CN115092592A - A special steel sample bar robot intelligent flaw detection method and system - Google Patents

Abstract

The invention discloses an intelligent flaw detection method and system for a special steel sample bar robot, wherein the method comprises the following steps of S100: acquiring continuous work or MES system production change requirements, and sending a sample bar ex-warehouse flaw detection instruction by a production line main control computer based on the roller conveying line state; s200: the multiplying-fortune controller receives an instruction from a production line general control computer, controls the multi-degree-of-freedom low-delay sample rod access unit to accurately move to the coordinate position of a sample rod to be detected, receives the instruction from the production line general control computer and controls the composite mechanical arm to realize the grabbing and storing of the sample rod; receiving an instruction from a production line general control computer, and controlling the operation of the roller conveying line through a roller conveying line controller; receiving an instruction from a production line main control computer and controlling a flaw detector to carry out automatic flaw detection on the sample bar through a flaw detector controller; s300: and after the calibrated flaw detection is finished, the multi-freedom-degree low-delay sample rod storing and taking unit stores the sample rods again. The invention realizes the low-delay warehouse-out, automatic flaw detection and intelligent warehouse assembly line control of the concurrency of multiple sample rods.

Description

A special steel sample bar robot intelligent flaw detection method and system

technical field

The invention belongs to the technical field of robot automatic heavy-load handling, and more particularly relates to a special steel sample bar robot intelligent flaw detection method and system.

Background technique

Special steel is also called alloy steel. An appropriate amount of one or several alloying elements is added to carbon steel to change the structure of the steel, so that the steel has various special properties, such as high strength, hardness, good plasticity, toughness, wear resistance, resistance corrosion, and many other good properties. After the special steel sample bar is smelted and formed in a high temperature furnace, it needs to be tested for flaw detection to ensure that its quality meets the special mechanical properties.

At present, the flaw detection of special steel samples relies on imported equipment, which needs to be re-calibrated every 4 hours, or for special steel samples of different batch numbers and models, it needs to be re-calibrated. The time limit for flaw detection of steel sample bars is very high. The traditional method mainly relies on truss trucks supplemented by manual methods to frequently take out or store special steel sample bars in the special steel sample bar storage warehouse. , Different batches, different models, storage areas, and pick-and-place sequences are not the same as the technical requirements for flaw detection control of special steel sample bars under multi-factor coupling conditions, and special steel sample bars are generally overweight, extremely labor-intensive, and there are many unsafe factors .

SUMMARY OF THE INVENTION

In view of the above defects or improvement needs of the prior art, the present invention provides an intelligent flaw detection control method and system for special steel sample bars. Sample related information, such as sample batch, model, specification, flaw detection requirements, storage coordinates, etc., are sent to the multi-DOF low-latency sample access unit, bidirectional sample conveying unit and sample flaw detection unit. The control instruction controls the multi-degree-of-freedom and low-latency sample rod access unit to move precisely to the coordinate position of the sample rod to be tested, and then grab the sample rod and leave the warehouse. The sample rods captured by the multi-DOF low-latency sample rod storage unit are transported to the sample rod flaw detection unit for calibration and flaw detection. The sample bar access unit grabs and stores it in the sample bar storage unit, and operates in a continuous cycle to realize intelligent data retrieval, calculation, and instruction issuance of special steel sample bars, and realize multiple bar concurrent low-latency delivery, automatic flaw detection, and storage. The intelligent control of the assembly line solves the flaw detection of a large number of special steel samples, different batches, different models, storage areas, and pick-and-place sequences under the coupling conditions of multiple factors within a very short time interval of the traditional method. Control technical problems.

In order to solve the above problems, according to one aspect of the present invention, a robot intelligent flaw detection method for special steel sample bars is provided, comprising the following steps:

S100: Obtain continuous work or MES system production change requirements, and the production line master control computer will send the sample rod out-of-warehouse flaw detection instruction based on the status of the roller conveyor line;

S200: The Beckhoff controller receives the instructions from the production line master control computer and controls the multi-degree-of-freedom low-latency sample bar access unit to precisely move to the coordinate position of the sample bar to be tested, receives the instructions from the production line master control computer and controls the composite The robotic arm realizes the grasping and depositing of the sample rod; receives the instructions from the production line master control computer to control the operation of the roller conveyor line through the roller conveyor line controller; receives the instructions from the production line master control computer and passes the flaw detector. The controller controls the flaw detector to perform automatic flaw detection on the sample rod;

S300: After the calibration flaw detection is completed, the production line master control computer controls the roller conveyor line to reverse transport to the vicinity of the multi-degree-of-freedom and low-latency sample rod access unit to trigger the limit switch to stop the roller conveyor line, and at the same time, the blocking baffle rises to prevent The sample rod moves forward, the multi-DOF and low-latency sample rod access unit restocks the sample rod, the multi-DOF low-latency sample rod access unit and the blocking baffle are reset, the roller transfer line and the flaw detector resume operation, and the bus control computer Control the production line to resume normal bar finishing and flaw detection operations.

