WO2019222968A1 - 一种智能上下料系统及其工作方法 - Google Patents

一种智能上下料系统及其工作方法 Download PDF

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Publication number
WO2019222968A1
WO2019222968A1 PCT/CN2018/088263 CN2018088263W WO2019222968A1 WO 2019222968 A1 WO2019222968 A1 WO 2019222968A1 CN 2018088263 W CN2018088263 W CN 2018088263W WO 2019222968 A1 WO2019222968 A1 WO 2019222968A1
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WO
WIPO (PCT)
Prior art keywords
loading
industrial
unloading system
tray
intelligent
Prior art date
Application number
PCT/CN2018/088263
Other languages
English (en)
French (fr)
Inventor
马朋巍
Original Assignee
深圳配天智能技术研究院有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 深圳配天智能技术研究院有限公司 filed Critical 深圳配天智能技术研究院有限公司
Priority to PCT/CN2018/088263 priority Critical patent/WO2019222968A1/zh
Priority to CN201880002359.9A priority patent/CN109415175B/zh
Publication of WO2019222968A1 publication Critical patent/WO2019222968A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G60/00—Simultaneously or alternatively stacking and de-stacking of articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/04—Detection means
    • B65G2203/041—Camera

Definitions

  • the present application relates to the field of industrial automation, and in particular, to an intelligent loading and unloading system and a working method thereof.
  • Automation refers to the process of achieving the desired goal through the automatic detection, information processing, analysis and judgment, and manipulation control according to the requirements of people without the direct participation of machines or equipment, systems, or processes.
  • manual supply of materials or pallets to the production line is often adopted, and the loading and unloading of the production line is performed by labor.
  • the labor intensity is tedious, and the work is tedious and mostly repetitive labor.
  • the repetitive labor of time will cause labor fatigue, which will reduce efficiency and work accuracy.
  • the technical problem mainly solved by this application is to provide an intelligent loading and unloading system and its working method, so as to solve the problem of low accuracy when the robot unstacks and stacks.
  • an intelligent loading and unloading system used in the present application includes: a conveying device, the conveying device is used for conveying materials, and the conveying device has a loading level and a unloading level; Material is transferred to the loading position and / or material located at the lower level is moved to a position away from the lower level; industrial vision equipment, industrial vision equipment is used to detect the position of the material; control equipment, the control equipment is used according to The position information of materials provided by industrial vision equipment controls the work of industrial robots.
  • the intelligent loading and unloading system includes a conveying device, an industrial robot, an industrial vision device, and a control device.
  • the conveying device has a loading level.
  • the method includes: detecting the position information of the material through the industrial vision device; sending the position information to the control device; the control device controlling the industrial robot to send the material according to the position information Transferring to the loading level and / or transferring material located at the lower level to a position leaving the lower level.
  • this application proposes an intelligent loading and unloading system and its working method, which cooperates with industrial robots to carry out loading and unloading work through industrial vision equipment, thereby realizing the automation of the entire loading and unloading operation process, It can also use industrial vision equipment to reduce the working error of industrial robots. Therefore, this application can effectively improve the working efficiency and working accuracy of industrial robots.
  • FIG. 1 is a schematic diagram of an embodiment of an intelligent loading and unloading system of the present application
  • FIG. 2 is a schematic structural diagram of an embodiment of an intelligent loading and unloading system of the present application
  • FIG. 3 is a schematic structural diagram of a loading tray in an embodiment of the intelligent loading and unloading system of the present application
  • FIG. 4 is a schematic diagram of an overall structure of an end execution device in an embodiment of the intelligent loading and unloading system of the present application
  • FIG. 5 is a schematic side structural diagram of an end effector in an embodiment of the intelligent loading and unloading system of the present application
  • FIG. 6 is a schematic structural diagram of an industrial vision device in an embodiment of the intelligent loading and unloading system of the present application
  • FIG. 7 is a schematic flowchart of an embodiment of a working method of the intelligent loading and unloading system of the present application.
  • FIG. 1 It is a schematic diagram of an embodiment of the intelligent loading and unloading system of the present application.
  • FIG. 2 is a schematic structural diagram of an embodiment of an intelligent loading and unloading system of the present application.
  • the intelligent loading and unloading system of the present application includes a conveying device 100, an industrial robot 200, an industrial vision device 500, and a control device 400.
  • the conveying device 100 is used for conveying the material 310, and the conveying device 100 is provided with an upper material level 160 and a lower material level 170.
  • the material 310 is loaded at the loading position 160 of the conveying equipment 100, and then the conveying equipment 100 conveys the material 310 to the next process.
  • the industrial robot 200 is used to transfer the material 310 to the upper material level 160 and / or to transfer the material 310 located at the lower material level 170 to a position away from the lower material level 170.
  • the industrial vision device 500 is used to detect the position of the material 310.
  • the control device 400 is used to control the operation of the industrial robot 200 according to the position information of the material 310 provided by the industrial vision device 500.
  • the control device 400 is used to control the industrial vision device 500, the conveying device 100, and the industrial robot 200 to perform information interaction between the devices.
  • the industrial vision device 500, the conveying device 100, and the industrial robot 200 may each be equipped with a control device, and the respective control devices may be connected through a communication device, which is not done in this application. limited.
  • the conveying equipment 100 includes an upper conveying line 151 and a lower conveying line 150.
  • the upper material level 170 of the material 310 is located on the upper conveying line 151
  • the lower material level 160 of the material 310 is located on the lower conveying line 150.
  • the position 160 is closer to the industrial robot 200 than the loading level 170, so that the robot can quickly transfer the material 310 on the loading level.
  • the conveying equipment 100 may also be in other forms, such as a circular conveying line.
  • the industrial robot 200 and the material 310 storage area are both inside the circular conveying line.
  • the conveying equipment may also be two horizontally placed conveying lines. It can be a conveyor belt or a chain, as long as the transport line can transport the loading tray 300, which is not limited in this application.
  • the industrial robot 200 includes a robot body 210 and an end effector 220.
  • the end effector 220 is used to grasp the loading tray 300.
