Wearable electronic product full-automatic feeding equipment control system

Abstract

The invention relates to the field of wearable electronic products, and particularly discloses a wearable electronic product full-automatic feeding equipment control system which comprises the following steps: S1, resetting PLC internal variables, communication ports and states of all motion shafts; s2, judging a system operation mode, if the system operation mode is a manual mode, entering a manual debugging process, and if the system operation mode is an automatic mode, continuing to execute the next step; s3, executing original point resetting of the whole machine; s4, the full TRAY feeding Z-axis module lifts the face shell loaded with the to-be-fed face shell to the first-layer material taking height in a full TRAY mode; s5, the feeding four-axis module moves to the position above the current face shell in the TRAY, the Z axis descends, and a vacuum suction head is started to suck the face shell; s6, a feeding four-axis module transfers the face shell to a code scanning station, a code scanning gun reads the two-dimensional code, and data are written into a PLC designated register; s7, a feeding four-axis module transfers the face shell to the position over the empty jig, and a Z axis descends to place the face shell in the jig; s8, the feeding four-axis module grabs the empty TRAY and transfers the empty TRAY to an empty TRAY discharging Z-axis module to be stacked and stored; and S9, whether the next full TRAY to be fed exists or not is judged.

Description

Technical Field

[0001] This invention belongs to the field of wearable electronic products, and in particular relates to a fully automatic feeding equipment control system for wearable electronic products. Background Technology

[0002] With the rapid growth in market demand for smart wearable electronic products (such as smartwatches and AR / VR glasses), their manufacturing processes are facing higher requirements for automation, production efficiency, and product quality consistency. Among these, the bonding of the faceplate and lens is one of the key process steps, and the loading of the faceplate, as a preliminary step, directly affects the cycle time and accuracy of subsequent processes.

[0003] In traditional production, the feeding of product shells relies heavily on manual operation or semi-automatic equipment, resulting in high labor intensity, slow work pace, high error rates, and low production capacity. Existing automated equipment often has limited functionality, only capable of processing fixed product models, lacking versatility and flexible design, and struggling to adapt to the production needs of diverse varieties and small batches. Furthermore, some equipment still has shortcomings in positioning accuracy, operational stability, and data traceability (such as scanning and uploading to the MES system). Summary of the Invention

[0004] This invention provides a fully automatic feeding equipment control system for wearable electronic products, aiming to solve the problems of low feeding efficiency, low automation, poor equipment versatility, and lack of data traceability in the existing technology of wearable electronic product shells. It provides a fully automatic feeding equipment control system with reasonable structure, precise control, and stable operation, realizing the full-process automatic control of shells from full TRAY material picking, barcode scanning, placement to jig, empty TRAY unloading, and jig return.

[0005] To solve the above problems, the technical solution provided by the present invention is as follows: A control system for a fully automatic feeding device for wearable electronic products, the system being executed based on a programmable logic controller (PLC), comprising the following steps: S1: After the system is powered on, it is initialized to reset the PLC internal variables, communication ports and the status of each motion axis; S2: Determine the system operation mode. If it is manual mode, proceed to the manual debugging process. If it is automatic mode, continue to the next step. S3: Perform the machine origin return, controlling the full TRAY loading Z-axis module, empty TRAY unloading Z-axis module, loading four-axis module and fixture return Z-axis module to return to the preset mechanical origin position; S4: The full TRAY loading Z-axis module lifts the full TRAY loaded with the surface shell to be loaded to the first layer picking height; S5: The four-axis loading module moves to the top of the current faceplate in the TRAY according to the preset matrix path, the Z-axis descends and the vacuum suction head is activated to pick up the faceplate; S6: The four-axis loading module moves the faceplate to the barcode scanning station, triggers the barcode scanner to read the QR code or barcode information on the faceplate, and writes the data into the designated register of the PLC; S7: The four-axis loading module moves the face shell to the top of the empty fixture on the fixture return Z-axis module. The Z-axis descends and precisely places the face shell inside the fixture. S8: The loading four-axis module grabs the empty TRAY and transfers it to the empty TRAY unloading Z-axis module for stacking and storage; S9: Determine if there is another full TRAY ready to be loaded. If yes, the full TRAY loading Z-axis module raises the new TRAY to the loading position and returns to step S4 to continue the loop; if no, prompt the user to manually load a full TRAY. When S6 is executed: Determine whether the scan is successful. If it fails, trigger an alarm and pause the process. If it succeeds, continue executing S7. After S7 is completed, determine whether all the shells in the current TRAY have been taken. If not, return to step S4 to continue taking materials; if so, execute S8. After S8 completes execution: Determine if the empty TRAY unloading Z-axis module is full. If so, prompt the user via HMI to manually remove the empty TRAY.

