CN115366118A - Relay detection system and method based on robot and vision technology - Google Patents
Relay detection system and method based on robot and vision technology Download PDFInfo
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- CN115366118A CN115366118A CN202210948522.9A CN202210948522A CN115366118A CN 115366118 A CN115366118 A CN 115366118A CN 202210948522 A CN202210948522 A CN 202210948522A CN 115366118 A CN115366118 A CN 115366118A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1602—Programme controls characterised by the control system, structure, architecture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/01—Subjecting similar articles in turn to test, e.g. "go/no-go" tests in mass production; Testing objects at points as they pass through a testing station
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/327—Testing of circuit interrupters, switches or circuit-breakers
- G01R31/3277—Testing of circuit interrupters, switches or circuit-breakers of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches
- G01R31/3278—Testing of circuit interrupters, switches or circuit-breakers of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches of relays, solenoids or reed switches
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a relay detection system based on a robot and a vision technology, belongs to the technical field of relay detection, and solves the technical problems of large workload and low efficiency of relay detection by manual work; the controller, operation display device, industrial robot, machine vision camera pass through LAN communication connection, and controller, mobile terminal pass through WAN communication connection with high in the clouds server, and industrial robot passes through field bus communication connection with relay testing arrangement, and machine vision camera fixed mounting is on industrial robot, and the two-dimensional code label pastes at the shell of relay, one of them end-to-end anchor clamps of industrial robot's end-to-end connection on industrial robot. The invention also discloses a relay detection method based on the robot and the vision technology.
Description
Technical Field
The invention relates to the technical field of relay detection, in particular to a relay detection system and method based on a robot and a vision technology.
Background
The relay is an important electrical element playing a role in protection and control in a secondary circuit of an industrial control system. In control systems of industries such as electric power, aviation, petroleum, chemical engineering, subway and the like, the relays are widely applied and have huge quantity. In the important industrial fields related to national economic production, the relay directly influences the safe and stable operation of a control system no matter whether the relay is refused to operate, is mistakenly operated or is degraded in performance, and even causes major accidents. Therefore, technicians can regularly check and test the relays in the control system to ensure that various performance parameters of the relays meet the operating standards.
In the prior art, the relay is verified and tested without manual work, and particularly, technical personnel are required to deeply participate in recording and managing the relay verification data.
Taking a hydraulic power plant as an example, the speed regulator, the excitation, the auxiliary machine and the monitoring system relate to hundreds of relays which need to be checked, the construction period is tight, the workload is large, and the efficiency is low. With the development of the technology, some relay checking instruments are available on the market for checking all electrical parameters of the relay at one time, so that the efficiency is improved. The using process is as follows: firstly, the serial number and the model of the current relay are judged manually, then the relay is inserted into the corresponding test base manually, then a technician correctly sets parameters of an instrument according to the model of the current relay, the instrument can automatically measure the coil voltage/resistance, the normally open/normally closed contact resistance, the pull-in/release voltage and other parameters of the relay, the result data of the test is recorded in the position of the serial number of the relay in a fixed inspection record table manually, and finally the relay is pulled out from the test base manually, so that the primary relay is verified.
Compared with the traditional mode of completely manually checking the relay, the prior art improves the working efficiency. There are six problems, however: 1. hundreds of relays are used for overhauling the hydraulic power plant unit, one relay is used for verification, and the working efficiency is still lower. 2. A large number of relays of the same type are present in a power station, a unit, or even a system, and the control function of each relay is different. For the convenience of distinguishing, each relay has a unique number, and the result data of the relay verification must be correctly registered in a regular inspection record table. However, due to repeated/fatigue manual work, the possibility of wrong login and missed login exists, and the work quality is difficult to ensure. 3. The traditional verification method can measure the contact resistance of all contacts of the relay, but each relay does not have all the contacts in actual use, the unused contacts participate in verification, the failure rate of the relay is increased, and the reliability of a control system after fixed inspection is reduced due to the fact that a new relay is replaced due to the fact that a running-in period exists. 4. The functions or action frequencies of different relays in the system are different, so that the fault consequences are different, for example, the fault of some relays can cause a serious accident, and the fault of some relays only can influence the display effect. In order to minimize the checking work time and the maintenance cost and maximize the reliability of the control system, different relays should adopt different maintenance modes. 5. The above 3,4 point is impractical to implement manually. 6. The relay is not fully utilized to check data, and a disc cabinet (system) which can work with diseases is analyzed and checked.