Further, in step S100, it specifically includes:

S101: The production line master control computer starts the sample bar automatic calibration program through the calibration of the flaw detection sample bar, triggered by the MES system production change command or the command information that the internal timer of the flaw detector continuously accumulates the calibration time to four hours;

S102: For the automatic calibration of production change, the master control computer of the production line needs to match the sample bar model to be calibrated in the sample bar database according to the bar information of MES replacement production. After matching and obtaining the best sample bar model, the general control The computer starts the automatic calibration process operation;

S103: For the case where the continuous cumulative working time reaches four hours, the production line master control computer calls the current production bar information to match the sample bar model to be calibrated in the sample bar database. After matching and obtaining the best sample bar model, the total control control The computer starts the automated calibration process job.

Further, in step S200, it specifically includes:

S201: Sample bar delivery: The production line control computer or the on-site control computer sends an instruction to the Beckhoff controller through the Ethernet interface to take the XX-numbered flaw detection sample bar from the bar stock library, and the Beckhoff controller calls the sample bar model after receiving the instruction. Database, check the specific position of No. XX flaw detection sample bar corresponding to this command in the bar stock library, and call the motion control subroutine of the sample bar of this type of sample bar of the robot system, and finally issue commands to the servo driver to control the functional components of the robot The action completes the corresponding operation and realizes the sample rod out of the warehouse;

S202: Sample bar unloading operation: After the flaw detection sample bar is out of the warehouse, the robot transports the flaw detection sample bar to the roller conveyor line of the flaw detector according to the pre-edited path. After the blanking is completed, the robot returns to the standby position and waits for the sample bar Inventory operation instructions.

Further, in step S300, it specifically includes:

S301: Sample bar storage operation: After the sample bar flaw detection and calibration is completed, the production line master control computer or on-site control calculation sends the XX sample bar storage command to the Beckhoff controller, and the Beckhoff controller calls the sample bar after receiving the command. Model database, check the position of the sample bar corresponding to the command in the sample bar three-dimensional warehouse, and call the multi-degree-of-freedom and low-latency sample bar access unit. The driver controls the functional parts of the robot to move in sequence to each station and complete the corresponding operations;

S302: During the calibration process of the sample bar, the production line master control computer needs to judge whether there is a bar on the roller conveyor line according to the pressure sensor and proximity sensor information sent by the roller conveyor line controller. After testing and judging that there is no bar, the production line master control computer sends control instructions to coordinate the work of the roller conveyor line, the special steel sample bar pick-and-place robot and the flaw detector, and complete the calibration of the flaw detector;

S303: The robot transports the flaw detection sample bar back to the corresponding position in the bar stock library to complete the sample bar storage operation. After the storage operation is completed, the robot reaches the initial position and waits for a new command.

According to another aspect of the present invention, a special steel sample bar robot intelligent flaw detection system is provided, comprising a sample bar storage unit, a multi-degree-of-freedom low-latency sample bar access unit matched with the sample bar storage unit, The two-way sample bar conveying unit at one end of the sample bar storage unit, the sample bar flaw detection unit located at the next station of the two-way sample bar conveying unit, and the multi-degree-of-freedom low-latency sample bar access unit, the two-way sample bar The production line master control unit that communicates with the conveying unit and the sample inspection unit. The production line master control unit calls the inspection sample database to retrieve sample information consistent with the current sample specifications, and obtain sample related information such as sample batch and model. , specifications, flaw detection requirements, storage coordinates, and concurrently control commands to the multi-DOF low-latency sample bar to access the single- and bi-directional sample bar conveying unit and sample bar flaw detection unit to control the multi-DOF low-latency sample bar The access unit moves precisely to the coordinate position of the sample rod to be tested, and then grabs the sample rod accurately and then leaves the warehouse. The sample rods are transported to the sample rod flaw detection unit for calibration and flaw detection. After the flaw detection is completed, the sample rods are successively transported back through the two-way sample rod conveying unit, and are captured and stored in the sample rod storage unit by the multi-degree-of-freedom and low-latency sample rod access unit. , and successively operate in a continuous cycle to realize intelligent data retrieval, calculation, and instruction issuance of special steel sample bars, and realize multiple bar concurrent low-latency out of the warehouse, automatic flaw detection, and intelligent control of the warehouse assembly line.

Further, the sample rod storage unit includes a foundation knot, a column assembly disposed on the foundation structure, and a sample rod library disposed between the foundation structure and the column assembly;

Further, the multi-degree-of-freedom low-latency sample rod access unit is matched with the sample rod access unit, and it includes a horizontal X-direction motion module arranged on the top side of the sample rod library, and a sample rod set on the sample rod. A Y-direction motion module on the other side of the top of the library, and a horizontal motion carrier board assembly respectively disposed on the X-direction motion module and the Y-direction motion module, the X-direction motion module, the Y-direction motion module, the composite robotic arm and the At least one servo motor is provided on the end holding tool.

Further, the multi-degree-of-freedom and low-latency sample rod access unit includes a composite manipulator connected to the horizontal motion carrier plate assembly, and the composite manipulator includes a vertical telescopic module, and a an attitude adjustment module and an end clamping tool arranged at one end of the vertical telescopic module.

Further, the bidirectional sample rod conveying unit includes a roller conveying line arranged between the sample storage unit and the sample rod flaw detection unit, and a pressure sensor and a proximity sensor arranged on the roller conveying line.