[0006] Preferably, in step S6, the barcode scanner establishes a communication connection with the PLC via the MC protocol, and the scanned data is directly written to the pre-allocated register address of the PLC, which is then defined as a scanning rule.

[0007] Preferably, it also includes a MES data upload step: the PLC stores the product information obtained by scanning the code in a designated register, the host computer reads the data in the register through the OPC protocol, and uploads it to the Manufacturing Execution System (MES) to realize data traceability in the production process.

[0008] Preferably, before step S2, a product model selection step is included: the operator selects the currently produced product model through the human-machine interface touch screen HMI, and the PLC automatically calls the parameter configuration file corresponding to the model. The parameters include the material picking matrix path, the coordinate offset of each station, the movement speed, and the barcode scanning rules.

[0009] Preferably, the coordinates of each workstation are pre-calibrated and stored through the coordinate positioning learning and teaching function. Specifically, in manual mode, the operator uses the HMI to jog the four-axis loading module to move to the precise position of the material picking position, barcode scanning position, or material placement position. After triggering the recording command, the PLC automatically reads and stores the absolute encoder position values ​​of the current X, Y, and Z axis servo motors to the data area of ​​the corresponding product model.

[0010] Preferably, the origin return in step S3 adopts a zero-return algorithm, which uses the origin sensor and the zero pulse signal of the servo motor encoder to ensure that the origin position of each axis is consistent each time.

[0011] Preferably, when the empty TRAY unloading Z-axis modules are stacked to a preset number of layers, the system will display a prompt message through the HMI and trigger an audible and visual alarm. Operation can only continue after manual confirmation that the empty TRAY has been removed.

[0012] Preferred components include a programmable logic controller (PLC), a human-machine interface touch screen (HMI), a full TRAY loading Z-axis module, an empty TRAY unloading Z-axis module, a loading four-axis module, and a fixture return Z-axis and track conveying module. The PLC, as the main control unit, communicates with the HMI via industrial Ethernet and controls the coordinated actions of each servo drive and actuator to achieve fully automated control of the entire process, including automatic loading of a full tray, automatic unloading of an empty tray, automatic scanning of the shell, and automatic return of the fixture.

[0013] Preferably, the four-axis loading module includes an X-axis, a Y-axis, a Z-axis, and an R-axis, used to pick up the faceplate from the full TRAY and transfer it to the barcode scanning station and the fixture return station.

[0014] Preferably, the fixture return Z-axis module is used to lift and lower the empty fixture to receive the surface shell. After the fixture is loaded with material, the track conveying module transports it to the next station and receives a new empty fixture after the Z-axis descends, so as to realize the cyclic use of the fixture.

