low and the data feedback function in the tightening process is not provided, the tightening tool with the torque closed-loop control function is adopted, and the corresponding tightening technology is provided according to the material characteristics of different bolts and fasteners by a torque control-rotation angle monitoring method, so that a better control effect is achieved, meanwhile, the upper software in a computer is utilized to communicate with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, the analysis of the tightening process and the judgment of the tightening result are facilitated, the tightening process data are further stored, and the tracing and tracking of assembly data are facilitated.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained from the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of the system components of a preferred embodiment of the visual positioning-based screw-on device of the present invention;
FIG. 2 is a schematic view of the structure of a conveyor belt and a module to be screwed in a preferred embodiment of the visual positioning-based screw tightening device of the present invention;
FIG. 3 is a schematic view of the overall structure of the tightening tool;
FIG. 4 is a schematic view of the overall structure of the tightening tool at another angle;
FIG. 5 is a schematic view of the overall structure of the tightening tool at yet another angle;
FIG. 6 is a schematic view of the structure of the tightening tool;
FIG. 7 is a schematic diagram of the structure of a vision measurement module;
FIG. 8 is a schematic flow chart of a method for controlling a screw tightening device based on visual positioning according to the present invention;
FIG. 9 is a schematic diagram of an image processing flow;
FIG. 10 is a schematic of a tightening torque-time model;
FIG. 11 is a torque-angle-time diagram of a tightening process;
FIG. 12 is an enlarged view of a torque-angle-time section of the tightening process;
fig. 13 is a graphical interface view of a tightening curve of a computer.
Reference numerals illustrate:
a robot 1; the module 2 is to be screwed down; a vision measurement module 3; a tightening tool 4; a frame 5; a conveyor belt 6; a tray 7; a material baffle 8; a blocking cylinder 9; a clamping cylinder 10; a photoelectric sensor 11; a screwed motor 12; a screwed motor mounting plate 13; a computer 14; a switch 15; a robotic control cabinet 16; a demonstrator 17; an air pump 18; a support plate 19; a column 20; tightening the shaft 21; tightening the shaft controller 22; tightening the screwdriver bit 23; an end cap 24; a coupling 25; a torque sensor 26; a speed reducer 27; a servo motor 28; an encoder 29; mounting a support 30; an L-shaped mounting plate 31; a camera 32; an optical lens 33; an annular light source 34; a camera mounting plate 35; an annular light source mounting plate 36.
The achievement of the objects, functional features and advantages of the present invention will be further described with reference to the accompanying drawings, in conjunction with the embodiments.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, if directional indications (such as up, down, left, right, front, and rear … …) are included in the embodiments of the present invention, the directional indications are merely used to explain the relative positional relationship, movement conditions, etc. between the components in a specific posture (as shown in the drawings), and if the specific posture is changed, the directional indications are correspondingly changed.
In addition, if there is a description of "first", "second", etc. in the embodiments of the present invention, the description of "first", "second", etc. is for descriptive purposes only and is not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In addition, the meaning of "and/or" as it appears throughout includes three parallel schemes, taking "a and/or B" as an example, including a scheme, or B scheme, or a scheme where a and B are satisfied simultaneously. In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection required by the present invention.
In order to solve the technical problems in the prior art, the invention provides a screw tightening device based on visual positioning, which utilizes a visual measurement module to provide an accurate position of a screw to be assembled on a screwed object for a robot, thereby guiding the robot to move to a proper position and posture, and utilizes a tightening tool to realize the tightening process of a screw by adopting a torque closed-loop control and angle monitoring method so as to achieve the purpose of controlling the axial pretightening force of threaded connection in a proper range. And drawing a torque-rotation angle-time curve according to data generated in the screwing process so as to further analyze and judge the screw tightening result and ensure that the screw assembling quality meets the expected requirement. And meanwhile, by utilizing the upper software and the communication function, the computer further stores and records the tightening process data, so that follow-up checking of the tightening process data and tracing of problems is facilitated.
