CN116027728A - A kind of intelligent sorting control method - Google Patents

Abstract

The invention relates to an intelligent sorting control method. In a PLC system, a target program is written for each raw material station according to the number of raw material stations of the equipment, and a target program is written for each receiving station according to the number of receiving stations of the equipment. According to the origin station of the robot, write the origin station target program and formula completion program; in the robot system, design the external program number according to the number of raw material stations and receiving stations, and the external program number corresponds to the external control program number of the PLC system . The control method of the present invention is only related to the preparation of on-site equipment, and has nothing to do with the formula and quantity. The control system is very adaptable. The number of raw material stations and receiving stations can be infinitely enlarged, and the number of grabs can also be infinitely enlarged, with a wide range of application scenarios ;Any kind of formula and quantity can be executed on the PLC system without secondary programming and teaching, which realizes high flexibility of the control method, achieves intelligence, digitization, and unmanned operation, and reduces manual intervention.

Description

A kind of intelligent sorting control method

technical field

The invention belongs to the technical field of automation, in particular to an intelligent sorting control method.

Background technique

The automatic sorting of robots has a wide range of application scenarios, and there are many types of sorted items. However, most manufacturers can only identify objects based on barcode readers or smart cameras for positioning, collection or classification, achieving a certain range of automation and flexibility, but they cannot When the plan changes, real-time automatic identification and change of grasping objects and collection positions cannot achieve centralized and flexible management of equipment.

At this stage, enterprises are relying on superior production lines, focusing on the intelligentization of key processes, the replacement of key positions by robots, the intelligent optimization control of the production process, and the digital management of the entire process, to build intelligent factories or digital workshops in key links. The demand for vertical control systems is becoming more and more prominent. In order to reduce the number of programming, improve control flexibility, and reduce personnel participation, higher requirements are put forward.

For sorting equipment in the prior art, there are generally two conventional control methods: a PLC program preset method and a robot program preset method.

PLC program preset method: According to the location of the equipment, the raw material frame area is divided into multiple feeding positions, and the material receiving frame area is also divided into multiple discharging positions. Assume that the raw material frame area is divided into 15, and the material receiving frame area is divided into 5 indivual. According to the existing process requirements, the raw material products are put into different raw material boxes 1-15 according to the categories. The raw material boxes corresponding to different raw material products are relatively fixed. After the raw material products are gone, the operator can freely replace or add them. According to the formula and quantity of the mixing drum model, write the program flow into the PLC controller in advance, and teach the 15-station path of the robot to grasp the material and the 5-station path of the material to be discharged, for each grasping station and The robot program is written at the feeding station, which is designed as different program numbers, and then the PLC controller automatically controls the robot's movement according to the preset program.

Robot program preset method: The hardware conditions of the robot program preset method are the same as those of the PLC program preset method, and will not be elaborated here. According to the formula and quantity of the mixing drum model, the program flow is written into the robot program in advance, and the program number is programmed for each formula and quantity program, and the 15 station paths of the robot for grabbing materials and the 5 stations for discharging materials are taught. A station path, and then the PLC controller calls the robot's program control action according to the model of the mixing drum.

These two methods are to write the required formula content and related quantities into the PLC or robot in advance, and then match the preset program to execute after receiving the model formula and quantity of the MES system (or other host system). The following technical issues:

1. The process of presetting the program is complex, with too much repetitive content, which is prone to errors, and causes program redundancy, and the execution time period is long, which affects the response of program execution.

2. Only the preset formula and quantity content can be executed, and the content issued by the host system must match.

3. When adding or changing process requirements, professionals must rewrite the PLC program or robot program.

4. The technical requirements for maintenance personnel are relatively high, which cannot be completed by ordinary operators.

5. The flexibility of the existing control methods is not high, and the intelligence, digitalization, unmanned, etc. are not perfect, and some of them require manual intervention.

To sum up, there is an urgent need to provide an intelligence that can meet the intelligent and digitalization of leaf sorting without restrictions on the formula and quantity, can improve the accuracy and flexibility of the upper system for field equipment scheduling, and realize the high efficiency of production scheduling. Sorting control method.