Therefore, it is necessary to provide a full-automatic relay detection method to improve the working efficiency, and the method replaces manual operation in the links of relay number and model judgment, relay plug/unplug, detection parameter setting, data recording, data analysis and the like, and simultaneously integrates a relay personalized maintenance mode, thereby realizing the solution of the whole process unmanned operation of the relay verification work
Disclosure of Invention
The technical problem to be solved by the present invention is to solve the above-mentioned deficiencies of the prior art, and an object of the present invention is to provide a relay detection system based on robot and vision technology, which can improve the measurement accuracy.
The invention also aims to provide a relay detection method based on a robot and a vision technology, which can improve the measurement precision.
In order to achieve the first purpose, the invention provides a relay detection system based on a robot and a vision technology, which comprises a controller, an operation display device, a cloud server, an industrial robot, a machine vision camera, a plurality of end clamps, a relay testing device, a two-dimensional code tag and a mobile terminal, wherein the operation display device is connected with the cloud server;
the controller, the operation display device, the industrial robot and the machine vision camera are connected through local area network communication, the controller is connected with the cloud server through wide area network communication, the mobile terminal is connected with the cloud server through wide area network communication, the industrial robot is connected with the relay testing device through field bus communication, the machine vision camera is fixedly mounted on the industrial robot, the two-dimensional code label is pasted on a shell of the relay, and the end of the industrial robot is connected with one of the end clamps.
As a further improvement, the controller, the operation display device, the industrial robot, the machine vision camera and the relay testing device are arranged on the same workbench, the workbench is provided with a clamp replacing area, a to-be-verified placing area, a qualified area and a unqualified area, and the tail end clamp is stored in the clamp replacing area.
Further, the two-dimensional code label stores information of a model, a serial number, importance, an action frequency and a used contact.
Further, the field bus is any one of an RS232 bus, an RS485 bus, a CAN bus and a USB bus.
Further, the tail end of the industrial robot is connected with a main disc end, the tail end clamp is connected with an auxiliary disc end matched with the main disc end, and the tail end of the industrial robot is connected with the tail end clamp through the main disc end and the auxiliary disc end.
In order to achieve the second objective, the invention provides a relay detection method based on a robot and a vision technology, which comprises the following steps:
pasting a two-dimensional code label with a unique identifier on each relay;
the method comprises the steps of calibrating an industrial robot and a machine vision camera by hands and eyes, and determining a pickup datum point of a relay to be calibrated, a plug-in point position of the calibrated relay on a relay testing device and a placement datum point position of the calibrated relay in a teaching mode;
taking the relay out of a disk cabinet of the control system, then placing the relay in a placement area to be verified, and enabling the two-dimensional code label of the relay to face to the right upper side;
selecting an item to be verified on the operation display equipment, clicking and starting after setting, and sending verification command data to the industrial robot by the controller;
the industrial robot moves to the position right above the placement area to be checked, images of all relays are obtained through a machine vision camera, the positions of all relays are positioned through a vision algorithm, and one relay is selected to be clamped according to the shortest route principle;
the machine vision camera acquires a two-dimensional code label image of the clamped relay, and obtains the model, the serial number, the importance, the action frequency and the information of the used contact of the relay according to the two-dimensional code label image;
the controller designs a relay risk level matrix according to the information of the importance degree and the action frequency recorded by the two-dimensional code, determines the checking times and the qualified standard of the relay, and sends the checking times and the qualified standard to the industrial robot;
the industrial robot inserts the clamped relay into a relay testing device;
according to the model, the importance, the action frequency and the information of the used contact of the relay, the industrial robot sends control data to a relay testing device so as to set correct detection parameters;
the industrial robot sends a starting command to the relay testing device to start the checking relay;
the relay testing device sends the checking data to the industrial robot, and the industrial robot forwards the checking data to the controller;
the controller sends the current verification result to the operation display equipment for display, and sends the current verification data to the cloud server for storage;
after the controller processes the data, the industrial robot pulls the relay out of the relay testing device, and if the verification result is qualified, the relay is placed in a qualified area; otherwise, the relay is placed in the unqualified area; completing the calibration of one relay;
the industrial robot continues to clamp and check the next relay until all relays are checked;
the cloud server intelligently analyzes the check results of all the relays, specifically, for all m disk cabinets of the control system, the check is the T-th regular inspection check from the commissioning of the control system, and the total amount of the relays in the ith disk cabinet is recorded by n i The quantity of the relays which are checked to be unqualified by the coil cabinet is x it And after the control system is put into operation, the accumulated fault rate of the relay in the disk cabinet i is expressed as follows:
the cumulative failure rate of the relays in all the disk cabinets in the whole control system is represented as follows:
finding the disk cabinet i to maximize the ratio of the formula (1) to the formula (2)
And calculating and searching the disk cabinets meeting the formula (3) in the T-2 th and T-1 th regular inspections according to historical data, wherein if the disk cabinets meeting the formula (3) in the T-2 th, T-1 th and T-th regular inspections are the same disk cabinet i
min(η T-2 ,η T-1 ,η T )>2 (4)
The abnormal operation condition in the disk cabinet i is indicated to be abnormal, and special attention and troubleshooting are needed by operation and maintenance personnel, wherein the abnormal operation condition comprises any one of temperature abnormality, humidity abnormality, insulation abnormality and power supply abnormality.