As shown in fig. 1 to 7, a preferred embodiment of the visually positioned screw tightening device of the present invention comprises: the device comprises a robot 1, a control system, a feeding mechanism for conveying a module 2 to be screwed, a vision measurement module 3 for photographing and positioning the module 2 to be screwed, and a screwing tool 4 for screwing the module 2 to be screwed according to the photographing result of the vision measurement module 3, wherein the control system is respectively in communication connection with the robot 1 and the screwing tool 4, the feeding mechanism comprises a frame 5, a conveyor belt 6, a tray 7, a material baffle 8, a blocking cylinder 9, a clamping cylinder 10 and a photoelectric sensor 11, the conveyor belt 6 is mounted on the frame 5, the tray 7 is placed on the conveyor belt 6, the material baffle 8 is mounted on two sides of the conveyor belt 6, the blocking cylinder 9 and the clamping cylinder 10 are mounted on the same side of the material baffle 8 and are sequentially arranged along the running direction of the conveyor belt 6, the photoelectric sensor 11 is mounted on the opposite side of the blocking cylinder 9 and is positioned at a position slightly behind the running direction of the conveyor belt 6; the vision measuring module 3 is mounted on the frame 5, the tightening tool 4 is mounted on the robot 1, and the vision measuring module 3 is located above the tightening operation area.
The module to be screwed 2 may include a screwed motor 12, a screwed motor mounting plate 13, and a plurality of screw bolts. The control system comprises a computer 14, a switch 15, a robot control cabinet 16 and a demonstrator 17, wherein the switch 15 is respectively connected with the vision measurement module 3, the robot control cabinet 16 and the computer 14, and the robot control cabinet 16 is connected with the robot 1.
As an embodiment, the present embodiment further comprises an air pump 18, and the air pump 18 is connected to the blocking cylinder 9 and the clamping cylinder 10, respectively.
Specifically, the computer 14 and the Vision measurement module 3 communicate with each other by using the Vision Gige protocol in the ethernet, the robot 1 and the computer 14 communicate with each other by using the TCP/IP protocol in the ethernet, and the tightening tool 4 and the computer 14 communicate with each other by using a specific protocol.
The tray 7 comprises a tray supporting plate 19 and vertical columns 20 symmetrically arranged at two ends of the bottom of the supporting plate 19. The tray 7 is mainly used for carrying the module 2 to be screwed, namely the screwed motor 12, the screwed motor mounting plate 13 and the mounting bolts.
In the embodiment, the material baffle plates 8 are arranged at two sides of the conveyor belt 6 and play a role in guiding and blocking the material tray 7; the blocking cylinder 9 is arranged in front of the running direction of the conveyor belt 6 and mainly plays a role in blocking the tray 7; the clamping cylinder 10 is arranged at a proper position behind the blocking cylinder 9 and mainly plays a role in clamping the material tray 7; the photoelectric sensor 11 is installed on the opposite side of the blocking cylinder 9 and is located at a slightly rear proper position relative to the running direction of the conveyor belt 6, and mainly plays a role in detecting the tray 7 to determine whether a material passes through.
According to the embodiment, the visual measurement module 3 can be utilized to photograph target bolts of different specifications and sizes in a complex environment, the offset of the bolts relative to the visual origin can be known by combining the visual origin and the same point on a product as the reference point of the screwing position of the robot 1, and is equal to the offset of the bolts relative to the reference point of the screwing position of the robot 1, so that the accurate positioning of the target bolts is realized, the robot 1 is guided to carry the screwing tool 4 to rapidly screw the corresponding bolts, meanwhile, a computer in a control system draws a screwing process curve according to screwing data sent by the screwing tool 4 and displays the screwing result, and if necessary, the screwing tool 4 is triggered to repeatedly screw so as to achieve the screwing target which is expected to be set, and meanwhile, the screwing process data is further stored and recorded, so that follow-up checking of screwing process data and the source of problems is facilitated.
Further, in the present embodiment, the tightening tool 4 includes a tightening shaft 21 connected to the robot 1, and a tightening shaft controller 22 connected to the tightening shaft 21, and the tightening shaft controller 22 is located at the distal end position of the tightening shaft 21 and connected to the tightening shaft 21.
The tightening shaft 21 comprises a tightening head 23, an end cover 24, a coupler 25, a torque sensor 26, a speed reducer 27, a servo motor 28 and an encoder 29, wherein the end cover 24 is arranged at the front end of the tightening shaft 21, the coupler 25 is respectively arranged between the end cover 24 and the torque sensor 26 and between the torque sensor 26 and the speed reducer 27, the speed reducer 27 is connected with the servo motor 28, and the encoder 29 is arranged at the tail end of the servo motor.
In this embodiment, the driving device of the tightening shaft 21 of the tightening tool 4 is installed at the end position of the tightening shaft 21 and is connected with the tightening shaft 21, so that the driving device mainly plays roles of driving control and signal transmission of the tightening shaft 21.