Contents of the invention

The purpose of the present invention is to provide an intelligent sorting that can meet the intelligent and digitalization of leaf sorting without restrictions on the formula and quantity, can improve the accuracy and flexibility of the upper system for field equipment scheduling, and realize the high efficiency of production scheduling Control Method.

The above purpose is achieved through the following technical solution: an intelligent sorting control method, comprising the following steps:

(1) The raw material box is parked at the raw material station, and the materials are placed in different raw material boxes according to different models, and the receiving box is empty, and it is parked at the receiving station;

(2) The PLC system automatically detects whether the status of various material boxes is normal, and waits for the formula and quantity to be issued;

(3) After the PLC system receives the formula and quantity, it automatically calculates the program sequence, and the external automatic start robot grabs the material from the target raw material box;

(4) The robot system receives the external start signal and the target signal, controls the robot to walk to the target position, the visual recognition system obtains the coordinates of the material and transmits it to the robot system, and the robot system controls the robot to start grabbing the material;

(5) When the robot finishes grabbing the material, it sends a grabbing completion signal to the PLC system. After the PLC system receives the completion status, it controls the machine to move to the target receiving box, and places the grabbed material in the receiving box. After completion, send a placement completion signal to the PLC system;

(6) When the PLC system receives the placement completion signal, repeat steps (3) to (5). After the material formula and quantity are completed, control the robot to return to the origin, send the overall completion signal to the upper system, and wait for new tasks;

Among them, in the PLC system, the target program is written for each raw material station according to the number of raw material stations of the equipment, the target program is written for each receiving station according to the number of receiving stations of the equipment, and the origin is programmed according to the origin station of the robot. Station target program and formula completion program; in the robot system, the external program number is designed according to the number of raw material stations and receiving stations, and the external program number corresponds to the external control program number of the PLC system.

The manufacturing control system (MES) of the present invention is provided by the entire production line, and the present invention does not provide hardware, and is mainly responsible for the delivery of recipes and quantities of the system, as well as the collection of equipment status data, and displays and schedules the entire system according to the equipment status information. Production line logistics.

The design of this control system is based on the principles of safety, advanced, reliable, stable and practical. Through the combination of manufacturing control system (MES), robot control system and electrical control system, the flexible and intelligent management of intelligent sorting of blades of concrete mixer truck mixing drums is realized.

The control method of the present invention is only related to field equipment preparation, and has nothing to do with formula and quantity. This invention writes the target program for each raw material station according to the number of raw material stations of the equipment; writes the target program for each receiving station according to the number of receiving stations of the equipment; writes the origin according to the origin station of the robot The station target program, so the control system is very adaptable, the number of raw material stations and receiving stations can be infinitely enlarged, and the number of grabs can also be infinitely enlarged, with a wide range of application scenarios. Any formula and quantity can be executed on the PLC system without secondary programming and teaching, and ordinary operators can complete it. It realizes the high flexibility of the control method, achieves intelligence, digitization, and unmanned, and reduces manual intervention.

A further technical solution is that the visual recognition system is a smart camera, and the smart camera includes an industrial 3D camera composed of two positions and an image processing industrial computer, which is used to quickly calculate the three-dimensional coordinates of the blade according to the control requirements. The system communicates directly with the robot system through the TCP/IP protocol, and the robot system controls and triggers the smart camera to work.

A further technical solution is that each material frame station is provided with a first sensor for detecting the presence or absence of a material frame, and the robot gripper is provided with a second sensor for detecting whether the blade falls, and the first sensor and the second sensor The second sensor is connected in communication with the PLC system. As such, detection sensors including the first sensor and the second sensor are used to detect the state and position of the device. For example, the detection sensor of the raw material frame and the receiving frame is to detect whether there is a frame in the position; the detection sensor of the robot gripper is to detect whether the blade has fallen. Such real-time detection of equipment working information provides a safety guarantee for the automatic operation of the equipment.

A further technical solution is that the PLC system uses an industrial PLC with high performance and expanded Profinet communication functions as a processor for calculation, control, storage and other functions, and the PLC system and the manufacturing control system use Ethernet communication, and communicate with all The above-mentioned robot system adopts Profinet field bus communication, and the detection with the first sensor is collected directly through hard wiring. The whole PLC controller network of the present invention is designed according to two independent network topologies, and the external network is isolated from the equipment control network to ensure the safety, reliability and stability of equipment control.

