Blind plug insertion machine teaching system based on PLC control and control method

Abstract

The invention discloses a blind plug insertion machine teaching system based on PLC control and a control method, and relates to the technical field of computers. The blind plug insertion machine teaching system based on PLC control comprises a PLC main control unit, a visual guidance positioning module, a force sensor, a human-computer interface, an execution mechanism, a feeding device and a teaching module. According to the blind plug insertion machine teaching system based on PLC control, an action process mode is set through a professional program function block to realize zero-code programming; a PLC program function block is designed by professional programming personnel, a man-machine interaction interface is integrated, and rapid operation of non-professional personnel is supported; for non-professional personnel, such as production line technicians or production line operators, the action process is set through teaching, so that the learning and use threshold is greatly reduced; hardware resource consumption is reduced, and the maintenance cost of manufacturers is reduced.

Description

Technical Field

[0001] This invention relates to the field of computer technology, specifically to a PLC-controlled blind plug insertion machine teaching system and control method. Background Technology

[0002] In traditional PLC programming for non-standard equipment, the electrical engineers from the equipment manufacturer design the program's action flow. However, many single-machine automated equipment require multiple processes, and the required action flow for each process is not fixed. Traditional PLC programming requires professional personnel to write the code, which often has the following problems:

[0003] 1. Traditional PLC programming relies on professionals to write code, which is complex and time-consuming;

[0004] 2. Existing teaching systems are mostly designed for complex multi-axis equipment, resulting in redundant functions and wasted resources;

[0005] 3. Traditional systems require additional industrial control computers or high-end PLCs, and small and medium-sized manufacturers find it difficult to bear the maintenance costs;

[0006] 4. Traditional teaching systems separate motion control and process control, making it impossible to record process parameters synchronously.

[0007] To address the shortcomings of existing technologies, this invention provides a PLC-controlled blind plug insertion machine teaching system and control method to solve the aforementioned problems. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a PLC-based blind plug insertion machine teaching system and control method. It achieves zero-code programming through professional program function blocks and set action flow modes. The PLC program function blocks are designed by professional programmers, integrating a human-machine interface to support rapid operation by non-professionals. For non-professionals, such as production line technicians or production line operators, the teaching and setting of action flows significantly lowers the learning and usage threshold, reduces hardware resource consumption, and lowers maintenance costs for manufacturers.

[0009] To achieve the above objectives, the present invention is implemented through the following technical solution: a PLC-controlled blind plug insertion machine teaching system, comprising a PLC main control unit, a vision guidance and positioning module, a force sensor, a human-machine interface, an actuator, a feeding device, and a teaching module;

[0010] The PLC main control unit is used to receive sensor signals, execute control logic, and coordinate the actions of various modules.

[0011] The vision-guided positioning module includes an industrial camera and an image processing unit, which is used to identify the hole positions of the workpiece and output three-dimensional coordinates to the PLC main control unit to guide the XYZ three-axis module and other actuators to complete the positioning task.

[0012] The force sensor is installed at the end of the pressing module. It is used to monitor the pressure data during the blind plug insertion process in real time and feed it back to the PLC main control unit.

[0013] The human-machine interface supports process parameter setting, motion flow programming, and equipment status monitoring;

[0014] The actuator includes an XYZ three-axis drive module and a pressing module, which are used to grasp, position and press in the sealing plug according to the instructions of the PLC main control unit;

[0015] The feeding device is connected to the PLC main control unit and is used to realize the automatic feeding and positioning of connector sealing plugs;

[0016] The XYZ three-axis module is used to drive the pressing module to achieve precise positioning and movement in three-dimensional space;

[0017] The teaching module is integrated into the PLC main control unit and is used to simulate and store the motion trajectory and pressure parameters of the blind plug insertion machine.

[0018] Preferably, the PLC main control unit adopts an FX3U series programmable controller, with a built-in high-speed pulse output module for controlling the XYZ three-axis module servo motor.

[0019] Preferably, the image processing unit uses HALCON image processing software and its algorithm to identify the hole positions on the workpiece.

[0020] Preferably, the force sensor is a strain gauge force sensor with a range of 0-100N and an accuracy of ±0.5N.

[0021] Preferably, the human-machine interface adopts a Weintek TK6071IP touch screen, which communicates with the PLC main control unit through an RS232 interface. The human-machine interface has an operation interface and alarm display functions.

[0022] Preferably, the XYZ three-axis module adopts high-precision ball screw drive with a transmission efficiency of ≥85%.

[0023] Preferably, the feeding device is equipped with a vibratory feeder, and the vibration frequency and amplitude are controlled by a PLC main control unit to achieve orderly feeding of the sealing plugs.