In this embodiment, the vision measurement module 3 obtains the accurate position of the target bolt mainly by photographing the screwed motor 12 and the matched fastening device.
The vision measurement module 3 comprises a vision measurement assembly and a mounting bracket 30, wherein the top of the mounting bracket 30 is L-shaped, the bottom of the mounting bracket 30 is arranged on the frame 5, and the vision measurement assembly is arranged on the top of the mounting bracket 30 through an L-shaped mounting plate 31.
The vision assembly comprises a camera 32, an optical lens 33 and an annular light source 34 which are coaxially arranged in sequence from top to bottom, wherein the camera 32 is arranged on an L-shaped mounting plate 31 through a camera mounting plate 35, the optical lens 33 is in threaded connection with a C interface of the camera 32, and the annular light source 34 is arranged on the L-shaped mounting plate 31 through an annular light source mounting plate 36.
The whole working process of the thread tightening device based on visual positioning is as follows:
after the system starts to operate, the photoelectric sensor 11 which is arranged on the conveyor belt 6 and is positioned below the visual field of the camera 32 is used for detecting the tray 7 carrying the screwed motor 12 and the matched fastening device, when the tray 7 touches the photoelectric sensor 11, the blocking cylinder 9 acts and stretches out to block the tray 7, meanwhile, the conveyor belt 6 stops operating and triggers the clamping cylinder 10 to act, the tray 7 is clamped, at the moment, the camera 32 which is arranged above the bracket beside the conveyor belt 6 performs photographing treatment on the screwed motor 12, the screwed motor mounting plate and the mounting bolt which are positioned below the camera 32, the photographed treatment result, namely the offset of the fastening bolt between the screwed motor and the screwed motor mounting plate relative to the visual origin point is transmitted to a computer in a control system, after the offset of the screwed motor fastening bolt relative to the visual origin point is received, the offset of the screwed motor fastening bolt relative to the visual origin point is transmitted to the robot 1 in a TCP/IP protocol mode, then the robot 1 moves to the corresponding position of the screw with the screwing tool 4, the camera 32 performs the communication treatment, the screwed motor mounting plate is clamped to the corresponding position, the screwed motor mounting plate is clamped to the screw down, the screwed down position is transmitted to the control system through a control string, the data is transmitted to the control system after the data is displayed, and the data is displayed on the system is drawn according to the result after the tightening result is displayed, and the tightening results are all the tightening results are displayed.
The visual positioning-based thread tightening device has the beneficial effects that:
1. aiming at the problems of high production cost and large influence of human factors on the tightening precision of the handheld tightening tool, the invention adopts a mode of carrying the tightening tool on a robot to rapidly tighten the bolt, thereby being beneficial to improving the production efficiency, reducing the production cost and improving the automation degree of screw thread assembly;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to the needs when special screw locking machine equipment and a robot teaching mode are assembled, the invention adopts vision to take photos and position threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; the method comprises the steps of carrying out a first treatment on the surface of the
3. Aiming at the problems of the tightening assembly direction and load limitation of the SCARA robot, the invention adopts a six-axis industrial robot + vision scheme matched with the load, and solves the problems of the limitation of the robot activity space and the assembly overload of the robot due to the degree of freedom of the robot;
4. aiming at the problems that a common electric batch carried by a robot cannot be provided with different tightening technologies according to different threaded fasteners in the tightening process, the torque control precision is low and the data feedback function in the tightening process is not provided, the tightening tool with the torque closed-loop control function is adopted, and the corresponding tightening technology is provided according to the material characteristics of different bolts and fasteners by a torque control-rotation angle monitoring method, so that a better control effect is achieved, meanwhile, the upper software in a computer is utilized to communicate with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, the analysis of the tightening process and the judgment of the tightening result are facilitated, the tightening process data are further stored, and the tracing and tracking of assembly data are facilitated.
In order to achieve the above object, the present invention also provides a method for controlling a screw tightening device based on visual positioning, the method being applied to the screw tightening device based on visual positioning as described above, the method comprising the steps of:
when the photoelectric sensor detects the material tray, the blocking cylinder carries out blocking treatment on the material tray, the clamping cylinder carries out clamping treatment on the material tray, and a clamping signal is sent to a computer in the control system;
the computer in the control system controls the vision measurement module to take a picture of the module to be screwed up according to the clamping signal, and sends the position information of the module to be screwed up to the robot;
the robot drives the tightening tool to tighten the bolt and sends tightening information to a computer in the control system;
and drawing a tightening process curve according to the tightening information by a computer in the control system, and displaying and storing a tightening result.