Further, the production line master control unit includes MES system computer, other production line equipment controllers, production line master control computer, roller conveyor line controller, flaw detector controller, Beckhoff controller, and X-direction motion modules, The servo connected to the servo electrical communication on the Y-direction motion module, the composite manipulator and the end-holding tool.

In general, compared with the prior art, the above technical solutions conceived by the present invention can achieve the following beneficial effects:

1. In the method of the present invention, the production line master control unit calls the flaw detection sample bar database to retrieve the sample bar information consistent with the current sample bar specifications, and obtains sample bar related information, such as sample bar batch, model, specification, flaw detection requirements, storage coordinates and other information, and issue control instructions to the multi-DOF low-latency sample access unit, bidirectional sample transfer unit, and sample flaw detection unit to control the multi-DOF low-latency sample access unit to move precisely to After the flaw detection sample rod is accurately grasped at its coordinate position, the sample rod is released from the warehouse. The two-way sample rod conveying unit will be in place after receiving the instruction, and the sample rod grasped by the multi-degree-of-freedom and low-latency sample rod storage unit will be transported to the sample rod. The flaw detection unit performs calibration and flaw detection. After the flaw detection is completed, the sample rods are successively transported back through the two-way sample rod conveying unit, and are captured and stored in the sample rod storage unit by the multi-degree-of-freedom and low-latency sample rod storage unit, and the continuous cycle operation in turn. Realize intelligent data retrieval, calculation, and instruction issuance of special steel sample bars, realize multiple bar concurrent low-latency out of warehouse, automatic flaw detection, and intelligent control of warehouse assembly line, which solves the problem of the traditional method in a very short time interval, a large number of special steel The technical problem of flaw detection control of special steel sample bars under the condition of multi-factor coupling of sample bars, different batches, different models, storage areas, and pick-and-place sequences are all different.

2. In the method of the present invention, the Beckhoff controller communicates with the multi-channel servo drives respectively through the bus. One is to receive the instructions from the production line master control computer and control the multi-degree-of-freedom and low-latency sample rod access unit to move accurately to the point to be tested. The coordinate position of the sample rod, the second is to receive the instructions from the production line master control computer and control the composite manipulator to grasp and store the sample rod; the third is to receive the instructions from the production line master control computer through the roller conveyor line controller Control the operation of the roller conveyor line; the fourth is to receive the instructions from the production line master control computer and control the flaw detector to perform automatic flaw detection on the sample rod through the flaw detector controller. This cycle realizes the multi-threaded complex sample rod flaw detection line. To ensure the intelligent operation of the entire production line.

3. The method of the present invention realizes large-scale movement in the horizontal direction through the multi-degree-of-freedom and low-latency sample bar access unit structure, which can cover the entire range of the entire bar stock library where the entire flaw detection sample bar is placed in the horizontal direction, and can be adjusted according to the The distance between the two composite manipulators can be adjusted according to the length of the flaw detection sample rod, so as to adjust the grasping position of the flaw detection sample rod; through the control of the telescopic arm, the desired flaw detection sample rod can be reached by the end gripper in the vertical direction. The position of the material warehouse; the attitude adjustment of the end clamping mechanism is realized by the attitude adjustment of the mechanical arm with two degrees of freedom, and the grasping operation of the flaw detection sample rod is realized with the optimal attitude; finally, the grasping operation of the flaw detection sample rod is realized through the end clamping mechanism fetch operation.

4. The method of the present invention is based on a double-arm collaborative robot system designed based on the multi-degree-of-freedom and low-latency sample rod access unit structure. It is connected to the production line control system for unified control to realize the automatic operation of picking and placing flaw detection samples.

5. The method of the present invention, on the one hand, can reduce the labor intensity of workers, avoid the safety problem of manual operation, and can control the robot to perform automatic operation on the on-site operation console or the general control room of the production line, on the other hand, it can greatly improve the Work efficiency, and due to the structural flexibility of this series, more flaw detection samples can be placed in the same space, saving work space.

Description of drawings

Fig. 1 is a kind of special steel sample rod robot intelligent flaw detection system composition structure schematic diagram according to the embodiment of the present invention;

2 is a schematic structural diagram of a special steel sample rod robot according to an embodiment of the present invention;

3 is a schematic diagram of the composition of a control unit of a special steel sample rod robot intelligent flaw detection system according to an embodiment of the present invention;

4 is a schematic diagram of a control flow of an intelligent flaw detection system for a special steel sample rod robot according to an embodiment of the present invention;

5 is a schematic flowchart of the automatic calibration process of a flaw detection sample rod for continuous production of special steel sample rods by a special steel sample rod robot according to an embodiment of the present invention;

6 is a schematic diagram of the automatic calibration process flow of a special steel sample bar robot for special steel bar material replacement according to an embodiment of the present invention;

In all drawings, the same reference numerals represent the same technical features, specifically: 1- foundation structure, 2- multi-degree-of-freedom low-latency sample access unit, 3- roller conveyor line, 4- flaw detector , 5-column assembly, 6-sample bar library, 7-horizontal X-direction motion module, 8-horizontal Y-direction motion module, 9-horizontal motion carrier plate assembly, 10-vertical telescopic module, 11-attitude adjustment module, 12 -End gripping tool.