[0015] Compared to existing technologies, the main advantage of this invention, employing the above-mentioned solution, is that it establishes a control system for the actuator based on the fundamental design of the mechanical structure device. This control system enables automatic feeding of wearable electronic product casings, reducing worker workload and increasing daily output. The control system automatically feeds full-loaded casings, automatically unloads empty casings, returns empty fixtures, and automatically scans casing codes. Operators only need to manually insert full-loaded casings and remove empty ones. Furthermore, this invention can switch between suction heads or grippers based on product type, automatically configuring control by selecting the product type number, thus achieving automatic feeding of different casings and meeting the equipment's versatility requirements. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments or prior art, the accompanying drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall process of the present invention; Figure 2 This is a schematic diagram of the full-tray loading process of the present invention; Figure 3 This is a schematic diagram of the empty TRAY unloading process of the present invention; Figure 4 This is a schematic diagram of the four-axis loading module of the present invention; Figure 5 This is a schematic diagram of the jig return process of the present invention. Detailed Implementation

[0018] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0019] It should be noted that when a component is described as being "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is described as being "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "fixed," "integral," "left," "right," and similar expressions used in this specification are for illustrative purposes only, and in the figures, structurally similar units are labeled with the same reference numerals.

[0020] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention.

[0021] A control system for a fully automated feeding device for wearable electronic products, including its hardware and corresponding structural layout: Full TRAY loading platform: Located on one side of the equipment, it is used to place the trays (full TRAY) loaded with the surface shells to be loaded.

[0022] Full TRAY loading Z-axis module: Connected to the bottom of the platform, this module is driven by a servo motor and can be vertically lifted to raise the TRAY layer by layer to the picking height.

[0023] The four-axis loading module, located above the equipment, includes an X-axis guide rail, a Y-axis slider, a Z-axis lifting mechanism, and an R-axis (rotation axis), forming a robotic arm capable of moving and rotating in three-dimensional space. A vacuum suction head is installed at the end for picking up the dough sheets.

[0024] Scanning equipment: barcode camera or barcode gun: a barcode scanning station fixed in the feeding path. When the four-axis feeding module moves the shell to this position, it automatically scans the QR code or barcode on the shell to identify product information.

[0025] Fixture return Z-axis module: Located in the middle of the equipment, it carries the empty fixture and lifts it to the height where it aligns with the four-axis loading mechanism. After unloading is complete, the Z-axis descends, sending the fixture carrying the face shell to the lower track.

[0026] Fixture return track conveyor module: includes upper and lower double-layer conveyor belts. The upper layer is used to transport empty fixtures to the receiving position, and the lower layer is used to transport fixtures carrying face shells to the next process station. The track is driven by a motor and has start-stop control function.

[0027] Empty TRAY unloading Z-axis module: Located on the other side of the equipment, it is used to receive and stack empty TRAY trays transferred by the loading four-axis module; this module can descend layer by layer to accommodate multiple empty TRAYs.

[0028] PLC Control Cabinet 8: Integrates a programmable logic controller (PLC), servo driver, power supply module and I / O module, providing the control core for the entire system.

[0029] Human-Machine Interface (HMI): Installed in front of the equipment, it is used by the operator to select modes, set parameters, monitor status, and view alarms.

[0030] Each module is fixed by a mechanical frame to form an integrated automatic feeding device.

[0031] The system includes the following steps: S1: After powering on, the system initializes, resetting PLC internal variables, communication ports, and the status of each motion axis. S2: The system operation mode is determined. If it's manual mode, the manual debugging process begins; if it's automatic mode, the next step continues. S3: The entire machine returns to its origin, controlling the full TRAY loading Z-axis module, empty TRAY unloading Z-axis module, loading four-axis module, and fixture return Z-axis module to return to the preset mechanical origin position. S4: The full TRAY loading Z-axis module lifts the full TRAY loaded with the shell to be loaded to the first layer picking height. S5: The loading four-axis module moves to above the current shell in the TRAY according to the preset matrix path, the Z-axis descends, and the vacuum suction head picks up the shell. S6: The loading four-axis module transfers the shell to the scanning station, triggering the barcode scanner to read the QR code or barcode information on the shell and write the data to the designated PLC register. S7: The four-axis loading module moves the face shell to the top of the empty fixture on the fixture return Z-axis module. The Z-axis descends and precisely places the face shell inside the fixture. S8: The loading four-axis module grabs the empty TRAY and transfers it to the empty TRAY unloading Z-axis module for stacking and storage; S9: Determine if there is another full TRAY to be loaded. If yes, the full TRAY loading Z-axis module raises the new TRAY to the material pick-up position and returns to step S4 to continue the loop. If no, prompt the user to manually place a full TRAY. When S6 is executed: Determine if the barcode scanning is successful. If it fails, trigger an alarm and pause the process. If successful, continue to execute S7. After S7 is completed, determine if all faceplates in the current TRAY have been picked up. If no, return to step S4 to continue picking up materials. If yes, execute S8. After S8 is completed: Determine if the empty TRAY unloading Z-axis module is full. If yes, prompt the user to manually remove the empty TRAY via HMI.