[0024] Preferably, the various structures of the system transmit data via the EtherNet / IP communication protocol, with a communication rate ≥10Mbps.

[0025] Preferably, if the force sensor insertion pressure exceeds a set threshold, the PLC main control unit triggers an emergency stop and records a fault code.

[0026] The second aspect of the present invention provides a control method for a teaching system of a blind plug insertion machine based on PLC control. The control method includes the following steps: Step 100, power-on self-test, the sensor transmits the position information of the actuator and the feeding system information to the PLC main control unit;

[0027] Step 101: The PLC main control unit controls the XYZ three-axis drive module to return to the mechanical zero point and checks whether the feeding device is in place.

[0028] Step 102: Manually plan the motion path. Select the teaching mode through the human-machine interface and manually plan the motion path and insertion parameters of the pressing module.

[0029] Step 103: Execute the program. The PLC main control unit parses the teaching data, generates multi-axis collaborative control instructions, and starts the blind plug insertion process.

[0030] Step 104: Produce the product. The actuator grabs the sealing plug according to the preset path, and the XYZ three-axis is positioned to the target hole. Insertion is completed under the feedback of the force sensor. If the insertion pressure exceeds the set threshold or the position is out of tolerance, the PLC main control unit triggers an emergency stop and records the fault code.

[0031] This invention discloses a PLC-controlled blind plug insertion machine teaching system and control method, which has the following beneficial effects:

[0032] 1. This PLC-controlled blind plug insertion machine teaching system allows operators to easily set process parameters and program motion flows using a touchscreen, without requiring specialized programming knowledge, through a human-machine interface and teaching module. In teaching mode, the motion path and insertion parameters of the pressing module can also be manually planned, and the system automatically stores and generates control commands, greatly simplifying the operation process, reducing operational difficulty and training costs, and improving production efficiency. The PLC main control unit integrates a high-speed pulse output module, which, when paired with ordinary industrial components, can achieve precise control without the need for an industrial PC or high-end PLC, significantly reducing equipment procurement and maintenance costs for small and medium-sized manufacturers and improving the equipment's cost-effectiveness and market competitiveness.

[0033] 2. This PLC-controlled blind plug insertion machine teaching system integrates the teaching module into the PLC main control unit, achieving deep integration of motion control and process control, and synchronously recording process parameters. In teaching mode, the motion trajectory and pressure parameters manually planned by the operator can be simulated, calculated, and stored. During subsequent automatic operation, the PLC main control unit generates multi-axis collaborative control commands based on the stored data, realizing automated blind plug insertion operation, improving the system's versatility and adaptability, meeting the needs of different workpiece specifications and production scenarios, avoiding the problem of separation between motion control and process control in traditional systems, and improving the overall system performance and production efficiency.

[0034] 3. This PLC-controlled blind plug insertion machine teaching system, with its vision-guided positioning module combined with HALCON image processing software algorithms, can accurately identify the three-dimensional coordinates of the workpiece hole, providing precise positioning data for the actuator. The XYZ three-axis drive module adopts high-precision ball screw transmission with a transmission efficiency of ≥85%, enabling rapid and accurate positioning of the sealing plug to the target hole. A force sensor monitors the insertion pressure in real time, ensuring the insertion force is within a reasonable range, avoiding workpiece damage and insertion failure, and effectively improving the accuracy of blind plug insertion and product quality stability. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the operation process of the present invention;

[0037] Figure 2 This is a schematic diagram of the teaching system of the present invention. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] This application provides a PLC-based blind plug insertion machine teaching system and control method, which solves the problems in traditional non-standard equipment PLC programming, such as the variable process flow for each set of processes, the need for professional personnel to write code, the complexity and time consumption of traditional PLC programming, the fact that existing teaching systems are mostly designed for complex multi-axis equipment with redundant functions and wasted resources, the need for additional industrial control computers or high-end PLCs in traditional systems, the difficulty for small and medium-sized manufacturers to bear the maintenance costs, and the separation of motion control and process control in traditional teaching systems, which makes it impossible to record process parameters synchronously.

[0040] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0041] Example 1: This embodiment of the invention discloses a teaching system for a blind plug insertion machine based on PLC control, according to the attached... Figure 1To be continued Figure 2 As shown, it includes a PLC main control unit, a vision-guided positioning module, a force sensor, a human-machine interface, an actuator, a feeding device, and a teaching module;

[0042] The PLC main control unit is the control core of the entire system. It is connected to the vision guidance and positioning module, force sensor, human-machine interface, actuator, and feeding device, and receives signals from each module and issues control commands.