  • the robot body 210 cooperates with the end effector 220 to transfer the loading tray 300 carrying the material 310 to the loading position 170 of the conveying equipment 100.
  • the conveying equipment 100 transfers the empty loading tray 300 to the lower At the material level 160, the robot body 210 cooperates with the end effector 220 to grab the empty loading tray 300 and transfer it.
  • the industrial vision device 500 is used to detect the position of the material 310, and the industrial vision device 500 is installed on the robot arm of the industrial robot 200.
  • the industrial vision device 500 detects the position of the loading tray 300 and the state of the loading position 170. If it is detected that the loading position 170 is empty, the industrial vision device 500 transmits information to the control device 400, and the control device 400 controls the industrial robot 200 to place the loading tray 300 on the loading position 170.
  • the industrial vision device 500 first detects whether there is an empty loading tray 300 at the loading level 160.
  • the industrial vision device 500 transmits the information to the control device 400, and the control device 400 controls the industrial robot 200 to grab the empty loading tray 300 and transfer it.
  • the industrial vision device 500 may also be installed at another position of the industrial robot 200 or at a position independent of the industrial robot 200, which is not limited in this application.
  • the intelligent loading and unloading system further includes two sets of pallets, the first group of pallets includes a first pallet 110 and the second pallet 120, the second group of pallets includes a third pallet 130 and a fourth pallet 140,
  • the loading tray 300 is stacked on two sets of pallets. Among them, the first stack tray 110 and the third stack tray 130 are used to place the loading tray 300 loaded with the material 310, and the second stack tray 120 and the fourth stack tray 140 are used to place the empty loading tray 300.
  • the disks are placed on both sides of the industrial robot 200 to play a complementary role.
  • the pallets here are not limited to the above two groups, and are specifically designed according to actual production requirements, which are not limited here.
  • the intelligent loading and unloading system further includes an automatic guided vehicle (not shown in the figure), which is used for transporting pallets. Specifically, when the pallets on which the empty pallets are placed are full (for example, when a preset number is placed), the control device 400 issues an instruction to control the automatic guided vehicle to transfer it away, and controls the automatic guided vehicle to transfer one The empty pallets are transferred; when the pallets for feeding are empty, the control device 400 sends instructions to control the automatic guided vehicle to transfer them away, and to control the automatic guided vehicles to transfer a pallet full of loaded pallets Come here, so back and forth.
  • an automatic guided vehicle (not shown in the figure), which is used for transporting pallets. Specifically, when the pallets on which the empty pallets are placed are full (for example, when a preset number is placed), the control device 400 issues an instruction to control the automatic guided vehicle to transfer it away, and controls the automatic guided vehicle to transfer one The empty pallets are transferred; when the pallets for feeding are empty, the control device 400 sends instructions to control the automatic guided vehicle
  • the intelligent loading and unloading system further includes a safety fence (not shown in the figure).
  • the safety fence surrounds the conveying equipment 100, the industrial robot 200, the industrial vision equipment 500, the control equipment 400, and the automatic guided vehicle to form a protective circle. Protects the entire automated operation area.
  • the industrial robot 200 is a 6-axis robot.
  • the 6-axis robot has 6 degrees of freedom.
  • a 6-degree-of-freedom robot means that it can pick up parts in any orientation, can be put into the packaging product at a special angle, and it can also execute Many operations can only be performed by skilled workers.
  • FIG. 3 is a schematic structural diagram of a loading tray in an embodiment of the intelligent loading and unloading system of the present application.
  • the loading tray 300 is used to store materials 310 (the loading tray in FIG. 3 is in an empty tray state).
  • a pin 301 is provided at the upper end of the loading tray 300, and a pin hole 302 is provided at the lower end of the loading tray 300.
  • the pin 301 and the pin hole 302 are in a corresponding relationship and cooperate to form a limiting structure.
  • the number of the pins 301 and the pin holes 302 are two each, which can prevent rotation between the loading trays 300 when the loading trays 300 are stacked together.
  • the number of the pins 301 and the pin holes 302 may be three, four, or more, and the position distribution of the pins 301 and the pin holes 302 may be determined according to actual needs, which is not limited in this application.
  • the pin 301 and the pin hole 302 cooperate to precisely position the loading tray 300, so that the loading trays 300 are stacked together to ensure consistency.
  • the conveying equipment 100 transports the material carrying tray 300 located at the loading position 170 to the next process. After the material 310 is removed, the conveying equipment 100 transports the empty material carrying tray 300. To the unloading position 160, the industrial robot 200 removes the empty loading tray 300, and so on.
  • the conveying line is a conveyor belt
  • the upper end of the loading tray 300 is provided with a pin hole
  • the lower end is provided with a pin.
  • Pin holes and pins can be used to precisely position the pallet so that the pallets are stacked together to ensure consistency.
  • first protrusions 303 and two second protrusions 304 are provided on the outer side of the side wall of the carrier tray 300, and the two first protrusions 303 and the two second protrusions 304 are symmetrical. Are distributed on the outside of the side wall of the loading tray 300.
  • the first raised portion 303 and the second raised portion 304 are used to cooperate with the end effector 220 so that the end effector 220 clamps or releases the loading tray 300.
  • the material 310 is contained in the loading tray, and the upper and lower ends of the loading tray are provided with a coordinated limiting structure, or other parts of the loading tray are provided with a coordinated limiting structure, which is convenient for the stacking of the loading trays to ensure that Product consistency and space-saving location are also conducive to the use of the next process.
  • FIG. 4 is a schematic diagram of the overall structure of an end effector in an embodiment of the intelligent loading and unloading system of the present application
  • FIG. 5 is a schematic diagram of a side structure of the end effector in an embodiment of the intelligent loading and unloading system of the application .
  • the end effector 220 holds the loading tray 300, and the loading tray 300 carries a material 310.
  • the end effector 220 includes a pair of first end effectors 221 disposed vertically and a pair of second end effectors 222 disposed horizontally.
  • the first end effectors 221 are symmetrically fixed On the outside of the end effector 220, the second end effector 222 is symmetrically fixed on the outside of the side wall of the end effector 220.