As a further improvement, the risk level matrix, the number of checks and the qualification standard are specifically:
the horizontal rows of the risk level matrix represent that the importance of the relay is increased from left to right, the importance coefficient is a, and the importance coefficient is a common level, a more important level and an important level; the vertical row of the matrix represents that the action frequency of the relay is increased progressively from top to bottom, the action frequency coefficient is b, and the action frequency coefficient is respectively in three grades of low frequency, common frequency and high frequency;
the risk level matrix divides the relays into 9 types, and the check weight coefficient p of each type of relays b ＝a c *b d B = 1-9, c = 1-3, d = 1-3, the 9 types of relays are divided into three weight zones according to the p-value range, which are respectively green, yellow and red,
the relays in different weight areas adopt different check standards, the darker the color is, the stricter the standard is, x is made to be the basic check times, the relays in the green area continuously check x times, the relays are stopped as long as the relays are qualified, and the relays which are not qualified for the continuous x times are unqualified; the relays in the yellow area are continuously checked for x times, the relays are qualified, and the relays stop checking to indicate that the relays are unqualified as long as the relays are unqualified; continuously checking the red area relay for 2*x times, wherein the red area relay is qualified, and stopping checking to indicate that the red area relay is unqualified as long as the red area relay is unqualified;
the relays in the green areas obtain the verification data of the current time of verification according to the verification result under the condition of qualified verification; under the condition of unqualified verification, the average value of the verification data of x times is taken as the verification result; the yellow area relay is used for taking the average value of the x times of verification data as the verification result under the condition of qualified verification; under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time; the red area relay is used for obtaining the average value of 2x times of verification data in the verification result under the condition of qualified verification; and under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time.
Further, when the end gripper of the industrial robot is not suitable for gripping the relay, the industrial robot moves to the gripper replacement area and replaces the suitable end gripper.
Furthermore, the tail end clamp is replaced to verify the relay of the next size after the relay of the same size is verified at one time, so that the frequency of replacing the tail end clamp is reduced.
Further, the relay placed in the to-be-verified placement area at one time is a relay in the same disk cabinet in the control system.
Advantageous effects
Compared with the prior art, the invention has the advantages that:
1. in the control system of the industries such as electric power, aviation, petroleum, chemical engineering, subway and the like, hundreds of relays are in operation, and through the technical scheme of the invention, unique two-dimensional codes are pasted on the relay shell to establish unique identification for each relay.
2. A plurality of relay information are stored in the two-dimensional code, and the correctness of parameter setting and verification result data recording of the relay testing device in the automatic operation mode of the system is ensured by identifying the two-dimensional code information through machine vision.
3. The industrial robot is adopted to cooperate with various clamps to replace manual picking and placing of the relay, and manpower can be liberated from repeated and boring relay checking work.
4. Utilize machine vision technique location to wait to check the relay and guide industrial robot to snatch for waiting to check the relay and placing the district relay nimble and put and become possible, saved the time that the user arrange in order specially, put and wait to check the relay, improved work efficiency.
5. The machine vision technology extracts the used contact information in the two-dimensional code, the function of accurately checking the actual used contact information in the relay is realized, and the overall reliability of the control system after the scheduled maintenance is also ensured while the qualification rate is improved.
6. According to the importance and the action frequency of the relay in the control system, a relay risk grade matrix is established, information of the importance and the action frequency in the two-dimensional code of the relay shell is extracted through a machine vision technology, and the verification weight coefficient and the belonged weight area are determined, so that different verification modes are adopted, the verification working time and the maintenance cost are minimized, and the running reliability of the control system after the scheduled maintenance is maximized.
7. According to the technical scheme, in an automatic operation mode, the relay verification data are automatically stored in the cloud database, so that a user can conveniently inquire historical data anytime and anywhere, a one-key export scheduled inspection report is supported, efficient utilization of data is realized, and a disk cabinet with potential operation problems is positioned through intelligent analysis of the relay verification data.
Drawings
FIG. 1 is a field paraphrasing diagram of two-dimensional code label information in the present invention;
FIG. 2 is an overall frame diagram of the present invention;
FIG. 3 is a schematic diagram of a two-dimensional code tag and a relay in the present invention;
FIG. 4 is a pin layout diagram of a sample relay;
figure 5 is a schematic view of the operation of an industrial robot according to the invention;
FIG. 6 is a schematic view of a manual verification according to the present invention;
fig. 7 is a relay risk rating matrix diagram.