[0043] The PLC main control unit adopts the FX3U series programmable controller, with a built-in high-speed pulse output module. Based on the preset program and control logic, it coordinates the actions of each module. After receiving sensor signals, visual positioning data, and force sensor feedback, it generates corresponding control commands through internal logic operations and judgments, realizing precise control of the entire blind plug insertion process.

[0044] The PLC main control unit boasts high reliability and stability, capable of processing multiple signals in real time and rapidly responding to system changes, ensuring precise synchronization and efficient execution of the blind plug insertion process. Its high-speed pulse output module precisely controls the XYZ three-axis module servo motors, guaranteeing accurate movement and positioning of the pressing module and improving the precision and efficiency of blind plug insertion.

[0045] The vision-guided positioning module includes an industrial camera and an image processing unit. It is used to identify the workpiece hole positions and output three-dimensional coordinates to the PLC main control unit, guiding the XYZ three-axis module and other actuators to complete the positioning task. The industrial camera is installed in a suitable position to clearly capture the workpiece hole position image. The image processing unit is connected to the PLC main control unit and transmits the recognition results to the PLC main control unit.

[0046] An industrial camera captures images of the workpiece's hole positions. The image processing unit uses the algorithms of HALCON image processing software to process and analyze the images, identify the three-dimensional coordinates of the workpiece's hole positions, and transmit them to the PLC main control unit to provide accurate coordinate basis for subsequent positioning operations.

[0047] The vision-guided positioning module can automatically identify the hole position of the workpiece without manual intervention, which greatly improves the positioning efficiency and accuracy. It is especially suitable for complex workpieces or batch production scenarios, effectively reducing the problem of blind plug insertion failure caused by manual positioning errors, and improving the overall production quality and efficiency.

[0048] A force sensor is installed at the end of the pressing module and connected to the PLC main control unit, feeding back pressure data to the PLC main control unit in real time. During blind plug insertion, the force sensor monitors the pressure changes in real time and converts the pressure signal into an electrical signal, which is then transmitted to the PLC main control unit. The PLC main control unit analyzes and judges the pressure data based on a set threshold. When the pressure exceeds the set threshold, the corresponding protection mechanism is triggered.

[0049] Force sensors can monitor the pressure during blind plug insertion in real time, ensuring that the insertion force is within a reasonable range. This effectively avoids damage to the workpiece or blind plug insertion failure due to excessive insertion force, ensuring product quality and production process stability. It also helps to identify potential production problems in a timely manner, facilitating subsequent optimization and improvement.

[0050] The human-machine interface (HMI) communicates with the PLC main control unit via an RS232 interface, allowing operators to interact with the system. The HMI uses a Weintek TK6071 IP touchscreen, enabling operators to set process parameters and program workflows. The set parameters are transmitted to the PLC main control unit via the HMI. Simultaneously, the PLC main control unit feeds back equipment operating status information to the HMI for display, including the operating status of each module on the interface and alarm display functions to indicate fault information.

[0051] The human-machine interface (HMI) provides operators with an intuitive and convenient operating platform, facilitating parameter setting and process programming, thus reducing operational difficulty and training costs. Its alarm display function promptly alerts operators to equipment malfunctions, enabling rapid fault location and troubleshooting, thereby improving production efficiency and ease of equipment maintenance.

[0052] The actuator includes an XYZ three-axis drive module and a pressing module, which are used to grasp, position and press in the sealing plug according to the instructions of the PLC main control unit;

[0053] The XYZ three-axis drive module drives the pressing module to move in three-dimensional space. The pressing module is responsible for grabbing the sealing plug and completing the pressing action. The two work together to form an actuator, which is controlled by the PLC main control unit.

[0054] The XYZ three-axis drive module employs high-precision ball screw transmission. Based on control commands from the PLC main control unit, it drives the pressing module to move precisely in the X, Y, and Z directions, achieving the gripping, positioning, and pressing operation of the sealing plug. The high-precision ball screw transmission of the XYZ three-axis module ensures the motion accuracy of the pressing module, with a transmission efficiency of ≥85%. It can quickly and accurately position the sealing plug to the target hole and complete the pressing action, effectively improving the accuracy and efficiency of blind plug insertion and meeting the requirements of high-precision production.

[0055] The feeding device is connected to the PLC main control unit and provides sealing plugs to the actuator. Its vibratory feeder controls the vibration frequency and amplitude through the PLC main control unit. The feeding device is equipped with a vibratory feeder. Under the control of the PLC main control unit, the vibratory feeder vibrates, causing the sealing plugs to be arranged in an orderly manner and fed. The sealing plugs are then transported to the designated position by the conveying mechanism for easy gripping by the actuator.