  • the first end effector 221 arranged vertically is used for holding the loading tray 300
  • the second end effector 222 arranged horizontally is used for holding the loading tray.
  • the number and position of the first end effector 221 and the second end effector 222 can be adjusted adaptively, as long as it can be held in cooperation with the loading tray 300 Or just release the loading tray 300, which is not limited in this application.
  • the first end effector 221 includes a first driving device 223 and a first clamping portion 224.
  • the first driving device 223 is an air cylinder
  • the first clamping portion 224 is a pneumatic claw
  • the first driving device 223 drives the first protrusion on the side wall of the loading tray 300 when the first clamping portion 224 is closed.
  • the first driving device 223 drives the first clamping portion 224 to release the first protruding portion 303 on the side wall of the loading tray 300 when the first clamping portion 224 is opened.
  • the first driving device 223 is an air cylinder
  • the first clamping portion 224 includes a first force arm 227 and a second force arm 228, and the first ends of the first force arm 227 and the second force arm 228 and the first drive
  • the output ends of the device 223 are screwed.
  • the second ends of the first force arm 227 and the second force arm 228 are provided with a groove 229.
  • the output ends of the first driving device 223 drive the first force arm 227 and the second force arm 228 to rotate. In order to allow the grooves 229 on the first force arm 227 and the second force arm 228 to clamp the first protrusion 303 from both sides of the first protrusion 303.
  • the first driving device 223 may also be two servo motors or stepping motors.
  • the output end of the first driving device 223 may also be connected to the first end card of the first force arm 227 and the second force arm 228.
  • the second end effector 222 includes a second driving device 225 and a second clamping portion 226.
  • the second driving device 225 is an air cylinder
  • the second clamping portion 226 is an “L” -shaped guide rod
  • the second driving device 225 drives the second clamping portion 226 to move in a horizontal direction so that the “L” -shaped guide rod
  • the second protrusion 304 on the side wall of the loading tray 300 is lifted or released.
  • the second driving device 225 is located between the first raised portion 303 and the second raised portion 304, the second clamping portion 226 is an “L” -shaped guide bar, and is located between the second raised portion 304 and the first protruding portion 304.
  • the output end of the second driving device 225 is screwed to the vertical end of the "L” -shaped guide rod, and the second driving device 225 drives the "L” -shaped guide rod to approach or move away from the second protruding portion 304 , So that the horizontal end of the “L” -shaped guide bar can lift or release the second protruding portion 304.
  • the first clamping portion 224 restricts the linear movement of the loading tray 300 by clamping the first protrusion 303, and the loading tray 300 can only surround the first protrusion 303 Rotation; and further, the rotation of the loading tray 300 is restricted by the lifting of the second clamping portion 226, so that the loading tray 300 is firmly held by the end effector 220, which can effectively prevent the loading tray 300 from being transported Medium fall off, improving equipment safety.
  • the specific structure of the end effector can be adaptively adjusted, which is not limited here.
  • the driving method of the end effector may be a servo motor, a steering gear or other types of driving equipment, which is not limited here.
  • the first driving device 223 and the second driving device 225 may be driving devices such as hydraulic cylinders, which are not limited here.
  • the industrial robot 200 when the industrial robot 200 wants to grip the loading tray 300, the industrial robot 200 moves the end effector 220 to the loading tray 300 so that the first clamping portion 224 surrounds the loading tray 300.
  • the first protruding portion 303 is such that the second clamping portion 226 is located between the first protruding portion 303 and the second protruding portion 304.
  • the first driving device 223 drives the first clamping portion 224 to close to clamp the first protruding portion 303
  • the second driving device 225 drives the second clamping portion 226 to extend to support the second protruding portion 304, thereby clamping The entire loading tray 300.
  • the first driving device 223 drives the first clamping portion 224 to release to clamp the first protruding portion 303, and the second driving device 225 drives the second clamping portion 226 is contracted to make the second clamping portion 226 away from the second protruding portion 304.
  • the industrial robot 200 can remove the loading tray 300 by removing the end effector 220.
  • FIG. 6 is a schematic structural diagram of an industrial vision device in an embodiment of the intelligent loading and unloading system of the present application.
  • the industrial vision device 500 includes a processor 520 and an industrial camera 510.
  • the control device 400 controls the industrial vision device 500 to perform detection and analysis, it is specifically: controlling the industrial camera 510 to photograph the material 310 and transmitting the photographed data information to the processor 520 for processing.
  • the industrial camera 510 is set on the robot arm of the industrial robot 200, and the industrial robot 200 drives the industrial camera 510 to the top and side of the loading tray 300 to take pictures.
  • the industrial camera 510 first moves to the side of the loading tray 300 to take a picture, collects the height information of the loading tray 300, calculates the height deviation value, and then moves to the top of the loading tray 300.
  • the processor 520 comprehensively processes the above information, issue an instruction to the industrial robot 200 to control it to grab the loading tray 300.
  • the processor 520 may execute pre-stored vision software.
  • the industrial robot 200 drives the industrial camera 510 to move to a photographing position, and the industrial robot 200 sends a trigger signal to the industrial camera 510 through the control device 400.
  • a trigger command is sent through TCP / IP, and then a pulse signal is sent through the I / O module to trigger the industrial camera 510 to take a picture.
  • the processor 520 executes pre-stored vision software to perform image analysis, thereby accurately positioning the position of the loading tray 300, specifically according to the shape and characteristics of the tray, in the image captured by the industrial camera 510. Search and locate the pallet, and then obtain the position information of the loading tray 300, and then send the position information to the industrial robot 200 through TCP / IP.
  • the industrial robot 200 drives the industrial camera 510 to first move to the side of the first stacking tray 110 to take a picture.
  • the first stacking tray 110 is loaded with a loading tray 300 and a loading tray. 300 is loaded with material 310.
  • the industrial camera 510 collects the height information of the loading tray 300, calculates the deviation value between the height of the current material and the height of the material at the preset position, and then moves to the top surface of the first stack tray 110 to take a picture, and collects the horizontal position of the loading tray 300 Information to calculate the deviation between the height of the current material and the height of the material at the preset position.