Wherein: the method comprises the following steps of 1-a controller, 2-an operation display device, 3-a cloud server, 4-an industrial robot, 5-a machine vision camera, 6-a terminal clamp, 7-a relay testing device, 8-a two-dimensional code label, 9-a mobile terminal, 10-a relay, 11-a workbench, 12-a clamp replacement area, 13-a placement area to be verified, 14-a qualified area, 15-a non-qualified area, 16-a main disc end and 17-an auxiliary disc end.
Detailed Description
The invention will be further described with reference to specific embodiments shown in the drawings.
Referring to fig. 1-7, a relay detection system based on robot and vision technology, including controller 1, operation display device 2, high in the clouds server 3, industrial robot 4, machine vision camera 5, multiple end anchor clamps 6, relay testing arrangement 7, two-dimensional code label 8, mobile terminal 9, end anchor clamps 6 are for treating the relay overall dimension of school specially tailor-made, industrial robot 4 can pick up the relay in order to simulate the staff after changing end anchor clamps 6, the relay of every model corresponds to there is an end anchor clamps 6. The controller 1, the operation display device 2, the industrial robot 4 and the machine vision camera 5 are in communication connection through a local area network, specifically, the controller 1, the operation display device 2, the industrial robot 4 and the machine vision camera 5 are connected through a switch, and IP addresses of the controllers are configured in the same network segment. The controller 1 is in communication connection with the cloud server 3 through a TCP/IP wide area network, the mobile terminal 9 is in communication connection with the cloud server 3 through the TCP/IP wide area network, the mobile terminal 9 is a smart phone or a tablet computer, and the controller end and the mobile terminal need to correctly configure information such as an IP address, a port number, a user name, a key, a password and the like according to the requirements of the server end. The industrial robot 4 is in communication connection with the relay testing device 7 through a field bus, the field bus is any one of an RS232 bus, an RS485 bus, a CAN bus and a USB bus, and when the industrial robot 4 is in communication with the relay testing device 7, the baud rate, the data bit, the stop bit, the parity bit and other communication parameters of the two parties are configured to be consistent. The machine vision camera 5 is fixedly mounted on the industrial robot 4 and is intended to be used normally after an eye-in-hand calibration arrangement. The two-dimensional code label 8 is pasted on the shell of the relay 10, and the tail end of the industrial robot 4 is connected with one of the tail end clamps 6.
The controller 1 is used as the core of the whole detection system and controls the normal operation of the whole detection system, and the controller 1 is an industrial personal computer. The operation display device 2 is used for human-computer interaction, on one hand, the operation of a user is facilitated, the whole system is controlled, and on the other hand, system information is displayed. The operation display device 2 is a display panel or an operation control box. The cloud server 3 can enable the database to run on the cloud server 3, and is used for storing the verification result data, so that a user can conveniently connect with the cloud to look up historical data at any time and any place. The industrial robot 4 is used to pick/place the relay instead of the human hand and to plug/unplug the relay into/out of the test base, the industrial robot 4 may be a multi-joint robot or a SCARA robot or a DELTA robot. The machine vision camera 5 is used for determining the position of the relay and recognizing and shooting the two-dimensional code pasted on the relay. The relay testing device 7 is a special testing device for automatically checking various electrical parameters of the relay, and can be in wired or wireless communication with the industrial robot 4 or external equipment.
The end of the industrial robot 4 is connected with a main disc end 16, the end clamp 6 is connected with an auxiliary disc end 17 matched with the main disc end 16, the end of the industrial robot 4 is connected with the end clamp 6 through the main disc end 16 and the auxiliary disc end 17, and the purpose of rapidly switching the end clamp 6 can be achieved. In order to improve the working efficiency, the relay testing device 7, the clamp replacing area 12, the to-be-verified placing area 13, the qualified area 14 and the unqualified area 15 are optimally distributed, so that the motion track of the industrial robot 4 is shortest, and the energy consumption is lowest.