A further technical solution is that the robot is a six-axis industrial robot, the seventh axis of the six-axis industrial robot is expanded as the ground rail walking axis, and the robot system is equipped with a Profinet communication card to communicate with the PLC system, and a The TCP/IP communication card communicates with the smart camera, and an I/O module of the robot is prepared as the related control and state detection of the gripper.

A further technical solution is that the robot is provided with an electro-permanent magnet gripper, and the electro-permanent magnet gripper is provided with a permanent magnetic head, and the control of the permanent magnetic head is controlled by a special controller and can realize fast magnetization and demagnetization. The electro-permanent magnet gripper maintains its current state when the power is turned off. As a fixture adsorption device, it is very important to be stable, safe and reliable, to ensure that the blade will not fall when the device moves.

A further technical solution is that the control process of the PLC system includes the following steps:

S1: Accept the recipe and quantity instructions of the manufacturing control system, use the upper system to directly write into the storage block, use the handshake signal mode to confirm that it is the latest information, and then dump the relevant content to ensure that the data will not be changed; or when selecting local data , to receive local data through the paradigm of manual data entry;

S2: According to the latest formula and quantity obtained, decompose the content of the formula and save the quantity, including the quantity and order of each type of leaf, and judge the type and quantity of the currently grabbed leaves;

S3: Decompose the goals and states of the raw material station, receiving station, and robot origin station, divide them into corresponding branch programs to process the goal and state logic according to the total number of raw material stations and receiving stations, and The origin station processes the logic of formula completion;

S4: Save the receiving completion status information, material model information, equipment status, and display and upload to the upper control system.

In order to realize step S3, the PLC system writes the target program for each raw material station according to the number of raw material stations of the equipment; writes the target program for each receiving station according to the number of receiving stations of the equipment; position, write out the origin station target program, and the formula completion program.

A further technical solution is that the control process of the robot control system includes the following steps:

S1: Prepare robot TCP/IP communication, profinet communication, seventh axis and I/O module, and test whether it is normal;

S2: Design the external program number according to the number of raw material stations and receiving stations, and the external program number corresponds to the external control program number of the PLC system;

S3: Under each external program number, teach the position according to the raw material station, receiving station, and origin station, and the origin station does not need an external program number;

S4: Under each external program number, write logic control signals including smart cameras, electropermanent magnets, and fixture detection;

S5: Under each external program number, process feedback signals including camera coordinates, electropermanent magnet status, and fixture detection status;

S6: The origin position transmits the recipe completion signal to the PLC system.

Compared with the prior art, the present invention applies PLC technology, smart camera technology, database technology, intelligent manufacturing system, advanced sensor detection technology, and electro-permanent magnet technology to realize the sorting of arbitrary formula and quantity through remote system control blades The flexible and intelligent management of collection and formula model information tracking can meet the functions of sorting, sorting, and transfer of blades by the mixing drum, solve the real demand of the mixing drum production line for current product accessories, and also solve the problem of new product development trials. During production, the contradiction of mismatching equipment parameters can improve the adaptability, accuracy and flexibility of equipment, and realize the high efficiency of production scheduling. It has the following advantages: the PLC control program has nothing to do with formula and quantity, the raw material station and receiving station can be enlarged infinitely, the control system of this invention can accept any formula and quantity of the upper system, and the robot program has nothing to do with formula and quantity.

Description of drawings

The drawings constituting a part of the present invention are used to provide a further understanding of the present invention, and the schematic embodiments and descriptions of the present invention are used to explain the present invention, and do not constitute an improper limitation of the present invention.

Fig. 1 is a schematic diagram of the principle of an intelligent sorting control method involved in an embodiment of the present invention;

Fig. 2 is a schematic diagram of the PLC system control principle involved in an embodiment of the present invention;

Fig. 3 is a schematic diagram of the control principle of the robot system involved in an embodiment of the present invention.

Detailed ways

The present invention will be described in detail below in conjunction with the accompanying drawings. The description in this part is only exemplary and explanatory, and should not have any limiting effect on the protection scope of the present invention. In addition, those skilled in the art can make corresponding combinations of features in the embodiments in this document and in different embodiments according to the descriptions in this document.