  • the processor 520 comprehensively processes the above information, it sends an instruction to the industrial robot 200 to control it to grab the load from the first pallet 110
  • the tray 300 is placed at the material loading place 170.
  • the empty loading tray 300 returns to the cutting place 160, and the industrial robot 200 drives the industrial camera 510 to first move to the side of the cutting place 160 to take pictures. Height information, calculate the height deviation value, then move to the top surface of the blanking place 160 to take a picture, collect the horizontal position information of the loading tray 300, and calculate the horizontal position deviation value.
  • the processor 520 comprehensively processes the above-mentioned information, it sends an instruction to the industrial robot 200 to control it to grab the empty loading tray 300 and place it on the second stack tray 120, so as to reciprocate.
  • the control device 400 sends an instruction to control the industrial camera 510 to position the position information of the second stacking tray 120, and transmits the position information to the industrial robot 200 and the automatic guided vehicle through the control device 400. .
  • the control device 400 controls the automatic guided vehicle to transfer the second pallet 120 according to the received position information, and controls the automatic guided vehicle to transfer an empty pallet.
  • the control device 400 issues an instruction to control the industrial camera to position the position information of the first pallet 110 and transmits the position information to the automatic guided vehicle.
  • the control device 400 controls the automatic guided vehicle to The received position information transfers the first stacking tray 110 and controls the automatic guided vehicle to transfer a stacking tray full of the loading tray 300.
  • the industrial robot 200 takes the loading tray 300 from the third pallet 130 carrying the materials to the loading place 170, and places the empty loading at the unloading place 160.
  • the material tray 300 is stacked on the fourth stack tray 140, and thus reciprocates in this manner.
  • this application proposes an intelligent loading and unloading system that uses industrial vision equipment to cooperate with industrial robots for loading and unloading, which not only realizes the automation of the entire loading and unloading operation process, but also makes use of industry Vision equipment to reduce the working error of industrial robots. Therefore, this application can effectively improve the working efficiency and working accuracy of industrial robots.
  • FIG. 7 is a schematic flowchart of an embodiment of a working method of an intelligent loading and unloading system of the present application.
  • the intelligent loading and unloading system of this embodiment is the above-mentioned intelligent loading and unloading system, and details are not described herein again.
  • the specific steps of the working method of the intelligent loading and unloading system of this embodiment include:
  • Step 601 Positioning the position information of the material through the industrial vision equipment.
  • the industrial vision device 500 includes a processor 520 and an industrial camera 510.