[0032] It should be noted that the programmable logic controller (PLC) of the fully automated feeding equipment control system for wearable electronic products serves as the main control core. It connects to a human-machine interface (HMI) via Ethernet communication, acting as the medium for user interaction and information exchange with the equipment system. The entire control system also includes equipment alarm systems (servo alarms, pneumatic alarms, limit alarms, alarms during automatic operation, etc.), manual / automatic operation, and parameter setting functions.

[0033] Furthermore, the main framework of the control system program: a. Main program: Initialization, PLC initial run signal initialization; Automatic action process, automatic process control, including origin reset and automatic action; OUTPUT, external output conversion; DISPLAY, a device status display program including indicator lights and tri-color lights; ALARM, alarm program (pneumatic alarm, shaft alarm, etc.); Axis control module: axis control data conversion and assignment, manual operation of each axis; CT & counting, Cycle Time function and capacity counting function.

[0034] b. Automated process: Origin reset module, whole machine origin reset process; Full TRAY loading Z-axis module, full TRAY loading Z-axis automatic motion process; Empty TRAY unloading Z-axis module, automatic motion process of empty TRAY unloading Z-axis; The four-axis loading module enables automatic loading of materials along the X, Y, Z, and R axes. Fixture return Z-axis and track module, automatic motion process of fixture return Z-axis and track conveyor; c. Touchscreen frame: Login screen, user permission selection and login screen; Main screen, automatic action operation and display screen; Full TRAY loading station, manual and positioning parameter settings for the Z-axis during full TRAY loading; Empty TRAY unloading station, manual and positioning parameter settings for the Z-axis of empty TRAY unloading; Loading station, manual and positioning parameter settings for the X, Y, Z, and R axes of the loading station; Fixture return station, manual and positioning parameter settings for fixture return Z-axis and track conveyor; Parameter settings, automatic parameter settings, delay time, masking function, etc.; View alarm information and historical alarm information; IO monitoring, input / output monitoring; Production statistics, hourly production capacity statistics.

[0035] Advantages of the control system: The equipment control system, centered on a PLC module, enables manual control, automated processes, product barcode scanning, and MES data integration for the entire machine. Its main advantages are as follows: a. Programming and motion control are implemented using the PLC LD+SFC programming language; b. The PLC automatic program uses the PLC SFC programming language, and the automatic process logic is clear and the structure is straightforward. c. PLC and LabVIEW communicate using OPC communication. Simply set the communication parameters and define the communication registers, and both parties can read and write freely. d. The barcode scanner uses the MC protocol for communication. Communication can be achieved simply by assigning the control and receiving addresses, without the need to write a communication program. e. MES system: After the barcode scanner reads the specified register through the PLC, the PC then reads it through the OPC.

[0036] Further system operation modes include manual mode and automatic mode; Manual Mode: When the equipment is in manual operation mode, each actuator can be operated individually to check whether it is in normal working condition. This includes jogging, homing, and manual positioning functions for each axis, manual functions for cylinders and vacuum, and manual operation of the production line. Equipment parameters can only be changed in manual mode. Appropriate parameters are a prerequisite for normal equipment operation. The parameters that need to be set in this equipment mainly include the position coordinates and movement speed of each module axis for point-to-point absolute positioning, cylinder and vacuum alarm delay time, production line speed and delay stop time, and sensor arrival delay time.