Embodiments of the present invention are as follows, with reference to Figures 1 to 3, an intelligent sorting control method includes the following steps:

(1) The raw material box is parked at the raw material station, and the materials are placed in different raw material boxes according to different models, and the receiving box is empty, and it is parked at the receiving station;

(2) The PLC system automatically detects whether the status of various material boxes is normal, and waits for the formula and quantity to be issued;

(3) After the PLC system receives the formula and quantity, it automatically calculates the program sequence, and the external automatic start robot grabs the material from the target raw material box;

(4) The robot system receives the external start signal and the target signal, controls the robot to walk to the target position, the visual recognition system obtains the coordinates of the material and transmits it to the robot system, and the robot system controls the robot to start grabbing the material;

(5) When the robot finishes grabbing the material, it sends a grabbing completion signal to the PLC system. After the PLC system receives the completion status, it controls the machine to move to the target receiving box, and places the grabbed material in the receiving box. After completion, send a placement completion signal to the PLC system;

(6) When the PLC system receives the placement completion signal, repeat steps (3) to (5). After the material formula and quantity are completed, control the robot to return to the origin, send the overall completion signal to the upper system, and wait for new tasks;

Among them, in the PLC system, the target program is written for each raw material station according to the number of raw material stations of the equipment, the target program is written for each receiving station according to the number of receiving stations of the equipment, and the origin is programmed according to the origin station of the robot. Station target program and formula completion program; in the robot system, the external program number is designed according to the number of raw material stations and receiving stations, and the external program number corresponds to the external control program number of the PLC system.

The manufacturing control system (MES) of the present invention is provided by the entire production line, and the present invention does not provide hardware, and is mainly responsible for the delivery of recipes and quantities of the system, as well as the collection of equipment status data, and displays and schedules the entire system according to the equipment status information. Production line logistics.

The design of this control system is based on the principles of safety, advanced, reliable, stable and practical. Through the combination of manufacturing control system (MES), robot control system and electrical control system, the flexible and intelligent management of intelligent sorting of blades of concrete mixer truck mixing drums is realized.

The control method of the present invention is only related to field equipment preparation, and has nothing to do with formula and quantity. This invention writes the target program for each raw material station according to the number of raw material stations of the equipment; writes the target program for each receiving station according to the number of receiving stations of the equipment; writes the origin according to the origin station of the robot The station target program, so the control system is very adaptable, the number of raw material stations and receiving stations can be infinitely enlarged, and the number of grabs can also be infinitely enlarged, with a wide range of application scenarios. Any formula and quantity can be executed on the PLC system without secondary programming and teaching, and ordinary operators can complete it. It realizes the high flexibility of the control method, achieves intelligence, digitization, and unmanned, and reduces manual intervention.

On the basis of the above embodiments, in another embodiment of the present invention, as shown in Figure 2, the visual recognition system is a smart camera, and the smart camera includes an industrial 3D camera composed of two positions and an image processing industrial computer for The three-dimensional coordinates of the blade are quickly calculated according to the control requirements, the visual recognition system communicates directly with the robot system through the TCP/IP protocol, and the robot system controls and triggers the smart camera to work.

On the basis of the above-mentioned embodiments, in another embodiment of the present invention, each material frame station is provided with a first sensor for detecting the presence or absence of a material frame, and the robot gripper is provided with a first sensor for detecting whether a blade falls. Two sensors, the first sensor and the second sensor are communicatively connected with the PLC system. As such, detection sensors including the first sensor and the second sensor are used to detect the state and position of the device. For example, the detection sensor of the raw material frame and the receiving frame is to detect whether there is a frame in the position; the detection sensor of the robot gripper is to detect whether the blade has fallen. Such real-time detection of equipment working information provides a safety guarantee for the automatic operation of the equipment.

On the basis of the foregoing embodiments, in another embodiment of the present invention, the PLC system uses an industrial PLC with high performance and extended Profinet communication functions as a processor for functions such as calculation, control, and storage. The PLC system and production The manufacturing control system adopts Ethernet communication, communicates with the robot system through Profinet field bus, and directly collects with the first sensor detection through hard wiring. The whole PLC controller network of the present invention is designed according to two independent network topologies, and the external network is isolated from the equipment control network to ensure the safety, reliability and stability of equipment control.