  • the control device 400 controls the image collected by the industrial camera 510; the processor 520 analyzes the image collected by the industrial camera 510 to locate the position information of the material.
  • control device 400 sends control instructions to the industrial robot 510 to cause the industrial robot 200 to drive the industrial camera 510 to move to the side of the material to take pictures, collect the height information of the material, and the processor 520 is based on the height information of the material. Calculate the deviation between the height of the current material and the height of the material at the preset position.
  • the industrial robot 200 drives the industrial camera 510 to move to the top surface of the material to take a picture, collect the horizontal position information of the material, and the processor 520 calculates the current material horizontal position and the preset position of the material based on the horizontal position information of the material. Based on the above-mentioned information, the industrial vision device 500 can locate the position information of the material.
  • Step 602 Send the location information to the control device.
  • the industrial vision device 500 locates the position information of the material, it sends the position information to the control device 400.
  • the control device 400 controls the industrial robot 200 according to the position information of the material, so that the industrial robot 200 can quickly and accurately grasp and transfer the material.
  • Step 603 The control device controls the industrial robot to transfer the material to the loading position and / or the material located at the lower position to a position leaving the lower position according to the position information.
  • control device 400 controls the industrial robot 200 to transfer the material located at the lower material level 160 to a position away from the lower material level 160 according to the position information of the material; and / or the control device 400 controls the industrial robot 200 according to the material
  • the position information will transfer the material to loading position 170.
  • this application proposes an intelligent loading and unloading system and its working method, which cooperates with industrial robots to carry out loading and unloading work through industrial vision equipment, thereby realizing the automation of the entire loading and unloading operation process, It can also use industrial vision equipment to reduce the working error of industrial robots. Therefore, this application can effectively improve the working efficiency and working accuracy of industrial robots.

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Abstract

一种智能上下料系统及其工作方法，包括输送设备（100），用于传输物料（310），输送设备（100）具有上料位（160）和下料位（170）；工业机器人（200），用于将物料（310）转移至上料位（160）和/或将位于下料位（170）的物料（310）转移至离开下料位（170）的位置；工业视觉设备（500），用于检测物料（310）的位置；控制设备（400），用于根据工业视觉设备（500）提供的物料（310）位置信息控制工业机器人（200）工作。

Description

一种智能上下料系统及其工作方法
【技术领域】
本申请涉及工业自动化领域，特别是涉及一种智能上下料系统及其工作方法。
【背景技术】
随着科技的进步发展，在越来越多的领域，机器逐渐取代了劳动力来完成一些高强度高精度的工作。工业自动化日趋成熟，也是工业、农业、国防和科技现代化的重要条件和标志。自动化是指将机器设备、系统或过程在没有人或较少人的直接参与下，按照人的要求，经过自动化检测、信息处理、分析判断、操纵控制，实现预期的目标过程。现有的流水线实际操作中，多采用人工给产线供应物料或托盘，通过劳动力来进行产线的上下料，劳动强度大、工作枯燥无味，且大多是重复性劳动，不仅浪费人工成本，且长时间的重复性劳动会造成劳动力的疲劳，进而降低效率和工作精度。
【发明内容】
本申请主要解决的技术问题是提供一种智能上下料系统及其工作方法,以解决机器人拆垛和码垛时精度低的问题。
为解决上述技术问题，本申请采用的一种智能上下料系统，该系统包括：输送设备，输送设备用于传输物料，输送设备具有上料位和下料位；工业机器人，工业机器人用于将物料转移至上料位和/或将位于所述下料位的物料转移至离开所述下料位的位置；工业视觉设备，工业视觉设备用于检测物料的位置；控制设备，控制设备用于根据工业视觉设备提供的物料位置信息控制工业机器人工作。