Detailed ways

In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, but not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

As shown in FIG. 1 and FIG. 2 , an embodiment of the present invention provides a special steel sample rod robot intelligent flaw detection system, which includes a sample rod storage unit, a multi-degree-of-freedom and low-latency sample rod storage unit matched with the sample rod storage unit. Taking unit 2, a two-way sample rod conveying unit located at one end of the sample rod storage unit, a sample rod flaw detection unit set at the next station of the two-way sample rod conveying unit, and the multi-degree-of-freedom low-latency sample rod The access unit 2, the two-way sample rod conveying unit and the sample rod flaw detection unit are communicatively connected to the production line master control unit. Among them, the general control unit of the production line calls the flaw detection sample bar database to retrieve the sample bar information that is consistent with the current sample bar specifications, and obtains sample bar related information, such as sample bar batch, model, specification, flaw detection requirements, storage coordinates, etc. The multi-DOF low-latency sample access unit 2, the two-way sample transfer unit and the sample flaw detection unit have concurrent control instructions to control the multi-DOF low-latency sample access unit to move precisely to the sample to be tested. After the sample rod is accurately grasped at the coordinate position, the two-way sample rod conveying unit is in place after receiving the instruction, and the sample rod grasped by the multi-degree-of-freedom and low-latency sample rod access unit 2 is transported to the sample rod flaw detection unit for processing. Calibration and flaw detection, after the flaw detection is completed, the sample rods are successively transported back through the two-way sample rod conveying unit, and are captured and stored in the sample rod storage unit by the multi-degree-of-freedom and low-latency sample rod access unit 2, and the continuous cycle operation is performed in turn to achieve special characteristics. The intelligent data retrieval, calculation, and instruction issuance of steel sample bars realize concurrent low-latency delivery of multiple bars, automatic flaw detection, and intelligent control of the warehouse assembly line, which solves the problem of a large number of special steel sample bars in a very short time interval by traditional methods. , Different batches, different models, storage areas, and pick-and-place sequences are not the same as the technical problems of special steel sample bar flaw detection control under multi-factor coupling conditions.

As shown in FIG. 1 and FIG. 2 , the sample storage unit includes a foundation structure 1 , a column assembly 5 arranged on the foundation structure 1 , and a sample warehouse 6 arranged between the foundation structure 1 and the column assembly 5 . The multi-degree-of-freedom and low-latency sample rod access unit 2 is matched with the sample rod access unit, and includes a horizontal X-direction motion module 7 arranged on the top side of the sample rod library 6, and a The Y direction motion module 8 on the other side of the top of the library 6, and the horizontal motion carrier board assembly 9 respectively provided on the X direction motion module 7 and the Y direction motion module 8, are connected with the horizontal motion carrier board assembly 9. The composite manipulator includes a vertical telescopic module 10 , an attitude adjustment module 11 disposed on the vertical telescopic module 10 , and an end clamping tool 12 disposed at one end of the vertical telescopic module 10 . The X-direction motion module 7 cooperates with the horizontal-direction carrier plate assembly 9 to realize precise movement of the composite manipulator in a large range in the horizontal direction to the coordinate position of the corresponding sample rod. Further, at least one servo motor is provided on the X-direction movement module 7 , the Y-direction movement module 8 , the composite mechanical arm and the end clamping tool 12 . Preferably, the composite mechanical part is provided with a plurality of parts, which can simultaneously realize the simultaneous grabbing and outgoing work of different samples, blanking, and the grabbing and storage of samples after flaw detection. In addition, the posture adjustment module includes two rotational degrees of freedom, such as rotating along the X direction and the Y direction, so as to adjust the posture of the end clamping tool 12, and at the same time adjust the vertical position of the end clamping tool 12 with the vertical telescopic module 10, Accurate grasping of sample rods is achieved. Preferably, the end gripping tool 12 is an envelope gripping structure, which can adaptively grip the cylindrical section plate, and the gripping mechanism is in a locked state during the gripping operation to ensure the sample rod during the gripping operation. Will not fall off.

As shown in Figure 1, the two-way sample rod conveying unit includes a roller conveyor line 3 arranged between the sample plate storage unit and the sample rod flaw detection unit, and a pressure sensor and a proximity sensor arranged on the roller conveyor line 3, By collecting the pressure sensor and contact sensor information on the roller conveyor line, it is judged whether there are any bars on the roller conveyor line; if there are bars, the roller conveyor line will continue to work until all the bars are conveyed; if no bars or bars are conveyed Completed, the production line master control computer directly controls the roller conveyor line to stop working.

As shown in Figure 1, the sample rod flaw detection unit includes a press flaw detector 4 and ancillary structural components (not shown in the figure). After the production line master control computer receives the instruction, it sends an instruction to control the roller conveyor to start the work of conveying the sample rod. , and send an instruction to the flaw detector to start the flaw detector calibration program, and the roller conveyor line sends the sample rod to the flaw detector for flaw detection and calibration.