On the basis of the above-mentioned embodiments, in another embodiment of the present invention, the robot is a six-axis industrial robot, and the sixth-axis industrial robot expands the seventh axis as the ground rail walking axis, and the robot system is equipped with Profinet The communication card communicates with the PLC system, and a TCP/IP communication card is prepared to communicate with the smart camera, and an I/O module of the robot is prepared as the gripper-related control and state detection.

On the basis of the above-described embodiments, in another embodiment of the present invention, as shown in Figure 1, the robot is provided with an electro-permanent magnet gripper, and the electro-permanent magnet gripper is provided with a permanent magnetic head, and the permanent magnetic head is controlled by a dedicated The controller is used to control and realize fast magnetization and demagnetization. The electro-permanent magnet gripper maintains its current state when the power is turned off. As a fixture adsorption device, it is very important to be stable, safe and reliable, to ensure that the blade will not fall when the device moves.

On the basis of the foregoing embodiments, in another embodiment of the present invention, as shown in Figure 2, the control process of the PLC system includes the following steps:

S1: Accept the recipe and quantity instructions of the manufacturing control system, use the upper system to directly write into the storage block, use the handshake signal mode to confirm that it is the latest information, and then dump the relevant content to ensure that the data will not be changed; or when selecting local data , to receive local data through the paradigm of manual data entry;

S2: According to the latest formula and quantity obtained, decompose the content of the formula and save the quantity, including the quantity and order of each type of leaf, and judge the type and quantity of the currently grabbed leaves;

S3: Decompose the goals and states of the raw material station, receiving station, and robot origin station, divide them into corresponding branch programs to process the goal and state logic according to the total number of raw material stations and receiving stations, and The origin station processes the logic of formula completion;

S4: Save the receiving completion status information, material model information, equipment status, and display and upload to the upper control system.

In order to realize step S3, the PLC system writes the target program for each raw material station according to the number of raw material stations of the equipment; writes the target program for each receiving station according to the number of receiving stations of the equipment; position, write out the origin station target program, and the formula completion program.

On the basis of the above embodiments, in another embodiment of the present invention, as shown in Figure 3, the control process of the robot control system includes the following steps:

S1: Prepare robot TCP/IP communication, profinet communication, seventh axis and I/O module, and test whether it is normal;

S2: Design the external program number according to the number of raw material stations and receiving stations, and the external program number corresponds to the external control program number of the PLC system;

S3: Under each external program number, teach the position according to the raw material station, receiving station, and origin station, and the origin station does not need an external program number;

S4: Under each external program number, write logic control signals including smart cameras, electropermanent magnets, and fixture detection;

S5: Under each external program number, process feedback signals including camera coordinates, electropermanent magnet status, and fixture detection status;

S6: The origin position transmits the recipe completion signal to the PLC system.

The above is only a preferred embodiment of the present invention, it should be pointed out that, for those of ordinary skill in the art, without departing from the principle of the present invention, some improvements and modifications can also be made, and these improvements and modifications can also be made. It should be regarded as the protection scope of the present invention.

Claims (8)

1. An intelligent sorting control method is characterized by comprising the following steps:

(1) The material frame is parked at the material station, the materials are respectively placed into different material frames according to different models, the material receiving frame is empty, and the material receiving frame is parked at the material receiving station;

(2) The PLC system automatically detects whether the states of various material frames are normal or not, and waits for issuing the formulas and the quantity;

(3) After the PLC system receives the formulas and the quantity, automatically calculating a program sequence, and automatically starting the robot from the outside to grasp materials from the target raw material frame;

(4) The robot system receives the external starting signal and the target signal, controls the robot to move to the target position, and the visual recognition system acquires the material coordinates and transmits the material coordinates to the robot system;

(5) After the robot finishes grabbing the materials, sending grabbing completion signals to a PLC system, after the PLC system receives the completing state, controlling the machine to move to a target material receiving frame, placing the grabbed materials in the material receiving frame, and after completing, sending placing completion signals to the PLC system;