Further, the step of drawing a tightening process curve according to the tightening information and displaying and storing the tightening result by the computer in the control system further comprises the following steps:
The computer in the control system judges whether the expected tightening requirement is met according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the bolts which are subjected to tightening processing to judge whether all the bolt tightening tasks are completed, if the tightening tasks of all the bolts are completed, the robot performs zero-return point movement, the camera measurement module stops photographing, and the flow is ended;
if the expected tightening requirement is not met, judging whether a screw tightening defect exists or not;
if the tightening defect does not exist, a computer in the control system controls the tightening tool to realize secondary tightening treatment on the screw;
and if the screw tightening defect exists, the control system displays and records abnormal tightening information.
The method of controlling the visual positioning-based screw tightening device according to the present invention is further described below with reference to fig. 8 to 13.
As shown in fig. 8, the specific flow of the control method of the screw tightening device based on visual positioning of the present invention is as follows:
step 1: the following preparation work is performed before the system enters the initialization:
1) The model selection work of cameras, robots, experimental objects and the like is completed according to the requirements of a system scheme, and finally a black-and-white industrial camera with a sea-Kangwei view of 600 ten thousand pixels, a common optical lens, an annular light source, a controller, a screwing tool and a six-axis robot with the model of ABB-1410 are determined as experimental objects;
2) Installing a calibration needle at a tightening tool bit arranged at the tail end of the robot to finish the establishment work of a tool coordinate system;
3) Finishing the programming of a robot motion control program and the design work of a tightening process of a tightening tool;
4) The network cables are respectively connected with a computer, a camera and a robot controller cabinet through a kilomega network card, and network addresses of the computer, the camera and the robot controller cabinet are arranged in the same network segment;
5) Completing the writing of a visual image processing program, wherein the writing comprises the steps of calibrating a camera, calibrating a hand and eye, matching a template, establishing a template coordinate system and the like, and fitting a circle to a nut of a bolt by using a circle finding tool and the like so as to confirm the circle center position;
6) And finishing writing of upper software, wherein the functions of the upper software comprise:
a) The computer is used for receiving a robot ready signal sent by the robot, sending position information of a nut center point of a bolt and a tightening completion signal of a tightening tool to the robot;
b) The communication function of the computer and the camera is used for sending an operation instruction to the camera in real time by the computer and receiving a real-time image or a single image fed back by the camera in real time by the computer for subsequent image processing;
c) The computer is used for sending an operation instruction and tightening process parameters to the tightening tool in real time, and receiving real-time tightening data fed back by the tightening tool in real time for subsequent curve drawing;
d) A function of displaying a camera shooting picture in real time, the function being used for displaying an image of the camera shooting picture in real time, so that the camera shooting picture can be more intuitively understood;
e) Invoking a function of an image processing program, wherein the function is used for invoking an image shot by a camera to process and outputting coordinate values of a screw cap center point of a bolt in the image after being processed by the image processing program;
f) A display function of a nut center point coordinate of the bolt for displaying a coordinate value of the nut center point of the bolt under a robot tool coordinate system;
g) The function of drawing a torque-rotation angle-time curve in real time according to tightening data can intuitively know the moment change trend in the tightening process;
h) And a function of saving and viewing tightening data, which can save the tightening data in real time and view the historical tightening data as needed.