[0037] Automatic Mode: After resetting the machine, manually place the full-filled tray into the loading position and press the start button. The full-pack Z-axis will move to the loading four-axis module's pick-up position. The loading four-axis module will then pick up the tray sequentially according to the set matrix pattern. The loading four-axis module will grab the tray and scan it at the barcode scanning position to upload the data. Then, it will place the tray into the empty fixture of the fixture return Z-axis module. The fixture return Z-axis track module's conveyor belt will start and transport the fixture to the next workstation. The Z-axis will then descend to the lower track to receive the next empty fixture, and the cycle will repeat. After all the full-packed trays are removed, the loading four-axis module will grab the empty tray and place it at the empty tray unloading Z-axis module. Once the empty tray is full, a prompt will appear for manual removal. The next tray on the full-pack Z-axis module will rise to the pick-up position for the loading four-axis module to pick up the tray, until all full trays are removed. A prompt will appear for manual reloading confirmation before the cycle repeats.

[0038] Furthermore, S3: Executes the overall machine origin return, controlling the full-tray loading Z-axis module, empty-tray unloading Z-axis module, loading four-axis module, and fixture return Z-axis module to return to the preset mechanical origin position; based on the zero-return algorithm jointly detected by the origin sensor and the servo motor encoder zero pulse signal (Z-phase pulse), this method combines high precision, high stability, and anti-interference capability. The following details the zero-return process using the X-axis as an example (the Y, Z, R axes, and other Z-axis modules use the same principle): 1. Hardware components: Servo motor: Equipped with a high-resolution incremental encoder (or an absolute encoder that must return to zero after power failure). Encoder output signal: includes three-phase signals A, B, and Z. Phases A and B: Quadrature pulses, used for direction determination and counting; Z-phase (zero pulse): Outputs one pulse per revolution, representing the fixed electrical zero point of one revolution of the motor; Origin sensor: Usually a proximity switch or photoelectric sensor, installed at a fixed position on the mechanical guide rail, used to detect the "origin stop" on the motion mechanism; PLC and servo drive: The PLC controls the servo drive through the bus or pulse command, and the servo drive provides real-time feedback on the encoder position.

[0039] 2. Zero-return algorithm process (taking the X-axis as an example): Step 1: Low-speed origin sensor location (coarse positioning): The PLC controls the X-axis servo motor to move at a low speed (e.g., 50mm / s) toward the preset "origin direction"; When the "origin stop" on the motion mechanism triggers the origin sensor, the sensor outputs a signal to the PLC; The PLC immediately issues a command to stop the servo motor. At this point, the X-axis has roughly reached the vicinity of the machine origin, completing the coarse positioning.

[0040] Step 2: Move in the opposite direction to detach from the origin sensor: The PLC controls the X-axis servo motor to move a small distance (e.g., 5mm) in the opposite direction at low speed, so that the origin stop block is disengaged from the origin sensor. The sensor signal has returned to normal. Objective: To avoid repeated sensor triggering due to mechanical vibration and to ensure the stability of subsequent steps.

[0041] Step 3: Search again at low speed to capture the encoder's Z-phase pulse (precise positioning): The PLC controls the X-axis servo motor to move back towards the origin at an extremely low speed (e.g., 10 mm / s); Meanwhile, the PLC or servo driver continuously monitors the Z-phase pulse signal of the encoder; When the encoder outputs the first Z-phase pulse during the rotation of the servo motor, the PLC immediately captures the signal. At the instant the Z-phase pulse is captured, the PLC issues a command to precisely stop the servo motor; At this point, the electrical zero point of the motor is aligned with its mechanical position.

[0042] Step 4: Set the machine origin coordinates: The PLC will reset the X-axis position counter to zero at this time, or assign it a preset "mechanical origin coordinate value" (such as X=0.000mm). This coordinate becomes the position reference for this axis during this operating cycle, and all subsequent absolute positioning commands will use this coordinate as a reference.