A relay detection method based on robot and vision technology comprises the following steps:
a two-dimensional code label 8 with a unique identifier is pasted on each relay 10; as shown in fig. 3. Each two-dimensional code is unique, namely 1 relay 1 code, and the number, the model, the importance, the action frequency and the information of a used contact of the relay can be distinguished; for example, the valid data information extracted from the two-dimensional code is "01010003 information 90 magnetism 12 information", which is specifically explained in fig. 1; the serial number in the two-dimensional code is a number which is defined by a power station operation and maintenance worker for facilitating equipment management, and each relay has a unique code; through coding, the disk cabinets (disk cabinets of a control system) to which each relay belongs can be distinguished; the type in the two-dimensional code is the specific type of the relay, such as the voltage grade (such as 5V, 12V, 24V and the like) of the relay, and the number of contact groups (such as 1-4 groups of normally open/normally closed contacts); as shown in fig. 4, the relay has 4 sets of normally open/normally closed contacts, wherein 1, 5 and 9 are 1 set of contacts (1 and 5 are normally open contacts, and 1 and 9 are normally closed contacts), and pins A1 and A2 are coil pins;
the method comprises the steps that an industrial robot 4 and a machine vision camera 5 are subjected to hand-eye calibration to obtain a pose relation between a camera coordinate system and a robot coordinate system, so that the relay to be verified can be positioned and two-dimensional code identification can be carried out in the following process, and the method is shown in figure 5; a picking datum point of the relay to be verified, an insertion point position of the relay on the relay testing device 7 and a placing datum point position of the corrected relay are determined in a teaching mode;
manually taking down the relay 10 from a disk cabinet of a control system, then placing the relay in a placement area 13 to be verified, and enabling the two-dimensional code label 8 of the relay to face to the right upper side; preferably, the relays 10 placed in the placement area to be verified 13 at one time are relays in the same disk cabinet in the control system, and the disk cabinet codes of the relays are consistent, so that the condition that individual relays recognize disk cabinet code errors due to damage, dirtying and the like of the two-dimensional code label 8 can be prevented, and the disk cabinet codes of other relays are used as the standard when the disk cabinet code errors are recognized;
selecting items to be verified such as coil voltage, coil resistance, contact resistance, pull-in/release voltage and a qualified range of a measured value in the operation display device 2, clicking and starting after setting, starting the detection system, and sending verification command data to the industrial robot 4 by the controller 1;
the industrial robot 4 moves to the position right above the placement area 13 to be verified, images of all the relays 10 are obtained through the machine vision camera 5, the positions of all the relays 10 are located through a vision algorithm, and one relay 10 is selected to be clamped according to the shortest route principle; the vision algorithm adopts the existing mature vision processing algorithm, or the machine vision camera 5 adopts a mature vision processing module in the market, such as a mechanical arm vision system of Genoshi company;
the machine vision camera 5 acquires the two-dimensional code label 8 image of the clamped relay 10, and obtains the model, the number, the importance, the action frequency and the information of the used contact of the relay 10 according to the two-dimensional code label 8 image;
the controller 1 designs a relay risk level matrix according to the information of the importance degree and the action frequency recorded by the two-dimensional code, determines the checking times and the qualified standard of the relay, and issues the checking times and the qualified standard to the industrial robot 4;
the industrial robot 4 inserts the gripped relay 10 into the relay testing device 7;
according to the model, the importance degree, the action frequency and the information of the used contact of the relay 10, the industrial robot 4 sends control data to the relay testing device 7 so as to set correct detection parameters; the used contact information indicates that several groups of all contacts of the current relay are actually used; not all of the contacts of each relay in operation in a plant control system are in actual use; the relay of fig. 3 has 4 sets of contacts, and if only the normally open/normally closed contacts of 1, 5, 9 are actually connected to the control loop, the used contact is 1; similarly, if the 1, 5, 9 contact group and the 2, 6, 10 contact group are actually connected to the control loop, the used contact is 2; according to field experience, contacts which are not used for a long time are easy to rust, pollute and the like because no current passes through the contacts which are not connected into a control loop for a long time, and the actual resistance value is easy to be abnormal, but the normal function of the contacts which are actually used by the relay in a control system is not influenced; only the actually used contact of each relay can be accurately verified, and the unused contact of each relay cannot be verified, so that the overall reliability of the control system after regular inspection is ensured while the verification qualified rate is improved;
as shown in fig. 7, the risk level matrix, the verification times and the qualification criteria are specifically:
the horizontal row of the risk level matrix represents that the importance of the relay is increased from left to right, the importance coefficient is a, and the importance coefficient is a, namely general, important and important levels; general indicates that the fault of the relay does not substantially affect the normal operation of the control system, for example, the relay is used for lighting an indicator light or displaying the state, and the problem in the operation process can be changed at any time; the importance degree is 'more important' which indicates that the fault of the relay can reduce the operation efficiency of the control system or cause the system to stop operation in a normal mode, and the system cannot be replaced when a problem occurs in the operation process; the importance degree indicates that the fault of the relay can directly cause the abnormal shutdown of the system or serious consequences such as accidents and the like;
the vertical rows of the matrix represent that the action frequency of the relay increases progressively from top to bottom, the action frequency coefficient is b, and the action frequency coefficient is respectively in three grades of low frequency, common frequency and high frequency; "Low frequency" indicates that the relay has relatively few actions per unit time; the action frequency is 'general', which indicates that the action times of the relay in unit time are centered; the action frequency is high frequency, which indicates that the relay has relatively more action times in unit time;