As shown in Figure 3 and Figure 4, the production line general control unit includes MES system computer, other production line equipment controllers, production line general control computer, roller conveyor line controller, flaw detector controller, Beckhoff controller, and A servo connected in electrical communication with the servo on the X-direction motion module 7 , the Y-direction motion module 8 , the composite manipulator and the end-holding tool 12 . Among them, MES system is also called Manufacturing Execution System (Manufacturing Execution Systems, MES) is defined as "Manufacturing Execution System transmits information to optimize the production process from order to finished product". The production line master control computer, the special steel sample rod robot intelligent flaw detection system adopts a centralized control method, and the production line master control computer communicates with the Beckhoff controller of the flaw detection sample rod pick and place robot, the roller conveyor line controller and the flaw detection through the Ethernet interface. The machine controller communicates and controls, and the communication protocol is TCP/IP or UDP protocol. The Beckhoff controller communicates with the multi-channel servo drives respectively through the bus, as shown in Figure 3, in one embodiment, the servo drive 1 communicates with the servo motor 1; the servo drive 2 communicates with the servo motor 2; the servo drives 3, 4 and 5 communicates with servo motors 3, 4 and 5 respectively; servo driver 6 communicates with servo motor 6; servo drivers 7, 8 and 9 communicate with servo motors 7, 8 and 9 respectively; servo driver 10 communicates with servo motor 10, and at the same time, The servo drives 1, 2, 3...10 communicate with the Beckhoff controller through the bus respectively, and the Beckhoff controller communicates with the proximity sensor/limit switch through the I/O switch. The servo drive and the proximity sensor, limit switch and other I/O are controlled centrally. Real-time bus is used between Beckhoff controller and servo drive to exchange control instructions and data information, such as EtherCAT bus, PROFINET bus, CANOpen bus, one is to receive instructions from the production line master control computer and control multiple degrees of freedom and low latency The sample bar access unit precisely moves to the coordinate position of the sample bar to be tested. The second is to receive the instructions from the production line master control computer and control the composite manipulator to grasp and store the sample bars. The third is to receive instructions from the production line master control. The instructions of the computer control the operation of the roller conveyor line through the roller conveyor line controller; the fourth is to receive the instructions from the production line master control computer and control the flaw detector to perform automatic flaw detection on the sample rod through the flaw detector controller. Precise control of the flaw detection line for complex sample rods ensures the intelligent operation of the entire production line.

Based on the above embodiment as shown in FIG. 4 , an embodiment of the present invention provides a method for storing and transporting a special steel sample rod by a special steel sample rod robot, comprising the following steps:

S100: Obtain the demand for continuous work or MES system production change, and the master control computer of the production line sends the sample bar out-of-warehouse instruction to the multi-degree-of-freedom and low-latency sample bar access unit 2 based on the state of the roller conveying line;

S200: Beckhoff controller accepts the command and controls the multi-degree-of-freedom and low-latency sample bar access unit 2 to transport the sample bar, complete the work of unloading and unloading, and place the sample bar on the roller conveyor line 3. The total production line The control computer controls the roller conveyor line 3 to be transported to the flaw detector 4 for calibration flaw detection;

S300: After the calibration flaw detection is completed, the production line master control computer controls the roller conveyor line 3 to reverse transport to the vicinity of the multi-degree-of-freedom and low-latency sample rod access unit 2 to trigger the limit switch, stop the roller conveyor line 3, and block the baffle from rising. To prevent the sample rod from advancing, the multi-DOF and low-latency sample rod access unit 2 restocks the sample rod, the multi-DOF low-latency sample rod access unit 2 and the blocking baffle are reset, and the roller transfer line and the flaw detector resume operation. , The bus control computer controls the production line to resume normal bar finishing and flaw detection operations.

Further, in step S100, it specifically includes:

S101: The production line master control computer starts the sample bar automatic calibration program through the calibration of the flaw detection sample bar, triggered by the MES system production change command or the command information that the internal timer of the flaw detector continuously accumulates the calibration time to four hours;

S102: For the automatic calibration of production change, the master control computer of the production line needs to match the sample bar model to be calibrated in the sample bar database according to the bar information of MES replacement production. After matching and obtaining the best sample bar model, the general control The computer starts the automatic calibration process operation;

S103: For the case where the continuous cumulative working time reaches four hours, the production line master control computer calls the current production bar information to match the sample bar model to be calibrated in the sample bar database. After matching and obtaining the best sample bar model, the total control control The computer starts the automated calibration process job.

Further, in step S200, it specifically includes:

S201: Sample bar delivery: The production line control computer (or on-site control computer) sends the Beckhoff controller an instruction to fetch No. XX flaw detection sample bar from the bar stock library through the Ethernet interface. After receiving the command, the Beckhoff controller calls the sample bar model database to check the specific position of the XX No. flaw detection sample bar corresponding to the command in the bar stock library, and calls the motion control subroutine of the robot system for the sample bar sampling operation of this model. , and finally issue an instruction to the servo drive to control the action of each functional component of the robot to complete the corresponding operation, so as to realize the sample rod out of the warehouse;

S202: Sample bar unloading operation: After the flaw detection sample bar is out of the warehouse, the robot transports the flaw detection sample bar to the roller conveyor line of the flaw detector according to the pre-edited path. After the blanking is completed, the robot returns to the standby position and waits for the sample rod storage operation instruction.