[0043] Overview: The origin-return method achieves coarse positioning through an origin sensor and precise positioning through the Z-phase pulse of a servo encoder, forming a two-stage positioning strategy of "coarse + fine." This effectively solves the positioning deviation problem caused by factors such as mechanical tolerances, signal interference, and power outages / restarts in automated equipment. This method ensures the absolute positioning accuracy and repeatability of the four-axis loading module in key actions such as material picking, barcode scanning, and material placement, and is an important technical guarantee for achieving efficient and stable production of "one product every 10 seconds."

[0044] Furthermore, in step S6, the barcode scanner establishes a communication connection with the PLC through the MC protocol, and the scanned data is directly written into the pre-allocated register address of the PLC, which is then defined as the scanning rule.

[0045] It should be noted that the QR code scanning rules involve the following aspects: 1) Triggering conditions: During the automatic feeding process of wearable electronic product faceplates, when the faceplate is moved to a specific position (such as a barcode scanning station), the barcode scanner is triggered to read the QR code or barcode information.

[0046] 2) Data Processing: The barcode scanner establishes a communication connection with the PLC via the MC protocol, eliminating the need for writing dedicated communication programs. Scanned data is directly written to the PLC's pre-allocated register address. Furthermore, this data needs to be uploaded to the MES system for further processing and recording.

[0047] 3) Verification Mechanism: Determine how to verify the correctness and validity of the information obtained after scanning. If scanning fails, an alarm is triggered and the process is paused; if successful, the process continues to the next step.

[0048] Product model matching: Since the equipment supports the production of multiple products, the scanning rules may include how to automatically identify which product model is being processed based on the product identifier obtained from the scan, and adjust the corresponding control parameters accordingly (such as the matrix path in step S4, the coordinate offset of each station, etc.).

[0049] Anomaly Handling: Define the actions to be taken when an invalid or unrecognizable barcode / QR code is encountered. This may include strategies such as retrying the scan, issuing a warning signal to the operator, or stopping the production line.

[0050] Example 2, detailed steps of the loading process for the full TRAY loading Z-axis module: see Figure 1 As shown: S10 tray cylinder returns to its original position, and full TRAY loading Z-axis module moves Z-axis to the upper tray position; S11 checks for TRAY functionality: When it is determined that there is no TRAY, a prompt will appear to manually add enough TRAY; after adding enough TRAY, press the confirmation button and the material tray cylinder will start working. When a TRAY is detected, the tray cylinder activates. The S12 full-tray loading Z-axis module performs JOG motion upwards along the Z-axis. S13 determines whether the high limit has been reached: An alarm will be triggered when the high limit is reached. If the upper limit is not reached, proceed to the next step; S14 determines whether the loading position has been reached; if so, it issues a signal that the material can be picked up. S15 awaits the material handling completion signal; When S16 receives the material picking completion signal, it determines whether there is a TRAY on the tray; If there is a TRAY on the tray, the full TRAY loading Z-axis module performs relative positioning downwards along the Z-axis, moves away from the sensor position, and executes S12; If there is no TRAY on the tray, execute S10.

[0051] Further details regarding the empty TRAY unloading process are attached. Figure 2 : The S21 empty TRAY unloading Z-axis module performs upward JOG motion; S22 determines whether the high limit has been reached: An alarm will be triggered when the high limit is reached. If the upper limit is not reached, proceed to the next step; S23 provides a playable TRAY signal; S24 is waiting to release the TRAY completion signal; When S25 receives the TRAY release completion signal, the empty TRAY unloading Z-axis module performs relative positioning downwards along the Z-axis, moving away from the sensor position; S26 determines whether the Z-axis of the empty TRAY unloading Z-axis module is less than the set coordinate of the lower TRAY: When the Z-axis of the TRAY blanking Z-axis module is less than the set coordinate of the lower TRAY, proceed to the next step; Conversely, if the condition is not met, then proceed to step S21; When the S27 empty TRAY unloading Z-axis module moves to the lower TRAY position, a pop-up window will prompt the lower TRAY. After removing the empty TRAY in step S28, press the confirmation button to proceed with step S21.