为解决上述技术问题，本申请还提出了一种智能上下料系统的工作方法，所述智能上下料系统包括，输送设备、工业机器人、工业视觉设备和控制设备，所述输送设备具有上料位和下料位，所述方法包括：通过所述工业视觉设备检测物料的位置信息；将所述位置信息发送给所述控制设备；所述控制设备控制所述工业机器人根据所述位置信息将物料转移至所述上料位和/或将位于所述下料位的物料转移至离开所述下料位的位置。
本申请的有益效果是：区别于现有技术，本申请提出一种智能上下料系统及其工作方法，通过工业视觉设备来配合工业机器人进行上下料工作，既实现整个上下料作业过程的自动化，又能利用工业视觉设备来降低工业机器人的工作误差。因此，本申请可以有效提高工业机器人的工作效率和工作精度。
【附图说明】
图1 是本申请智能上下料系统一实施方式的原理示意图；
图2是本申请智能上下料系统一实施方式的的结构示意图；
图3是本申请智能上下料系统一实施方式中载料托盘的结构示意图；
图4是本申请智能上下料系统一实施方式中末端执行装置的整体结构示意图；
图5是本申请智能上下料系统一实施方式中末端执行装置的侧面结构示意图；
图6是本申请智能上下料系统一实施方式中工业视觉设备的结构示意图；
图7是本申请智能上下料系统的工作方法一实施方式的流程示意图。
【具体实施方式】
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，均属于本申请保护的范围。
参阅图1和图2，图1 是本申请智能上下料系统一实施方式的原理示意图。图2是本申请智能上下料系统一实施方式的的结构示意图。
结合图1和图2，本申请的智能上下料系统包括输送设备100、工业机器人200、工业视觉设备500以及控制设备400。输送设备100用于传输物料310，且输送设备100设置有上料位160和下料位170。物料310在输送设备100的上料位160进行上料，然后输送设备100将物料310输送至下一个工序。工业机器人200用于将物料310转移至上料位160和/或将位于下料位170的物料310转移至离开下料位170的位置。工业视觉设备500用于检测物料310的位置。控制设备400用于根据工业视觉设备500提供的物料310的位置信息控制工业机器人200工作。控制设备400用于控制工业视觉设备500、输送设备100以及工业机器人200，进行各个设备之间的信息交互。需要说明的是，在其他实施方式中，工业视觉设备500、输送设备100以及工业机器人200也可以各自配备一个控制设备，将各自的控制设备通过通信设备连接起来即可，本申请对此不做限定。
本实施方式中，输送设备100包括上层输送线151和下层输送线150，物料310的上料位170位于上层输送线151上，物料310的下料位160位于下层输送线150上，且下料位160比上料位170更靠近工业机器人200，这样方便机器人快速转移下料位上的物料310。在其他实施场景中，输送设备100也可以是其他形式，比如环形输送线，工业机器人200和物料310存放区都在环形输送线内，输送设备还可以是水平放置的两条输送线，输送线可以是传送带或链条等，只需保证输送线能够输送载料托盘300即可，本申请对此均不作限定。
本实施方式中，工业机器人200包括机器人本体210及末端执行装置220，末端执行装置220用于抓取载料托盘300。机器人本体210配合末端执行装置220将承载有物料310的载料托盘300转移至输送设备100的上料位170，在物料310被取用后，输送设备100将空的载料托盘300传输至下料位160，机器人本体210配合末端执行装置220抓取空的载料托盘300并转移出去。
本实施方式中，工业视觉设备500用于检测物料310的位置，工业视觉设备500安装在工业机器人200的机器臂上。当工业机器人200需要转移载料托盘300至上料位170时，工业视觉设备500检测载料托盘300的位置及上料位170的状态。若检测到上料位170为空时，工业视觉设备500将信息传递给控制设备400，控制设备400控制工业机器人200将载料托盘300放置在上料位170。当工业机器人200需要将下料位160的载料托盘300转移出去时，工业视觉设备500先检测下料位160是否有空的载料托盘300。若有，工业视觉设备500将信息传递给控制设备400，控制设备400控制工业机器人200抓取该空的载料托盘300并转移出去。在其他实施方式中，工业视觉设备500也可以安装在工业机器人200的其他位置或者安装在独立于工业机器人200的位置，本申请对此不作限定。
进一步的，智能上下料系统还包括两组垛盘，第一组垛盘包括第一垛盘110和第二垛盘120，第二组垛盘包括第三垛盘130以及第四垛盘140，载料托盘300堆叠放置于两组垛盘上。其中，第一垛盘110和第三垛盘130用于放置装载有物料310的载料托盘300，第二垛盘120和第四垛盘140用于放置空的载料托盘300，两组垛盘分别置于工业机器人200的两边，起到互补的作用。这里的垛盘不限于上述两组，具体根据实际生产要求来设计，此处不予限定。
进一步的，智能上下料系统还包括自动导引车（图中未示出），自动导引车用于运输垛盘。具体地，当放置空载料托盘的垛盘被满垛时（例如放置了预设数量时），控制设备400发出指令以控制自动导引车将其转移走，并控制自动导引车将一个空垛盘转移过来；当用于供料的垛盘为空时，控制设备400发出指令以控制自动导引车将其转移走，并控制自动导引车将一个满载载料托盘的垛盘转移过来，如此往复。
进一步的，智能上下料系统还包括安全围栏（图中未示出），安全围栏将输送设备100、工业机器人200、工业视觉设备500、控制设备400及自动导引车包围，形成一个防护圈，起到保护整个自动化操作区域的作用。
进一步的，工业机器人200为6轴机器人，6轴机器人具有6个自由度，6自由度机器人意味着它可以拿起任意朝向的部件，能以特殊的角度放入包装产品里，它还可以执行许多由熟练工人才能完成的操作。
参阅图3，图3是本申请智能上下料系统一实施方式中载料托盘的结构示意图。
本实施方式中，载料托盘300用于收容物料310（图3中的载料托盘处于空盘状态）。载料托盘300的上端设置有销钉301，载料托盘300的下端设置有销孔302，销钉301和销孔302成对应关系，相互配合形成限位结构。本实施方式中，销钉301和销孔302的数量均为2两个，可以防止载料托盘300堆叠在一起时载料托盘300之间发生转动。在其他实施方式中，销钉301和销孔302的数量可以为3个、4个或者更多个，销钉301和销孔302的位置分布可以根据实际需要来确定，本申请对此不做限定。销钉301和销孔302配合即可精确定位载料托盘300，这样载料托盘300堆叠在一起可以保证一致性。
当载料托盘300收容有物料310时，输送设备100将位于上料位170的载料托盘300运输至下一个工序，待物料310被取走后，输送设备100将空的载料托盘300运输至下料位160，工业机器人200将空的载料托盘300取走，如此循环。
在另一个具体的实施方式中，输送线为传送带，载料托盘300的上端设置有销孔，下端设置有销钉。销孔和销钉配合即可精确定位托盘，这样托盘堆叠在一起可以保证一致性。
进一步的，载料托盘300的侧壁的外侧设置有两个第一凸起部303和两个第二凸起部304，两个第一凸起部303和两个第二凸起部304对称的分布在载料托盘300的侧壁的外侧。第一凸起部303和第二凸起部304用于与末端执行装置220配合，以使末端执行装置220夹持载料托盘300或松开载料托盘300。
物料310收容于载料托盘内，载料托盘的上端和下端设置有相互配合的限位结构，或者，载料托盘的其他部位设置有相互配合的限位结构，便于载料托盘堆叠放置，保证产品的一致性且节约空间位置，也利于下一个工序的使用。
进一步的参阅图4和图5，图4是本申请智能上下料系统一实施方式中末端执行装置的整体结构示意图，图5是本申请智能上下料系统一实施方式中末端执行装置的侧面结构示意图。需要说明的是，在图4中，末端执行装置220夹持载料托盘300，载料托盘300上载有物料310。