Step 2: after the preparation before the initialization is completed, the system enters an initialization state, which includes: the robot performs the original return movement, detects whether the functions of all the parts are normal, confirms whether the circuits and the communication are normal, and sends corresponding tightening technological parameters according to the types of the bolts;
Step 3: placing a tray provided with a screwed motor, a mounting plate and a fastening bolt of the screwed motor on a conveyor belt, starting the conveyor belt to run, and enabling the motor and the fastening device above the tray to move along with the conveyor belt; simultaneously, a photoelectric sensor is started to detect the material tray;
step 4: when the charging tray triggers the photoelectric sensor, the blocking cylinder acts and extends out to block the charging tray, meanwhile, the operation of the conveyor belt is stopped, the action of the clamping cylinder is triggered, and the charging tray is clamped;
step 5: after receiving a signal from a clamping cylinder of the robot, the computer triggers the camera to take a picture of the screwed motor on the conveying belt, the mounting plate and the fastening bolt of the screwed motor, invokes an image processing program to process the shot image, and finally, the computer sends a processing result, namely the center point position of the screw to be screwed to the robot;
step 6: the robot moves to the corresponding bolt with the tightening tool to carry out tightening treatment and sends tightening process data to the computer in a serial port communication mode;
step 7: the computer draws a tightening process curve according to the tightening data and displays the tightening result;
step 8: judging whether the tightening task reaches an expected tightening requirement according to the tightening data, if so, jumping to a step 13, and judging whether the tightening task is completed; if the expected tightening requirement is not met, the flow jumps to step 9, and whether the screw tightening defect exists is judged;
Step 9: judging whether a screw tightening defect exists according to the torque change trend in the tightening data, if so, jumping to a step 12, and displaying and recording abnormal tightening information; if the screw tightening defect does not exist, the flow jumps to step 10, and the tightening tool performs secondary tightening treatment on the bolt;
step 10: the computer sends a re-tightening signal, and the tightening tool performs secondary tightening treatment on the bolt;
step 11: judging whether the tightening times exceeds 3 times, if so, judging that the tightening is abnormal, jumping to the step 12 to display and record abnormal tightening information; if the tightening times are not more than 3 times, the flow jumps to step 8, and whether the expected tightening requirement is met is judged again;
step 12: displaying the abnormal tightening result and recording corresponding abnormal tightening information;
step 13: judging whether all the bolt tightening tasks are completed according to the statistics of the number of the bolts which are subjected to tightening processing by the computer, and if all the bolt tightening tasks are completed, jumping the flow to the step 14; if the tightening tasks of all the bolts are not completed, the flow jumps to step 3, and the conveyor belt is restarted;
Step 14: the tightening task is completed, the robot performs zero-point motion, the camera stops photographing, and the process is finished.
As shown in fig. 9, the image processing flow is a process flow of image, before the image processing flow, the work such as camera calibration, hand-eye calibration and the like is needed, so that the vision measurement system can be directly applied to the experiment of the invention, wherein the image processing flow comprises the processes of image acquisition, template matching, template coordinate system establishment, image filtering processing, image dynamic threshold segmentation processing, expansion corrosion processing and bolt center point position determination by using a circle finding tool, the image acquisition is that the camera is triggered by the upper software to take a picture, and the picture is acquired to the upper software to carry out the image processing; the template matching is to establish a matching template according to the shape characteristics of the tail part of the twisted motor and is used for confirming a photographing processing object of a camera; establishing a template coordinate system is to establish the coordinate system according to the characteristics of template matching, and is mainly used for determining and shrinking the image processing area; the image filtering processing mainly suppresses noise of the target image, selectively enhances or suppresses the noise, thereby highlighting required image characteristics and enhancing visual recognition effect; the dynamic threshold segmentation processing mainly comprises the steps of obtaining a binarized image capable of reflecting the whole and part of the image, so that the contour contrast of the captured features is improved, and the complexity of later image processing is reduced; the expansion corrosion treatment mainly highlights the characteristics of the screw cap, and reduces interference factors of the background, so that the shape of the screw cap is clearer in the image; the main purpose of using a rounding tool is to find the circle of the nut head and determine its center point position.
As shown in fig. 10, a torque control model diagram of a tightening process, wherein the tightening process includes the following stages: the specific process comprises the following steps of cap searching, thread defect detecting, screwing up holding and back screwing up stages:
1. cap searching stage (0-t) 1 ): the batch head or the sleeve rotates for one circle at a low speed to combine the batch head or the sleeve with the bolt;
2. thread defect detection stage (t) 1 –t 2 ): the electric batch rotates to enable the bolt to rotate downwards, whether abnormal increase occurs in the torque is detected in the process, and if abnormal increase occurs, the defect of the thread is indicated;
3. bonding point detection stage (t) 2 –t 3 ): the laminating torque is detected at this stage, and the lower end of the bolt and the nut is at t 3 Is attached to the connecting body, called t 3 The corresponding point is the bonding point for bonding time;
4. stage of tightening (t) 3 –t 4 ): the stage starts to tighten according to the set target torque from the joint point by using a torque method, and is switched to the next stage when the set torque value is reached, wherein different target torques can be set for different bolts in the stage;
5. screw-down holding stage (t 4 –t 5 ): the stage starts from reaching the set torque, and the tightening torque is kept for a period of time, and the keeping time can be set according to the requirement;
6. Counter-twisting stage (t) 5 –t 6 ): the proper reverse rotation control is carried out on the tightening head at the stage, the bolt is not reversely loosened (nail is removed) in the practical sense, the holding moment is mainly removed, the friction force between the tightening head and the bolt is reduced, the tightening head is conveniently pulled out, the original tightening effect is not influenced, the reverse tightening angle is in the range of 1-10 degrees, and the reverse tightening angle can be set according to the practical condition of the site.