[0052] Further details regarding the four-axis loading module process are attached. Figure 3 ; The XYZR axes of the S31 four-axis loading module move to the material waiting position; a pop-up window confirms the number of rows and columns to be picked up. S32XYR moves to the dynamic row / column position; determines if the tray is ready: After receiving the information that the material tray is ready, the Z-axis of the four-axis loading module moves to the material picking position to pick up the material. In the S34 four-axis loading module, the XYZR axes move to the barcode scanning position to scan the barcode and upload the MES data. The X and Y axes of the S35 four-axis loading module move to the fixture placement position; determine if the fixture is ready; when ready, the Z axis of the four-axis loading module moves to the fixture placement position to release the material; When the Z-axis of the S36 four-axis loading module moves to the material waiting position, a material unloading completion signal is given; the number of material tray rows is incremented by 1. S37 checks if the number of columns has reached the maximum value. If it has not reached the maximum value, proceed to step S32. If it has reached the maximum value, increment the number of rows in the material tray by 1 and set the number of columns to 1; then proceed to the next step. S37 checks if the number of rows has reached the maximum value. If it has not reached the maximum value, proceed to step S32. If it has reached the maximum value, set the number of rows to 1, move XY to the disk retrieval position, and proceed to the next step. After S38 picks up the tray, the X and Y axes of the four-axis loading module move to the tray placement position; S39 determines whether the disk placement position is ready; upon receiving the readiness information, it executes the disk placement and issues a disk placement completion signal, then executes step S32.

[0053] Further details regarding the fixture return process are provided in the appendix. Figure 4 : S41 awaits assembly line preparation; The S42 fixture moves along the Z-axis of the return track to the feed position of the lower track. S43 sends a signal to the host computer board; S44 is waiting for board arrival / board available signal; When S45 receives the board in / board in signal, the production line starts and the fixture flows into place; S46 production line stops, and the fixture returns to the Z-axis of the return track and moves to the upper discharge position; S47 fixture scanning indicates fixture is ready; S48 awaits the signal indicating completion of material feeding; After receiving the material feeding completion signal, S49 sends a board-on signal to the lower-level machine; S50 awaits a signal from the lower-level machine board; The S51 production line starts, the fixture flows out of the equipment, and the S41 step is executed.

[0054] This invention improves the efficiency of sheet material feeding and reduces worker fatigue. Under normal operating conditions, personnel availability is increased. This control system achieves a production efficiency of one product every 10 seconds, a fourfold improvement compared to a manual machine producing one product every 40 seconds.

[0055] This invention features a highly automated control system that automatically performs functions such as full-tray loading, empty-tray unloading, barcode scanning, and fixture return for the faceplate. It operates stably with high positioning accuracy. The designed positioning function has strong anti-interference capabilities, and there is no cumulative error across the axes during movement.