结合图4和图5，本实施方式中，末端执行装置220包括一对垂直设置的第一末端执行器221和一对水平设置的第二末端执行器222，第一末端执行器221对称地固定在末端执行装置220的外侧，第二末端执行器222对称地固定在末端执行装置220的侧壁外侧。垂直设置的第一末端执行器221用于夹持载料托盘300，水平设置的第二末端执行器222用于托举载料托盘。在其他实施方式中，根据不同的设计和使用需求，第一末端执行器221和第二末端执行器222的个数和位置可以做适应性调整，只需保证能够与载料托盘300配合夹持或松开载料托盘300即可，本申请对此不予限定。
进一步的，第一末端执行器221包括第一驱动装置223和第一夹持部224。具体地，第一驱动装置223为气缸，第一夹持部224为气动卡爪，第一驱动装置223驱动第一夹持部224合拢时夹持载料托盘300侧壁上的第一凸起部303，第一驱动装置223驱动第一夹持部224张开时松开载料托盘300侧壁上的第一凸起部303。更具体地，第一驱动装置223为气缸，第一夹持部224包括第一力臂227和第二力臂228，第一力臂227和第二力臂228的第一端与第一驱动装置223的输出端螺接，第一力臂227和第二力臂228的第二端设有凹槽229，第一驱动装置223的输出端驱动第一力臂227和第二力臂228转动，以使第一力臂227和第二力臂228上的凹槽229从第一凸起部303的两侧夹持第一凸起部303。在其他实施方式中，第一驱动装置223也可以为两个伺服电机或步进电机，第一驱动装置223的输出端也可以与第一力臂227和第二力臂228的第一端卡接或焊接等等，本申请对此不作限定。第二末端执行器222包括第二驱动装置225和第二夹持部226。具体地，第二驱动装置225为气缸，第二夹持部226为“L”型导杆，第二驱动装置225驱动第二夹持部226沿水平方向移动，以使“L”型导杆托举或松开载料托盘300侧壁上的第二凸起部304。更具体地，第二驱动装置225位于第一凸起部303和第二凸起部304之间，第二夹持部226为“L”型导杆，且位于第二凸起部304和第二驱动装置225之间，第二驱动装置225的输出端与“L”型导杆的竖直端螺接，第二驱动装置225驱动“L”型导杆靠近或远离第二凸起部304，以使“L”型导杆的水平端托举或松开第二凸起部304。末端执行装置220夹持载料托盘300时，第一夹持部224通过夹持第一凸起部303限制了载料托盘300的线性运动，载料托盘300只能绕第一凸起部303转动；而进一步通过第二夹持部226的托举限制了载料托盘300的转动，从而使得载料托盘300被末端执行装置220牢牢的夹持，可以有效防止载料托盘300在搬运过程中脱落，提高了设备安全性。在其他实施方式中，根据不同的设计和使用需求，末端执行器的具体结构可以做适应性调整，此处不予限定。末端执行器的驱动方式可以是伺服电机、舵机或者其他类型的驱动设备，此处不予限定。第一驱动装置223和第二驱动装置225也可以为液压缸等驱动装置，此处不予限定。
在一个具体的实施场景中，当工业机器人200欲夹持载料托盘300时，工业机器人200将末端执行装置220移动至载料托盘300，以使第一夹持部224包围载料托盘300上的第一凸起部303，使第二夹持部226位于第一凸起部303和第二凸起部304之间。第一驱动装置223驱动第一夹持部224合拢以夹持第一凸起部303，第二驱动装置225驱动第二夹持部226伸长以托举第二凸起部304，从而夹持整个载料托盘300。当工业机器人200欲卸载载料托盘300时，第一驱动装置223驱动第一夹持部224松开以解除对第一凸起部303的夹持，第二驱动装置225驱动第二夹持部226收缩，以使第二夹持部226远离第二凸起部304。工业机器人200将末端执行装置220移开，即可卸载载料托盘300。
进一步的，参阅图6，图6是本申请智能上下料系统一实施方式中工业视觉设备的结构示意图。本实施方式中，工业视觉设备500包括处理器520、工业相机510。当控制设备400控制工业视觉设备500进行检测分析时，具体为：控制工业相机510对物料310进行拍摄，并将拍摄的数据信息传递给处理器520进行处理。
在一个具体的实施场景中，工业相机510设置在工业机器人200的机器臂上，工业机器人200带动工业相机510到达载料托盘300的顶部和侧面进行拍照。当工业机器人200抓取载料托盘300时，工业相机510先移动至载料托盘300的侧面拍照，采集载料托盘300的高度信息，计算高度的偏差值，然后移动至载料托盘300的顶面拍照，采集载料托盘300的水平位置信息，计算水平位置的偏差值，处理器520对上述信息进行综合处理后，向工业机器人200发出指令，控制其抓取载料托盘300。
更具体地，处理器520可以执行预存的视觉软件。工业机器人200带动工业相机510移动至拍照位置，工业机器人200通过控制设备400向工业相机510发送触发信号。具体地，通过TCP/IP发送触发命令，然后通过I/O模块发送脉冲信号触发工业相机510拍照。控制设备400控制工业相机510采集图像后，处理器520通过执行预存的视觉软件以进行图像分析，从而精确定位载料托盘300位置，具体为根据托盘的形状特征，在工业相机510拍摄的图像中搜索托盘并定位，进而得到载料托盘300的位置信息，然后将位置信息通过TCP/IP发送给工业机器人200。
结合图1-6，本申请提供的智能上下料系统具体的工作原理如下：
当工业机器人200需要将物料310转移至上料位170时，工业机器人200带动工业相机510先移动至第一垛盘110的侧面拍照，第一垛盘110上装载有载料托盘300，载料托盘300上装有物料310。工业相机510采集载料托盘300的高度信息，计算当前物料的高度与预设位置的物料的高度的偏差值，然后移动至第一垛盘110的顶面拍照，采集载料托盘300的水平位置信息，计算当前物料的高度与预设位置的物料的高度的偏差值，处理器520对上述信息进行综合处理后，向工业机器人200发出指令，控制其从第一垛盘110上抓取载料托盘300，并将其放置在物料上料处170。
待载料托盘300中的物料被取用后，空的载料托盘300回到下料处160，工业机器人200带动工业相机510先移动至下料处160的侧面拍照，采集载料托盘300的高度信息，计算高度的偏差值，然后移动至下料处160的顶面拍照，采集载料托盘300的水平位置信息，计算水平位置的偏差值。处理器520对上述信息进行综合处理后，向工业机器人200发出指令，控制其抓取空的载料托盘300，并将其放置在第二垛盘120上，如此往复。
当第二垛盘120被满垛时，控制设备400发出指令以控制工业相机510定位第二垛盘120的位置信息，并通过控制设备400将该位置信息传递给工业机器人200和自动导引车。控制设备400控制自动导引车根据接收到的位置信息将第二垛盘120转移出去，并控制自动导引车将一个空垛盘转移过来。当第一垛盘110空垛时，控制设备400发出指令以控制工业相机定位第一垛盘110的位置信息，并将该位置信息传递给自动导引车，控制设备400控制自动导引车根据接收到的位置信息将第一垛盘110转移出去，并控制自动导引车将一个满载载料托盘300的垛盘转移过来。在垛盘运输的过程中，为避免工业机器人200工作间断，工业机器人200从载有物料的第三垛盘130取载料托盘300至上料处170，并将位于下料处160的空的载料托盘300堆叠在第四垛盘140上，如此循环往复。
本申请的有益效果是：区别于现有技术，本申请提出一种智能上下料系统，通过工业视觉设备来配合工业机器人进行上下料工作，既实现整个上下料作业过程的自动化，又能利用工业视觉设备来降低工业机器人的工作误差。因此，本申请可以有效提高工业机器人的工作效率和工作精度。
参阅图7，图7是本申请智能上下料系统的工作方法一实施方式的流程示意图。本实施方式的智能上下料系统为以上所述的智能上下料系统，在此不再赘述。结合图1-7，本实施方式智能上下料系统的工作方法的具体步骤包括：
步骤601：通过工业视觉设备定位物料的位置信息。