(6) When the PLC system receives the placement completion signal, repeating the steps (3) - (5) until the material formula and the quantity are completed, controlling the robot to return to the original point, sending an overall completion signal to the upper system, and waiting for a new task;

the method comprises the steps of programming a target program for each raw material station according to the number of raw material stations of equipment, programming a target program for each material receiving station according to the number of material receiving stations of the equipment, and programming an origin station target program and a formula completion program according to an origin station of a robot in a PLC system; the robot system designs external program numbers according to the number of the raw material stations and the number of the material receiving stations, and the external program numbers correspond to external control program numbers of the PLC system.

2. The intelligent sorting control method according to claim 1, wherein the visual recognition system is an intelligent camera, the intelligent camera comprises an industrial 3D camera formed by two cameras and an image processing industrial personal computer, the intelligent camera is used for rapidly calculating three-dimensional coordinates of the blade according to control requirements, the visual recognition system is in direct communication with a robot system through a TCP/IP protocol, and the robot system controls and triggers the intelligent camera to work.

3. The intelligent sorting control method according to claim 2, wherein each material frame station is provided with a first sensor for detecting whether a material frame exists or not, the robot clamp is provided with a second sensor for detecting whether a blade falls off or not, and the first sensor and the second sensor are in communication connection with the PLC system.

4. The intelligent sorting control method according to claim 3, wherein the PLC system uses a high-performance industrial PLC with extended Profinet communication functions as a processor for calculation, control, storage, etc., and the PLC system uses ethernet communication with the manufacturing control system, uses Profinet field bus communication with the robot system, and directly collects the signals through hard wiring with the first sensor detection.

5. The intelligent sorting control method according to claim 3, wherein the robot is a six-axis industrial robot, the six-axis industrial robot is expanded to be a seventh axis as a ground rail traveling axis, the robot system is configured with a Profinet communication card to communicate with a PLC system, a TCP/IP communication card to communicate with the intelligent camera, and an I/O module of the robot is further configured to be a gripper-related control and status detection.

6. The intelligent sorting control method according to claim 3, wherein the robot is provided with an electro-permanent magnet gripper, the electro-permanent magnet gripper is provided with a permanent magnet head, and the permanent magnet head is controlled by a special controller and can realize rapid magnetization and demagnetization.

7. The intelligent sorting control method according to any one of claims 2 to 6, wherein the control process of the PLC system includes the steps of:

s1: receiving instructions of the formula and the quantity of the production and manufacture control system, adopting an upper system to directly write the instructions into a storage block, adopting a handshake signal mode to confirm that the instructions are the latest information, and then transferring related contents to ensure that data are not changed; or when the local data is selected, receiving the local data through a normal form of manually input data;

s2: decomposing the content and the storage quantity of the formula according to the latest formula and quantity obtained, wherein the quantity and the sequence of each blade are included, and judging the type and the quantity of the currently grabbed blades;

s3: decomposing targets and states of a raw material station, a material receiving station and a robot origin station, respectively dividing the targets and states into corresponding branch programs according to the total number of the raw material stations and the total number of the material receiving stations to process target and state logic, and processing logic completed according to a formula of the robot origin station;

s4: and storing the material receiving completion state information, the material model information and the equipment state, and displaying and uploading the material receiving completion state information, the material model information and the equipment state to an upper control system.

8. The intelligent sorting control method according to claim 7, wherein the control process of the robot control system includes the steps of:

s1: preparing a TCP/IP communication, a profinet communication, a seventh axis and an I/O module of the robot, and testing whether the robot is normal;

s2: the method comprises the steps of designing external process numbers according to the number of raw material stations and the number of material receiving stations, wherein the external process numbers correspond to external control process numbers of a PLC system;

s3: teaching positions according to a raw material station, a material receiving station and an origin station below each external program number, wherein the origin station does not need the external program number;

s4: logic control signals including intelligent cameras, electro-permanent magnets and clamp detection are compiled under each external program number;

s5: processing feedback signals including camera coordinates, electro-permanent magnet state, fixture detection state under each external program number;

s6: the origin position transmits a formula completion signal to the PLC system.

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