Further, in step S300, it specifically includes:

S301: Sample bar storage operation: After the sample bar flaw detection and calibration are completed, the production line master control computer (or on-site control computer) sends the XX sample bar storage command to the Beckhoff controller, and the Beckhoff controller calls after receiving the command. Sample bar model database, check the position of the sample bar corresponding to the command in the sample bar three-dimensional warehouse, and call the multi-degree-of-freedom low-latency sample bar access unit motion control subroutine of the sample bar storage operation of this model, and issue the command Give the servo drive to control the functional parts of the robot to move in sequence to each station and complete the corresponding operations;

S302: During the calibration process of the sample bar, the production line master control computer needs to judge whether there is a bar on the roller conveyor line according to the pressure sensor and proximity sensor information sent by the roller conveyor line controller. After testing and judging that there is no bar, the production line master control computer sends control commands to coordinate the work of the roller conveyor line, the special steel sample bar pick-and-place robot, and the flaw detector to complete the calibration of the flaw detector.

S303: The robot transports the flaw detection sample bar back to the corresponding position in the bar stock library to complete the sample bar storage operation. After the storage operation is completed, the robot reaches the initial position and waits for a new command.

Example 1:

As shown in Figure 5, in one embodiment of the present invention, a kind of automatic flaw detection method of flaw detection sample rod for continuous production of special steel is provided, comprising the following steps:

(1) The flaw detector controller keeps timing through the internal clock, and the flaw detector controller continuously counts to judge whether it has been working continuously for 4 hours, if so, it controls the flaw detector to continue to work; if not, it passes the bus or I/O interface every 4 hours. Send the information to be calibrated to the production line master control computer;

(2) After receiving the information to be calibrated, the production line master control computer separates the roller conveyor line of the bar flaw detection part from the control of other parts of the production line, and judges the roller conveyor line by collecting the pressure sensor and contact sensor information on the roller conveyor line. Check whether there are still bars on it; if there are bars, the roller conveying line will continue to work until all bars are conveyed; if no bars or bars are conveyed, the production line master control computer directly controls the roller conveying line to stop working;

(3) The general control computer of the production line calls the flaw detection sample bar database to retrieve the sample bar information consistent with the current bar specifications, and obtain the relevant information of the sample bar;

(4) The production line computer sends the out-of-warehouse instruction for the xx type sample rod to the special steel sample rod pick-and-place robot. After receiving the control instruction from the production line computer, the Beckhoff controller calls the operation program of the sample rod in its instruction database and implement;

(5) The Beckhoff controller controls the motion of each joint of the robot to reach the position in the storage library where the sample rod is located according to the program. The Beckhoff controller controls the two sets of clamping mechanisms at the end to move at the same time through the servo bus to complete the grasping work of the sample rod. After the picking is completed, the Beckhoff controller controls the robot to transport the sample rod to the roller conveyor line through the servo bus, and the end clamping mechanism releases the clamping state of the sample rod, and the special steel sample rod picking and placing robot moves to the standby position. Wait for the next instruction from the Beckhoff controller;

(6) After the standby action of the special steel sample rod picking and placing robot is completed, the Beckhoff controller sends the sample rod unloading completion instruction to the production line master control computer. After the production line master control computer receives the instruction, it sends the instruction to control the drum output. Start the work of conveying the sample rod, and send an instruction to the flaw detector to start the calibration procedure of the flaw detector;

(7) The roller conveying line sends the sample rod to the flaw detector for flaw detection and calibration. After the flaw detector calibration is completed, it sends an instruction to the production line master control computer. After the production line master control computer receives the flaw detection completion instruction, it sends a control instruction Feed the roller conveyor line and control the reversal of the roller conveyor line, that is, the sample rods are transported in reverse;

(8) When the roller conveyor line transports the sample rod to the position of the special steel sample rod pick and place robot, the limit switch is triggered, and the production line master control computer immediately stops the movement of the roller conveyor line after receiving the limit signal, and blocks the action of the baffle Raise and block the advance of the sample rod;

(9) After the roller conveyor line stops, the production line master control computer sends instructions to the special steel sample bar pick and place robot. After the special steel sample bar pick and place robot receives the instruction, it will clamp the sample bar on the roller conveyor line, and put the sample bar on the roller conveyor line. The sample bar is transported back to the sample bar warehouse. After the sample bar is stored in the warehouse, the special steel sample bar pick-and-place robot returns to the initial position, and sends the sample bar has been put into the warehouse instruction to the production line master control computer;

(10) The production line master control computer issues instructions to restore the roller conveyor line to normal working state, sends instructions to the flaw detector controller, calls the steel flaw detection work program and runs it, and realizes the joint operation of the special steel finishing operation and production line.

Example 2:

As shown in FIG. 6 , another embodiment of the present invention provides an automatic flaw detection method for a flaw detection sample bar for changing production of a special steel bar, including the following steps:

(1) The MES system of the special steel production line issues a production change instruction to the production line master control computer, and the production line master control computer stops the work of the entire production line after all processes are completed after receiving the instruction;

(2) The main control computer of the production line retrieves the sample bar information that matches the current bar specification in the flaw detection sample bar database according to the MES system production change information and the steel specifications and requirements.