the risk level matrix divides the relays into 9 types, and the check weight coefficient p of each type of relays b ＝a c *b d B = 1-9, c = 1-3, d = 1-3, the 9 types of relays are divided into three weight zones according to the p-value range, which are respectively green, yellow and red,
the relays in different weight areas adopt different check standards, the darker the color is, the stricter the standard is, x is made to be the basic check times, the relays in the green area continuously check x times, the relays are stopped as long as the relays are qualified, and the relays which are not qualified for the continuous x times are unqualified; the relays in the yellow area are continuously checked for x times, the relays are qualified, and the relays stop checking to indicate that the relays are unqualified as long as the relays are unqualified; the red area relay is continuously verified for 2*x times, the red area relay is qualified when being qualified, and the red area relay stops verifying to indicate that the red area relay is unqualified as long as being unqualified;
the relays in the green areas obtain the verification data of the current time of verification according to the verification result under the condition of qualified verification; under the condition of unqualified verification, the average value of the verification data of x times is taken as the verification result; the yellow area relay is used for taking the average value of the x times of verification data as the verification result under the condition of qualified verification; under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time; the red area relay is used for obtaining the average value of 2x times of verification data in the verification result under the condition of qualified verification; under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time;
the industrial robot 4 sends a starting command to the relay testing device 7 to start the checking relay;
after the relay testing device 7 completes the calibration, the calibration data is sent to the industrial robot 4, and the industrial robot 4 forwards the calibration data to the controller 1;
the controller 1 sends the current verification result to the operation display device 2 for displaying, and sends the current verification data to the cloud server 3 for storing; because the machine vision identifies and confirms the serial number of the current relay, the data can be accurately recorded into a storage area where the relay is located in a cloud database;
after the controller 1 finishes processing data, the industrial robot 4 pulls the relay 10 out of the relay testing device 7, and if the verification result is qualified, the relay 10 is placed in a qualified area 14; otherwise, the relay 10 is placed in the defective area 15; completing the verification of one relay 10;
the industrial robot 4 continues to clamp and verify the next relay 10 until all relays 10 are verified;
the cumulative failure rate of the relays in all the disk cabinets in the whole control system is represented as follows:
finding the disk cabinet i to maximize the ratio of the formula (1) to the formula (2)
And calculating and searching the disk cabinets meeting the formula (3) in the T-2 th and T-1 th regular inspections according to historical data, wherein if the disk cabinets meeting the formula (3) in the T-2 th, T-1 th and T-th regular inspections are the same disk cabinet i
min(η T-2 ,η T-1 ,η T )>2 (4)
The abnormal operation condition in the disk cabinet i is indicated to be abnormal, and special attention and troubleshooting are needed by operation and maintenance personnel, wherein the abnormal operation condition comprises any one of temperature abnormality, humidity abnormality, insulation abnormality and power supply abnormality.
When the end gripper 6 of the industrial robot 4 does not properly grip the relay 10, the industrial robot 4 moves to the gripper replacing area 12 and replaces the proper end gripper 6. When no relay exists in the placement area 13 to be verified or the storage quantity of the relays in the qualified area 14/the unqualified area 15 reaches the upper limit, the detection system pauses verification, the operation display device 2 pops up a prompt interface, and the user waits for selecting 'continuing verification' or 'ending verification'. The user adds a relay in the placement area 13 to be verified, or selects 'continue verification' after removing the relay in the qualified area 14/the unqualified area 15, and the user selects 'end verification' after all the relays are verified.
The end clamp 6 is replaced to verify the relay 10 of the next size after the relay 10 of the same size is verified at one time, so that the number of times of replacing the end clamp 6 is reduced, the whole operation time is reduced by saving the number of times of replacing the clamp, and the efficiency is improved.
The above is the automatic verification of the relay 10 by the industrial robot 4 and the machine vision camera 5. The invention can also verify the relay 10 manually, as shown in fig. 6, specifically as follows:
a user holds the mobile terminal 9 by hand, and operates an APP program to enable the mobile terminal 9 to be connected with the relay testing device 7 in a wireless mode such as Bluetooth and the like, wherein the APP program is a special relay program;
the user picks up a relay from the placement area to be verified 13;
a user uses a camera of the mobile terminal 9 to shoot a two-dimensional code on the relay shell, and the APP automatically identifies and confirms the model, the serial number, the importance, the action frequency and the information of a used contact of the relay;
according to the model of this relay, APP sends control data to relay testing arrangement 7 in to set up exact detection parameter, like the 24V direct current relay of two sets of normally open normally closed contact, should set up to coil voltage: 0-24VDC, contact type: 2, converting;
the user inserts the relay into the relay testing device 7;
a user operates the APP of the mobile terminal 9 to issue a control command to the relay testing device 7, and the check relay is started;
after the relay is checked, the relay testing device 7 sends the checking result data to the mobile terminal APP, and then the APP sends the data to the cloud server 3 for storage; since the APP identifies and confirms the number of the current relay, the data can be accurately recorded into a storage area where the relay R3 is located in the cloud database;
the user pulls the relay out of the relay testing device 7, and if the verification result is qualified, the relay 10 is placed in a qualified area 14; otherwise, the relay 10 is placed in the defective area 15; completing the verification of one relay 10;
the user continues to check the next relay 10 until all relays 10 are checked;
the cloud server 3 intelligently analyzes the verification results of all the relays.