For the purpose, technical solutions and advantages of the control model, the model will be further described with reference to the accompanying drawings.
As shown in fig. 11, the graph is a practical application effect graph according to the control model, wherein an angle curve with a triangle mark in the tightening process and a torque curve with a circle mark in the tightening process correspond to a left angle scale line and a right torque scale line respectively, a horizontal axis is a time axis, and an acquisition interval of each data point is 50ms on average.
As can be seen from fig. 11, the tightening tool succeeds in finding the cap from the beginning of approximately half a turn, and the torque measured by the torque sensor at this stage gradually rises from zero to a certain value and is switched to the thread defect detection stage; in the thread defect detection stage, a tightening tool is quickly rotated to enable a bolt to be downwards rotated, a torque value is monitored in real time, and when the torque reaches a set fitting point torque value, the tightening stage is switched; the tightening tool controls the electric batch according to a torque method in the tightening stage so that the tightening torque gradually rises to a set value, and the tightening tool is switched to a tightening holding stage when the set value of the tightening torque is reached; the tightening tool in the tightening and holding stage keeps the target torque in the previous stage for a period of time according to the set holding time, and is switched to the counter-tightening stage when the holding time is reached; the tightening tool is suitably reverse-controlled according to the position pattern during the reverse-tightening phase, in which the reverse-tightening angle is 8 degrees in fig. 11 and the partial enlarged view of the reverse-tightening phase in fig. 11 is shown in fig. 12, while the holding torque is removed and the friction between the head and the bolt is reduced without affecting the previous tightening effect.
As shown in FIG. 13, the tightening curve display interface in the upper software developed by the invention is developed in Visual Studio based on Net language, and comprises the functions of communication, image display, image processing, tightening curve display, tightening process setting and the like. Wherein the image processing function is to call an image processing file generated by VisionPro software under the American Cognex company to process the photographed image.
The visual positioning-based thread tightening method has the beneficial effects that:
1. aiming at the problems of high production cost and large influence of human factors on the tightening precision of the handheld tightening tool, the invention adopts a mode of carrying the tightening tool on a robot to rapidly tighten the bolt, thereby being beneficial to improving the production efficiency, reducing the production cost and improving the automation degree of screw thread assembly;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to the needs when special screw locking machine equipment and a robot teaching mode are assembled, the invention adopts vision to take photos and position threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; the method comprises the steps of carrying out a first treatment on the surface of the
3. Aiming at the problems of the tightening assembly direction and load limitation of the SCARA robot, the invention adopts a six-axis industrial robot + vision scheme matched with the load, and solves the problems of the limitation of the robot activity space and the assembly overload of the robot due to the degree of freedom of the robot;
4. aiming at the problems that a common electric batch carried by a robot cannot be provided with different tightening technologies according to different threaded fasteners in the tightening process, the torque control precision is low and the data feedback function in the tightening process is not provided, the tightening tool with the torque closed-loop control function is adopted, and the corresponding tightening technology is provided according to the material characteristics of different bolts and fasteners by a torque control-rotation angle monitoring method, so that a better control effect is achieved, meanwhile, the upper software in a computer is utilized to communicate with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, the analysis of the tightening process and the judgment of the tightening result are facilitated, the tightening process data are further stored, and the tracing and tracking of assembly data are facilitated.
The foregoing description is only of the preferred embodiments of the present invention and is not intended to limit the scope of the invention, and all equivalent structural changes made by the specification and drawings of the present invention or direct/indirect application in other related technical fields are included in the scope of the present invention.