(3) The production line computer sends the retrieved out-of-warehouse instruction for the sample bar No. XX to the special steel sample bar pick-and-place robot. After receiving the control command from the production line computer, the Beckhoff controller calls the sample bar's instruction database. Run the program and execute it. The Beckhoff controller controls the movement of each joint of the robot according to the program to reach the position in the storage library where the sample rod is located. The Beckhoff controller controls the two sets of clamping mechanisms at the end to move at the same time through the servo bus to complete the grasping of the sample rod. , After the grasping is completed, the Beckhoff controller controls the robot to transport the sample rod to the roller conveyor line through the servo bus, and the end clamping mechanism releases the clamping state of the sample rod, and the special steel sample rod picking and placing robot moves to standby position, waiting for the next command from the Beckhoff controller;

(4) After the standby action of the special steel sample bar pick-and-place robot is completed, the Beckhoff controller sends the sample bar unloading completion instruction to the production line master control computer. Start the work of conveying the sample rod, and send an instruction to the flaw detector to start the calibration procedure of the flaw detector;

(5) The roller conveyor line sends the sample rod to the flaw detector for flaw detection and calibration. After the flaw detector calibration is completed, it sends instructions to the production line master control computer;

(6) After the production line master control computer receives the instruction to complete the flaw detection, it sends a control instruction to the roller conveyor line, and controls the reverse rotation of the roller conveyor line, that is, the sample bar is transported in reverse, and the roller conveyor line transports the sample bar to the special steel. When the sample rod pick and place robot is near the position, the limit switch is triggered, and the production line master control computer immediately stops the movement of the roller conveyor line after receiving the limit signal, and the blocking baffle moves up and blocks the progress of the sample rod;

(7) After the roller conveyor line stops moving, the production line master control computer sends an instruction to the special steel sample bar pick and place robot. After the special steel sample bar pick and place robot receives the instruction, it clamps the sample bar on the roller conveyor line, and puts the sample bar on the roller conveyor. The sample bar is transported back to the sample bar warehouse. After the sample bar is stored in the warehouse, the special steel sample bar pick-and-place robot returns to the initial position, and sends the sample bar has been put into the warehouse instruction to the production line master control computer;

(8) The production line master control computer issues instructions to restore the roller conveyor line to normal working state, sends instructions to the flaw detector controller, calls the steel flaw detection work program and runs it, and realizes the joint operation of the special steel finishing operation and production line.

Those skilled in the art can easily understand that the above are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, etc., All should be included within the protection scope of the present invention.

Claims (10)

1. An intelligent flaw detection method for a special steel sample bar robot is characterized by comprising the following steps:

s100: acquiring continuous work or MES system production change requirements, and sending a sample bar ex-warehouse flaw detection instruction by a production line main control computer based on the roller conveying line state;

s200: the multiplying-fortune controller receives an instruction from a production line general control computer, controls the multi-degree-of-freedom low-delay sample rod access unit to accurately move to the coordinate position of a sample rod to be detected, receives the instruction from the production line general control computer and controls the composite mechanical arm to realize the grabbing and storing of the sample rod; receiving an instruction from a production line general control computer, and controlling the operation of the roller conveying line through a roller conveying line controller; receiving an instruction from a production line general control computer and controlling a flaw detector to carry out automatic flaw detection on the sample bar through a flaw detector controller;

s300: after the calibration flaw detection is completed, the production line general control computer controls the roller conveying line to reversely convey to the position near the multi-freedom-degree low-delay sample rod access unit to trigger the limit switch, the roller conveying line is stopped, the blocking baffle plate rises to prevent the sample rod from advancing, the multi-freedom-degree low-delay sample rod access unit puts the sample rod into a warehouse again, the multi-freedom-degree low-delay sample rod access unit and the blocking baffle plate reset, the roller conveying line and the flaw detector resume operation, and the bus control computer controls the production line to resume normal rod finishing and flaw detection operation.

2. The intelligent robot flaw detection method for the special steel sample bar according to claim 1, wherein the step S100 specifically comprises:

s101: the production line main control computer starts an automatic calibration program of the sample bar by calibrating the flaw detection sample bar and triggering through an MES system production change instruction or continuously accumulating instruction information of a timer in the flaw detector until the calibration time reaches four hours;

s102: for automatic calibration work of production change, a production line main control computer needs to match a sample rod model needing to be calibrated in a sample rod database according to bar information of MES production change, and after the optimal sample rod model is obtained through matching, the main control computer starts automatic calibration flow operation;

s103: and for the condition that the continuous accumulated working time reaches four hours, calling the information of the currently produced bar by the production line master control computer to match the model of the sample bar to be calibrated in the sample bar database, and after the optimal model of the sample bar is obtained by matching, starting the automatic calibration flow operation by the master control computer.

3. The intelligent robot flaw detection method for special steel sample bars according to claim 2, wherein the step S200 specifically comprises:

s201: taking the sample bar out of the warehouse: a production line control computer or an on-site control computer issues an XX flaw detection sample rod taking instruction from a rod stock library to a Fu controller through an Ethernet interface, the Fu controller calls a sample rod model database after receiving the instruction, checks the specific position of the XX flaw detection sample rod corresponding to the instruction in the rod stock library, calls a motion control subprogram of sampling and ex-warehouse operation of the sample rod of the model of the robot system, and finally issues the instruction to each functional part of a servo driver and a controller to move to complete corresponding operation so as to realize ex-warehouse of the sample rod;

s202: sample rod blanking operation: and after the flaw detection sample rods are delivered out of the warehouse, the robot carries the flaw detection sample rods to a roller conveying line of the flaw detector according to a pre-edited path, and after blanking is completed, the robot returns to a standby position to wait for warehousing operation instructions of the sample rods.