The check data is queried as follows:
the user holds the mobile terminal, can connect the cloud server database through the special APP, inquire, upgrade, delete operation etc. to the historical verification data of each relay;
a user can click and select a plurality of relay entries by operating the mobile terminal APP, so that a scheduled inspection report can be generated at one time, scheduled inspection data of all relays are displayed, and PDF format export of the report is supported;
the historical check record of the relay can be used for carrying out big data trend analysis through an intelligent analysis algorithm, judging the health state and potential hidden danger of relevant equipment and providing decision support for the state maintenance work of the equipment.
The above is only a preferred embodiment of the present invention, and it should be noted that it is obvious to those skilled in the art that several variations and modifications can be made without departing from the structure of the present invention, which will not affect the effect of the implementation of the present invention and the utility of the patent.
Claims (10)
1. A relay detection system based on a robot and a vision technology is characterized by comprising a controller (1), an operation display device (2), a cloud server (3), an industrial robot (4), a machine vision camera (5), a plurality of end clamps (6), a relay testing device (7), a two-dimensional code label (8) and a mobile terminal (9);
the device comprises a controller (1), an operation display device (2), an industrial robot (4) and a machine vision camera (5) which are connected through local area network communication, wherein the controller (1) is connected with a cloud server (3) through wide area network communication, a mobile terminal (9) is connected with the cloud server (3) through wide area network communication, the industrial robot (4) is connected with a relay testing device (7) through field bus communication, the machine vision camera (5) is fixedly installed on the industrial robot (4), a two-dimensional code label (8) is pasted on a shell of a relay (10), and the end of the industrial robot (4) is connected with one end clamp (6).
2. The relay detection system based on the robot and vision technology is characterized in that the controller (1), the operation display device (2), the industrial robot (4), the machine vision camera (5) and the relay testing device (7) are installed on the same workbench (11), the workbench (11) is provided with a clamp replacing area (12), a to-be-verified placing area (13), a qualified area (14) and a unqualified area (15), and the end clamp (6) is stored in the clamp replacing area (12).
3. The relay detection system based on robot and vision technology as claimed in claim 1, characterized in that the two-dimensional code label (8) stores information of model, number, importance, action frequency, used contact.
4. The relay detection system based on robot and vision technology as claimed in claim 1, wherein the fieldbus is any one of RS232 bus, RS485 bus, CAN bus, USB bus.
5. A relay detection system based on robot and vision technology according to claim 1, characterized in that the end of the industrial robot (4) is connected with a main disc end (16), the end clamp (6) is connected with a sub disc end (17) which is paired with the main disc end (16), and the end of the industrial robot (4) is connected with the end clamp (6) through the main disc end (16) and the sub disc end (17).