Claims (7)
1. A visual positioning-based screw tightening device, comprising: the device comprises a six-axis industrial robot, a control system, a feeding mechanism for conveying a module to be screwed down, a vision measurement module for photographing and positioning threaded holes of various shapes and layouts of the module to be screwed down and target bolts of different specifications and guiding the six-axis industrial robot to move to a proper position and posture, and a screwing tool for screwing down the module to be screwed down according to the photographing result of the vision measurement module, wherein the control system is respectively in communication connection with the robot and the screwing tool, the feeding mechanism comprises a frame, a conveyor belt, a material tray, a material baffle, a blocking cylinder, a clamping cylinder and a photoelectric sensor, the conveyor belt is mounted on the frame, the material tray is placed on the conveyor belt, the material baffle is mounted on two sides of the conveyor belt, the blocking cylinder and the clamping cylinder are mounted on the same side of the material baffle, and are sequentially arranged front and back along the running direction of the conveyor belt, and the photoelectric sensor is mounted on the opposite side of the blocking cylinder and is positioned at a position later than the running direction of the conveyor belt. The visual measurement module is arranged on the frame, the tightening tool is arranged on a flange of a sixth shaft of the robot, and the visual measurement module is positioned above a tightening operation area;
The visual measurement module comprises a visual measurement assembly and a mounting bracket, wherein the top of the mounting bracket is L-shaped, the bottom of the mounting bracket is mounted on the frame, and the visual measurement assembly is mounted on the top of the mounting bracket through an L-shaped mounting plate;
the vision measurement assembly comprises a camera, an optical lens and an annular light source which are sequentially and coaxially arranged from top to bottom, wherein the camera is arranged on the L-shaped mounting plate through a camera mounting plate, the optical lens is in threaded connection with a C interface of the camera, and the annular light source is arranged on the L-shaped mounting plate through an annular light source mounting plate;
the tightening tool comprises a tightening shaft connected with the robot and a tightening shaft controller connected with the tightening shaft, wherein the tightening shaft controller is positioned at the tail end of the tightening shaft and is connected with the tightening shaft; the tightening shaft comprises a tightening head, an end cover, a coupler, a torque sensor, a speed reducer, a servo motor and an encoder, wherein the end cover is arranged at the front end of the tightening shaft, the coupler is respectively arranged between the end cover and the torque sensor as well as between the torque sensor and the speed reducer, the speed reducer is connected with the servo motor, and the encoder is arranged at the tail end of the servo motor;
The module to be screwed comprises a screwed motor, a screwed motor mounting plate and mounting bolts, wherein a plurality of screwed bolts are arranged on the screwed motor to be screwed;
the vision measurement module photographs the module to be screwed up, and the processing flow of photographed pictures is as follows: the method comprises the steps of image acquisition, template matching, template coordinate system establishment, image filtering processing, image dynamic threshold segmentation processing, expansion corrosion processing and bolt center point position determination by using a circle finding tool, wherein the image acquisition is to trigger a camera to take a picture through upper software; the template matching is to establish a matching template according to the shape characteristics of the tail part of the twisted motor and is used for confirming a photographic processing object of a camera; establishing a template coordinate system is to establish the coordinate system according to the characteristics of template matching and is used for determining and shrinking the image processing area; the image filtering processing is to inhibit the noise of the target image, selectively enhance or inhibit the noise, thereby highlighting the required image characteristics and enhancing the visual recognition effect; the dynamic threshold segmentation processing is to obtain a binary image capable of reflecting the whole and part of the image, so that the contour contrast of the captured features is improved, and the complexity of the later image processing is reduced; the expansion corrosion treatment is characterized by highlighting the nut, and simultaneously reduces interference factors of the background, so that the shape of the nut is clearer in the image; the round finding tool is used for finding the circle of the head of the nut and determining the position of the center point of the circle;
The blocking cylinder is used for blocking the material tray when the photoelectric sensor detects the material tray, and the clamping cylinder is used for clamping the material tray and sending a clamping signal to the control system;
the robot is used for driving the tightening tool to tighten the bolt and sending tightening information to the control system;
the control system is used for controlling the vision measurement module to take a picture of the module to be screwed according to the clamping signal, and sending the position information of the connecting bolt of the screwed motor on the module to be screwed to the robot; and then guiding the robot to carry a tightening tool to quickly tighten the corresponding bolt;
the control system is also used for sending corresponding tightening process parameters according to the types of the bolts, drawing a tightening process curve according to the tightening information, setting corresponding tightening processes according to the material characteristics of different bolts and fasteners by adopting a torque control-rotation angle monitoring method, displaying and storing tightening results, and triggering a tightening tool to perform repeated tightening work when necessary so as to achieve the preset tightening target;
The control system is also used for judging whether the expected tightening requirement is met according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the bolts which are subjected to tightening processing to judge whether all the tightening tasks of the bolts to be tightened are completed, if the tightening tasks of all the bolts are completed, the robot performs zero-return movement, the camera measurement module stops photographing, and the process is finished;
if the expected tightening requirement is not met, judging whether a screw tightening defect exists or not;
if the tightening defect does not exist, a computer in the control system controls the tightening tool to realize secondary tightening treatment on the bolt;
if the screw tightening defect exists, the computer in the control system displays and records abnormal tightening information.