在一个具体的实施场景中，工业视觉设备500包括处理器520和工业相机510。控制设备400控制工业相机510采集物料的图像；处理器520通过分析工业相机510采集的图像以定位物料的位置信息。
在一个更具体的实施场景中，控制设备400向工业机器人510发送控制指令以使工业机器人200驱动工业相机510移动至物料的侧面拍照，采集物料的高度信息，处理器520基于物料的高度信息，计算当前物料的高度与预设位置的物料的高度的偏差值。工业机器人200驱动工业相机510移动至物料的顶面拍照，采集物料的水平位置信息，处理器520基于物料的高度水平位置信息，计算当前物料的水平位置与预设位置的物料的所述水平位置的偏差值，工业视觉设备500基于上述信息即可以定位物料的位置信息。
步骤602：将位置信息发送给控制设备。
工业视觉设备500定位物料的位置信息后，将位置信息发送给控制设备400，控制设备400根据物料的位置信息对工业机器人200进行控制，以使工业机器人200快速准确的抓取并转移物料。
步骤603：控制设备控制工业机器人根据位置信息将物料转移至上料位和/或将位于下料位的物料转移至离开下料位的位置。
在一个具体的实施场景中，控制设备400控制工业机器人200根据物料的位置信息将位于下料位160的物料转移至离开下料位160的位置；和/或控制设备400控制工业机器人200根据物料的位置信息将物料转移至上料位170。
关于本实施方式智能上下料系统的工作方法更具体工作步骤请参阅前述描述，此处不再赘述。
本申请的有益效果是：区别于现有技术，本申请提出一种智能上下料系统及其工作方法，通过工业视觉设备来配合工业机器人进行上下料工作，既实现整个上下料作业过程的自动化，又能利用工业视觉设备来降低工业机器人的工作误差。因此，本申请可以有效提高工业机器人的工作效率和工作精度。
以上所述仅为本申请的实施方式，并非因此限制本申请的专利范围，凡是利用本申请说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本申请的专利保护范围内。

Claims (20)

  1. 一种智能上下料系统，其特征在于，包括：
    输送设备，所述输送设备用于传输物料，所述输送设备具有上料位和下料位；
    工业机器人，所述工业机器人用于将物料转移至所述上料位和/或将位于所述下料位的物料转移至离开所述下料位的位置；
    工业视觉设备，所述工业视觉设备用于检测物料的位置；
    控制设备，所述控制设备用于根据所述工业视觉设备提供的物料位置信息控制工业机器人工作。
  2. 根据权利要求1所述的智能上下料系统，其特征在于，所述物料收容于载料托盘内，所述载料托盘的上端和下端设置有互相配合的限位结构，所述载料托盘的侧壁设置有第一凸起部和第二凸起部，所述第一凸起部和所述第二凸起部用于与所述工业机器人配合以使所述工业机器夹持或松开所述载料托盘。
  3. 根据权利要求2所述的智能上下料系统，其特征在于，所述载料托盘的上端设置有销孔，所述载料托盘的下端设置有销钉。
  4. 根据权利要求2所述的智能上下料系统，其特征在于，所述载料托盘的下端设置有销孔，所述载料托盘的上端设置有销钉。
  5. 根据权利要求2所述的智能上下料系统，其特征在于，所述工业机器人包括机器人本体及末端执行装置，所述末端执行装置用于抓取所述载料托盘。
  6. 根据权利要求5所述的智能上下料系统，其特征在于，所述末端执行装置包括一对水平设置的第二末端执行器和一对垂直设置的第一末端执行器，所述一对水平设置的第二末端执行器托举所述载料托盘，所述一对垂直设置的第一末端执行器夹持所述载料托盘。
  7. 根据权利要求6所述的智能上下料系统，其特征在于，所述第一末端执行器包括第一驱动装置和第一夹持部，所述第一夹持部为气动卡爪，所述第一驱动装置驱动所述第一夹持部夹持或松开所述载料托盘，所述第二末端执行器包括第二驱动装置和第二夹持部，所述第二夹持部为导杆，所述第二驱动装置驱动所述第二夹持部托举或松开所述载料托盘。
  8. 根据权利要求7所述的智能上下料系统，其特征在于，所述第一驱动装置为气缸，所述第一夹持部包括第一力臂和第二力臂，所述第一力臂和所述第二力臂的第一端与所述第一驱动装置的输出端螺接，所述第一力臂和所述第二力臂的第二端设有凹槽，所述第一驱动装置的输出端驱动所述第一力臂和所述第二力臂转动，以使所述第一力臂和所述第二力臂上的所述凹槽从所述第一凸起部的两侧夹持所述第一凸起部；所述第二驱动装置为气缸，所述第二驱动装置位于所述第一凸起部和所述第二凸起部之间，所述第二夹持部为“L”型导杆，且位于所述第二凸起部和所述第二驱动装置之间，所述第二驱动装置的输出端与所述“L”型导杆的竖直端螺接，所述第二驱动装置驱动所述“L”型导杆靠近或远离所述第二凸起部，以使所述“L”型导杆的水平端托举或松开所述第二凸起部。
  9. 根据权利要求1所述的智能上下料系统，其特征在于，所述工业机器人为6轴机器人。
  10. 根据权利要求1所述的智能上下料系统，其特征在于，所述输送设备包括上层输送线和下层输送线，所述上料位位于所述上层输送线上，所述下料位位于所述下层输送线上，且所述下料位比所述上料位更靠近所述工业机器人。
  11. 根据权利要求1所述的智能上下料系统，其特征在于，所述智能上下料系统还包括垛盘，所述载料托盘堆叠放置于垛盘上。
  12. 根据权利要求11所述的智能上下料系统，其特征在于，所述垛盘包括两组，每组包括一个空垛盘和一个放置有载料托盘的垛盘。
  13. 根据权利要求11所述的智能上下料系统，其特征在于，所述智能上下料系统还包括自动导引车，所述自动导引车用于运输所述垛盘。
  14. 根据权利要求1所述的智能上下料系统，其特征在于，所述智能上下料系统还包括安全围栏，所述安全围栏将所述输送设备、所述工业机器人、所述工业视觉设备、所述控制设备及所述自动导引车包围。
  15. 根据权利要求1所述的智能上下料系统，其特征在于，所述工业视觉设备包括处理器、工业相机，所述控制设备控制所述工业相机对物料进行检测，并将检测的数据信息传递给所述处理器进行处理。
  16. 根据权利要求15所述的智能上下料系统，其特征在于，所述工业相机设置在所述输送设备和所述工业机器人的上方及侧面。
  17. 一种智能上下料系统的工作方法，其特征在于，所述智能上下料系统包括，输送设备、工业机器人、工业视觉设备和控制设备，所述输送设备具有上料位和下料位，所述方法包括：
    通过所述工业视觉设备检测物料的位置信息；
    将所述位置信息发送给所述控制设备；
    所述控制设备控制所述工业机器人根据所述位置信息将物料转移至所述上料位和/或将位于所述下料位的物料转移至离开所述下料位的位置。
  18. 根据权利要求17所述的智能上下料系统的工作方法，其特征在于，所述工业视觉设备包括处理器、工业相机，所述通过工业视觉设备定位物料的位置信息的步骤具体包括：
    所述控制设备控制所述工业相机采集物料的图像；
    所述处理器通过分析工业相机采集的图像以定位物料的位置信息。
  19. 根据权利要求18所述的智能上下料系统的工作方法，其特征在于，所述控制设备控制所述工业相机采集物料的图像的步骤具体包括：
    所述控制设备向所述工业机器人发送控制指令以使所述工业机器人驱动所述工业相机移动至所述物料的侧面拍照，采集所述物料的高度信息，
    所述控制设备向所述工业机器人发送控制指令以使所述工业机器人驱动所述工业相机移动至所述物料的顶面拍照，采集所述物料的水平位置信息。
  20. 根据权利要求19所述的智能上下料系统的工作方法，其特征在于，所述处理器通过分析工业相机采集的图像以定位物料的位置信息的步骤具体包括：
    所述处理器基于所述物料的高度信息，计算当前物料的高度与预设位置的物料的高度的偏差值，
    所述处理器基于所述物料的水平位置信息，计算当前物料的水平位置与预设位置的物料的所述水平位置的偏差值。
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