4. The intelligent robot flaw detection method for the special steel sample bars according to any one of claims 1 to 3, characterized in that the step S300 specifically comprises:

s301: and (3) sample rod warehousing operation: after the flaw detection calibration of the sample rod is completed, a production line general control computer or field control calculation sends an XX sample rod warehousing instruction to a Fugu controller, the Fugu controller calls a sample rod model database after receiving the instruction, checks the position of the sample rod corresponding to the instruction in a sample rod three-dimensional warehouse, calls a motion control subprogram of the multi-freedom-degree low-delay sample rod warehousing operation of a sample rod access unit of the model, and sends an instruction to a servo driver to control each functional part of the robot to sequentially move to reach each station and complete corresponding operation;

s302: in the calibration process of the sample rod, the production line general control computer needs to judge whether the rod material exists on the roller conveying line according to the information of the pressure sensor and the proximity sensor sent by the roller conveying line controller. After detecting and judging that no bar exists, the production line main control computer sends a control instruction to coordinate the work of the roller conveying line, the special steel sample bar taking and placing robot and the flaw detector to finish the calibration work of the flaw detector;

s303: and the robot transports the flaw detection sample rod to the corresponding position in the rod stock to finish the warehousing operation of the sample rod. And after the warehousing operation is finished, the robot reaches the initial position and waits for a new instruction.

5. An intelligent robot flaw detection system for special steel sample rods is characterized by comprising a sample rod storage unit, a multi-degree-of-freedom low-delay sample rod access unit (2) matched with the sample rod storage unit, a bidirectional sample rod conveying unit arranged at one end of the sample rod storage unit, a sample rod flaw detection unit arranged at the next step of the bidirectional sample rod conveying unit, and a production line general control unit in communication connection with the multi-degree-of-freedom low-delay sample rod access unit (2), the bidirectional sample rod conveying unit and the sample rod flaw detection unit, wherein the production line general control unit calls a flaw detection sample rod database to search sample rod information consistent with the specification of the current sample rod, obtains sample rod related information such as sample rod batch, model, specification, flaw detection requirements and storage coordinates, and sends control instructions to the multi-degree-of freedom low-delay sample rod access unit (2), the bidirectional sample rod conveying unit and the sample rod flaw detection unit, the multi-freedom-degree low-delay sample rod storing and taking unit is controlled to accurately move to a coordinate position of a sample rod to be detected to accurately grab the sample rod and then take out of a warehouse, the two-way sample rod conveying unit receives an instruction and then takes place, the sample rod grabbed by the multi-freedom-degree low-delay sample rod storing and taking unit (2) is conveyed back through the two-way sample rod conveying unit, the sample rod grabbed by the multi-freedom-degree low-delay sample rod storing and taking unit (2) is grabbed and stored in the sample rod storage unit, continuous and cyclic operation is carried out in sequence, intelligent data calling, calculation and instruction issuing of special steel sample rods are achieved, and the multi-freedom-degree low-delay sample rod storing and taking, automatic detection and intelligent control of a warehouse assembly line are achieved.

6. The special steel sample rod robot intelligent flaw detection system according to claim 5, wherein the sample rod storage unit comprises a foundation structure (1), a stand column assembly (5) arranged on the foundation structure (1), and a sample rod library (6) arranged between the foundation structure (1) and the stand column assembly (5).

7. The special steel sample rod robot intelligent flaw detection system according to claim 6, wherein the multi-degree-of-freedom low-delay sample rod access unit (2) and the sample rod access unit are arranged in a matched manner, and comprise a horizontal X-direction motion module (7) arranged on one side of the top of the sample rod library (6), a Y-direction motion module (8) arranged on the other side of the top of the sample rod library (6), and horizontal motion carrier plate assemblies (9) respectively arranged on the X-direction motion module (7) and the Y-direction motion module (8), wherein at least one servo motor is arranged on each of the X-direction motion module (7), the Y-direction motion module (8), the composite mechanical arm and the tail end clamping tool (12).

8. The special steel sample rod robot intelligent flaw detection system according to claim 7, wherein the multi-degree-of-freedom low-delay sample rod access unit (2) comprises a composite mechanical arm connected with the horizontal motion carrier plate assembly (9), and the composite mechanical arm comprises a vertical telescopic module (10), an attitude adjusting module (11) arranged on the vertical telescopic module (10), and a tail end clamping tool (12) arranged at one end part of the vertical telescopic module (10).

9. The special steel sample bar robot intelligent flaw detection system according to any one of claims 5-8, wherein the bidirectional sample bar conveying unit comprises a roller conveying line (3) arranged between a sample storage unit and a sample bar flaw detection unit, and a pressure sensor and a proximity sensor arranged on the roller conveying line (3).

10. The intelligent robot flaw detection system for special steel sample bars as claimed in claim 7 or 8, wherein the production line general control unit comprises an MES system computer, other production line equipment controllers, a production line general control computer, a roller conveyor line controller, a flaw detector controller, a Beckman controller, and a server which is connected with the X-direction movement module (), the Y-direction movement module (8), the composite mechanical arm and the end clamping tool (12) in servo electrical communication.

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