2. The visual positioning-based screw-on device of claim 1, wherein camera calibration, hand-eye calibration is required.
3. The visual positioning-based screw-on device of claim 2, wherein the photo is captured by a host software for image processing.
4. The visual positioning-based screw-on device of claim 1, wherein the tray comprises a support plate and posts symmetrically mounted at both ends of the bottom of the support plate.
5. The visual positioning-based screw tightening device according to any one of claims 1 to 4, wherein the control system comprises a computer, a switch, a robotic control cabinet, and a teach pendant, wherein the switch is connected to the visual measurement module, the robotic control cabinet, and the computer, respectively, and the robotic control cabinet is connected to the robot.
6. A method of controlling a visual positioning-based screw tightening device, characterized in that the method is applied to the visual positioning-based screw tightening device according to any one of claims 1 to 5, the method comprising the steps of:
step 1: the system enters an initialization state, which includes: the robot performs the original return movement, detects whether the functions of all the parts are normal, confirms whether the circuits and the communication are normal, and sends corresponding tightening technological parameters according to the types of the bolts;
step 2: placing a tray provided with a screwed motor, a mounting plate and a fastening bolt of the screwed motor on a conveyor belt, starting the conveyor belt to run, and enabling the motor and the fastening device above the tray to move along with the conveyor belt; simultaneously, a photoelectric sensor is started to detect the material tray;
step 3: when the charging tray triggers the photoelectric sensor, the blocking cylinder acts and extends out to block the charging tray, meanwhile, the operation of the conveyor belt is stopped, the action of the clamping cylinder is triggered, and the charging tray is clamped;
Step 4: after receiving a signal from a robot that a clamping cylinder acts in place, a computer triggers a camera to photograph a screwed motor, a mounting plate and a fastening bolt of the screwed motor on a conveyor belt, invokes an image processing program to process a photographed image, and finally, the computer sends a processing result, namely a central point position of the bolt to be screwed to the robot;
step 5: the robot moves to the corresponding bolt with the tightening tool to carry out tightening treatment and sends tightening process data to the computer in a serial port communication mode;
step 6: the computer draws a tightening process curve according to the tightening data and displays the tightening result;
step 7: judging whether the tightening task reaches the expected tightening requirement according to the tightening data, if so, jumping to a step 12, and judging whether the tightening task is completed; if the expected tightening requirement is not met, the flow jumps to step 8, and whether the screw tightening defect exists is judged;
step 8: judging whether a screw tightening defect exists according to the torque variation trend in the tightening data, if so, jumping to a step 11, and displaying and recording abnormal tightening information; if the screw tightening defect does not exist, the flow jumps to step 9, and the tightening tool performs secondary tightening treatment on the bolt;
Step 9: the computer sends a re-tightening signal, and the tightening tool performs secondary tightening treatment on the bolt;
step 10: judging whether the tightening times exceeds 3 times, if so, judging that the tightening is abnormal, jumping to the step 11 to display and record abnormal tightening information; if the tightening times are not more than 3 times, the flow jumps to step 6, and whether the expected tightening requirement is met is judged again;
step 11: displaying the abnormal tightening result and recording corresponding abnormal tightening information;
step 12: judging whether all the bolt tightening tasks are completed according to the statistics of the number of the bolts which are subjected to tightening processing by the computer, and if all the bolt tightening tasks are completed, jumping the flow to the step 13; if the tightening tasks of all the bolts are not completed, the flow jumps to step 2, and the conveyor belt is restarted;
step 13: the tightening task is completed, the robot performs zero-point motion, the camera stops photographing, and the process is finished.
7. The method for controlling a screw tightening device based on visual positioning according to claim 6, wherein the step of the control system drawing a tightening process curve based on the tightening information and displaying and storing the tightening result further comprises:
The computer in the control system judges whether the expected tightening requirement is met according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the bolts which are subjected to tightening processing to judge whether all the tightening tasks of the bolts to be tightened are completed, if the tightening tasks of all the bolts are completed, the robot performs zero-return movement, the camera measurement module stops photographing, and the process is finished;
if the expected tightening requirement is not met, judging whether a screw tightening defect exists or not;
if the tightening defect does not exist, a computer in the control system controls the tightening tool to realize secondary tightening treatment on the bolt;
if the screw tightening defect exists, the computer in the control system displays and records abnormal tightening information.
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