6. A relay detection method based on robot and vision technology is characterized by comprising the following steps:
a two-dimensional code label (8) with a unique identifier is pasted on each relay (10);
the method comprises the steps that hand-eye calibration is conducted on an industrial robot (4) and a machine vision camera (5), and a picking reference point of a relay to be calibrated, an insertion point of the relay on a relay testing device (7) and a placing reference point of the calibrated relay are determined in a teaching mode;
taking the relay (10) out of a disk cabinet of a control system, then placing the relay in a placement area (13) to be verified, and enabling the two-dimensional code label (8) of the relay to face to the right upper side;
selecting an item to be verified on the operation display device (2), clicking and starting after setting is finished, and sending verification command data to the industrial robot (4) by the controller (1);
the industrial robot (4) moves to the position right above the placement area (13) to be verified, images of all relays (10) are obtained through the machine vision camera (5), the positions of all relays (10) are located through a vision algorithm, and one relay (10) is selected to be clamped according to the shortest route principle;
the machine vision camera (5) acquires a two-dimensional code label (8) image of the clamped relay (10), and obtains the model, the number, the importance, the action frequency and the information of the used contact of the relay (10) according to the two-dimensional code label (8) image;
the controller (1) designs a relay risk level matrix according to the information of the importance degree and the action frequency recorded by the two-dimensional code, determines the checking times and the qualified standard of the relay, and sends the checking times and the qualified standard to the industrial robot (4);
the industrial robot (4) inserts the clamped relay (10) into the relay testing device (7);
according to the type, the importance degree, the action frequency and the information of the used contact of the relay (10), the industrial robot (4) issues control data to the relay testing device (7) so as to set correct detection parameters;
the industrial robot (4) sends a starting command to the relay testing device (7) so as to start the checking relay;
the relay testing device (7) sends the checking data to the industrial robot (4), and the industrial robot (4) forwards the checking data to the controller (1);
the controller (1) sends the current verification result to the operation display device (2) for display, and sends the current verification data to the cloud server (3) for storage;
after the controller (1) processes data, the industrial robot (4) pulls the relay (10) out of the relay testing device (7), and if the verification result is qualified, the relay (10) is placed in a qualified area (14); otherwise, the relay (10) is placed in the unqualified area (15); completing the verification of one relay (10);
the industrial robot (4) continues to clamp and check the next relay (10) until all relays (10) are checked;
the cloud server (3) intelligently analyzes the checking results of all the relays at this time, specifically, for all m disk cabinets of the control system, the checking is the T-th regular checking from the commissioning of the control system, and the total amount of the relays in the ith disk cabinet is counted to be n i The quantity of the relays which are checked to be unqualified by the disk cabinet is x it And after the control system is put into operation, the accumulated fault rate of the relay in the disk cabinet i is expressed as follows:
the cumulative failure rate of the relays in all the disk cabinets in the whole control system is represented as follows:
finding the disk cabinet i to maximize the ratio of the formula (1) to the formula (2)
And calculating and searching the disk cabinets meeting the formula (3) in the T-2 th and T-1 th regular inspections according to historical data, wherein if the disk cabinets meeting the formula (3) in the T-2 th, T-1 th and T-th regular inspections are the same disk cabinet i
min(η T-2 ,η T-1 ,η T )>2 (4)
The abnormal operation condition in the disk cabinet i is indicated to be abnormal, and special attention and troubleshooting are needed by operation and maintenance personnel, wherein the abnormal operation condition comprises any one of temperature abnormality, humidity abnormality, insulation abnormality and power supply abnormality.
7. The relay detection method based on the robot and the vision technology as claimed in claim 6, wherein the risk level matrix, the number of verification times and the qualified standard are specifically as follows:
the horizontal row of the risk level matrix represents that the importance of the relay is increased from left to right, the importance coefficient is a, and the importance coefficient is a, namely general, important and important levels; the vertical row of the matrix represents that the action frequency of the relay is increased progressively from top to bottom, the action frequency coefficient is b, and the action frequency coefficient is respectively in three grades of low frequency, common frequency and high frequency;
the risk level matrix divides the relays into 9 types, and the check weight coefficient p of each type of relays b ＝a c *b d B =1 to 9, c =1 to 3, d =1 to 3, 9 types of relays are divided into three weight zones of green, yellow and red according to the p-value range,
the relays in different weight areas adopt different check standards, the darker the color is, the stricter the standard is, x is made to be the basic check times, the relays in the green area continuously check x times, the relays are stopped as long as the relays are qualified, and the relays which are not qualified for the continuous x times are unqualified; the relays in the yellow area are continuously checked for x times, the relays are qualified, and the relays stop checking to indicate that the relays are unqualified as long as the relays are unqualified; continuously checking the red area relay for 2*x times, wherein the red area relay is qualified, and stopping checking to indicate that the red area relay is unqualified as long as the red area relay is unqualified;
the relays in the green areas obtain the verification data of the current time of qualified verification according to the verification result under the condition of qualified verification; under the condition of unqualified verification, the average value of the verification data of x times is taken as the verification result; the yellow area relay is used for taking the average value of the x times of verification data as the verification result under the condition of qualified verification; under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time; the red area relay is used for taking the average value of 2x times of verification data in the verification result under the condition of qualified verification; and under the condition of unqualified verification, the verification result takes the verification data of the unqualified current time.
8. A relay detection method based on robot and vision technology according to claim 6, characterized in that when the end gripper (6) of the industrial robot (4) is not suitable for gripping the relay (10), the industrial robot (4) moves to the gripper exchanging area (12) and exchanges the suitable end gripper (6).
9. The relay detection method based on the robot and vision technology is characterized in that the relay (10) of the next size is verified by replacing the end clamp (6) after the relay (10) of the same size is verified at one time, so that the frequency of replacing the end clamp (6) is reduced.
10. The relay detection method based on the robot and vision technology as claimed in claim 6, characterized in that the relay (10) placed at one time in the placement area (13) to be verified is a relay in the same disk cabinet in the control system.
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