[0056] It should be noted that the above-mentioned technical features can be combined with each other to form various embodiments not listed above, all of which are considered to be within the scope of this invention specification; and, for those skilled in the art, improvements or modifications can be made based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A control system for a fully automatic feeding device for wearable electronic products, characterized in that; The system is based on a programmable logic controller (PLC) and includes the following steps: S1: After the system is powered on, it is initialized to reset the PLC internal variables, communication ports and the status of each motion axis; S2: Determine the system operation mode. If it is manual mode, proceed to the manual debugging process. If it is automatic mode, continue to the next step. S3: Perform the machine origin return, controlling the full TRAY loading Z-axis module, empty TRAY unloading Z-axis module, loading four-axis module and fixture return Z-axis module to return to the preset mechanical origin position; S4: The full TRAY loading Z-axis module lifts the full TRAY loaded with the surface shell to be loaded to the first layer picking height; S5: The four-axis loading module moves to the top of the current faceplate in the TRAY according to the preset matrix path, the Z-axis descends and the vacuum suction head is activated to pick up the faceplate; S6: The four-axis loading module moves the faceplate to the barcode scanning station, triggers the barcode scanner to read the QR code or barcode information on the faceplate, and writes the data into the designated register of the PLC; S7: The four-axis loading module moves the face shell to the top of the empty fixture on the fixture return Z-axis module. The Z-axis descends and precisely places the face shell inside the fixture. S8: The loading four-axis module grabs the empty TRAY and transfers it to the empty TRAY unloading Z-axis module for stacking and storage; S9: Determine if there is another full TRAY to be loaded. If yes, the full TRAY loading Z-axis module raises the new TRAY to the material pick-up position and returns to step S4 to continue the loop. If no, prompt the user to manually place a full TRAY. When S6 is executed: Determine if the barcode scanning is successful. If it fails, trigger an alarm and pause the process. If successful, continue to execute S7. After S7 is completed, determine if all faceplates in the current TRAY have been picked up. If no, return to step S4 to continue picking up materials. If yes, execute S8. After S8 is completed: Determine if the empty TRAY unloading Z-axis module is full. If yes, prompt the user to manually remove the empty TRAY via HMI.

2. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; In step S6, the barcode scanner establishes a communication connection with the PLC via the MC protocol, and the scanned data is directly written to the pre-allocated register address of the PLC, which is then defined as the scanning rule.

3. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; It also includes the MES data upload step: the PLC stores the product information obtained by scanning the code in a designated register, the host computer reads the data in the register through the OPC protocol and uploads it to the Manufacturing Execution System (MES) to realize data traceability in the production process.

4. The control system for a fully automatic feeding device for wearable electronic products according to claim 2, characterized in that; Before step S2, there is also a product model selection step: the operator selects the product model currently being produced through the human-machine interface touch screen HMI, and the PLC automatically calls the parameter configuration file corresponding to the model. The parameters include the material picking matrix path, the coordinate offset of each station, the movement speed, and the barcode scanning rules.

5. The control system for a fully automatic feeding device for wearable electronic products according to claim 4, characterized in that; The coordinates of each workstation are pre-calibrated and stored through the coordinate positioning learning and teaching function. Specifically, in manual mode, the operator uses the HMI to jog the four-axis loading module to move to the precise position of the material picking position, barcode scanning position, or material placement position. After triggering the recording command, the PLC automatically reads and stores the absolute encoder position values ​​of the current X, Y, and Z axis servo motors to the data area of ​​the corresponding product model.

6. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that... The origin return algorithm in step S3 is adopted. The origin sensor and the servo motor encoder zero pulse signal work together to ensure that the origin position of each axis is consistent each time.

7. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; When the Z-axis modules for empty TRAY unloading reach the preset number of layers, the system will display a prompt message via HMI and trigger an audible and visual alarm. Operation can only continue after manual confirmation that the empty TRAY has been removed.

8. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; Includes a programmable logic controller (PLC), a human-machine interface touch screen (HMI), a full-tray loading Z-axis module, an empty-tray unloading Z-axis module, a loading four-axis module, and a fixture return Z-axis and track conveying module. The PLC, as the main control unit, communicates with the HMI via industrial Ethernet and controls the coordinated actions of each servo drive and actuator to achieve fully automated control of the entire process, including automatic loading of a full tray, automatic unloading of an empty tray, automatic scanning of the shell, and automatic return of the fixture.

9. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; The four-axis loading module includes X-axis, Y-axis, Z-axis and R-axis, used to pick up the shell from the full TRAY and transfer it to the barcode scanning station and the fixture return station.

10. The control system for a fully automatic feeding device for wearable electronic products according to claim 1, characterized in that; The fixture return Z-axis module is used to lift and lower the empty fixture to receive the surface shell. After the fixture is loaded with material, the track conveying module transports it to the next station and receives a new empty fixture after the Z-axis descends, realizing the cyclic use of the fixture.

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