[0056] The feeding device enables automatic feeding and positioning of the sealing plugs, eliminating the need for frequent manual feeding, thus improving the level of production automation, reducing labor costs and labor intensity, while ensuring the stability and continuity of the feeding, which is conducive to improving overall production efficiency.

[0057] The teaching module is integrated into the PLC main control unit and works closely with it to simulate and store the motion trajectory and pressure parameters of the blind plug insertion machine. In teaching mode, operators can manually plan the motion path and insertion parameters of the pressing module through the human-machine interface. The teaching module simulates and calculates these motion trajectories and pressure parameters and stores them in the PLC main control unit. During subsequent automatic operation, the PLC main control unit generates multi-axis coordinated control commands based on the stored data to automate the blind plug insertion operation.

[0058] The teaching module allows operators to flexibly adjust the blind plug insertion process according to actual production needs. Through the teaching mode, the motion path and parameters can be quickly planned and optimized without the need for complex programming knowledge, which reduces the difficulty of operation and technical threshold. At the same time, it improves the versatility and adaptability of the system and can meet the needs of different specifications of workpieces and production scenarios.

[0059] The various components of the system transmit data via the EtherNet / IP communication protocol, forming the communication network for the entire system. Leveraging the high-speed and reliable data transmission characteristics of the EtherNet / IP protocol, data generated by each module is transmitted to the PLC main control unit in real time. Simultaneously, control commands issued by the PLC main control unit are sent to each execution module promptly and accurately, ensuring coordinated operation of all parts of the system.

[0060] The system's communication network has a communication rate of ≥10Mbps, which enables the rapid transmission of large amounts of data. This ensures the real-time and accurate data interaction between various modules of the system, avoids production failures or inefficiencies caused by data transmission delays, improves the overall system's operating efficiency and stability, and provides support for high-precision, high-speed blind plug insertion production.

[0061] This PLC-controlled blind plug insertion machine teaching system integrates advanced PLC control technology, visual guidance and positioning technology, force feedback technology, and teaching functions to achieve full automation, high precision, and intelligence in the blind plug insertion process. It not only improves production efficiency and reduces labor costs and intensity, but also significantly enhances the stability and consistency of product quality. It effectively solves problems such as inaccurate positioning, difficulty in controlling insertion force, and low automation in traditional blind plug insertion processes. It is suitable for various production scenarios requiring high-precision blind plug insertion operations and has broad prospects for widespread application.

[0062] The second aspect of the present invention provides a control method for a teaching system of a blind plug insertion machine based on PLC control. The control method includes the following steps: Step 100, power-on self-test, the sensor transmits the position information of the actuator and the feeding system information to the PLC main control unit;

[0063] Step 101: The PLC main control unit controls the XYZ three-axis drive module to return to the mechanical zero point and checks whether the feeding device is in place.

[0064] Step 102: Manually plan the motion path. Select the teaching mode through the human-machine interface and manually plan the motion path and insertion parameters of the pressing module.

[0065] Step 103: Execute the program. The PLC main control unit parses the teaching data, generates multi-axis collaborative control instructions, and starts the blind plug insertion process.

[0066] Step 104: Produce the product. The actuator grabs the sealing plug according to the preset path, and the XYZ three-axis is positioned to the target hole. Insertion is completed under the feedback of the force sensor. If the insertion pressure exceeds the set threshold or the position is out of tolerance, the PLC main control unit triggers an emergency stop and records the fault code.

[0067] This PLC-controlled blind plug insertion machine teaching system achieves zero-code programming through professional program function blocks and set action flow modes. The PLC program function blocks are designed by professional programmers and integrated with a human-machine interface, supporting rapid operation by non-professionals. For non-professionals, such as production line technicians or production line operators, the teaching and setting of action flow significantly reduces the learning and usage threshold, reduces hardware resource consumption, and lowers the manufacturer's maintenance costs.

[0068] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0069] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A teaching system for a blind plug insertion machine based on PLC control, characterized in that, include: The PLC main control unit is used to receive sensor signals, execute control logic, and coordinate the actions of various modules. The vision-guided positioning module includes an industrial camera and an image processing unit, which is used to identify the hole positions of the workpiece and output three-dimensional coordinates to the PLC main control unit to guide the XYZ three-axis module and other actuators to complete the positioning task. A force sensor, installed at the end of the pressing module, is used to monitor the pressure data during the blind plug insertion process in real time and feed it back to the PLC main control unit. The human-machine interface supports process parameter setting, motion flow programming, and equipment status monitoring. The actuator, including the XYZ three-axis drive module and the pressing module, is used to complete the gripping, positioning and pressing of the sealing plug according to the instructions of the PLC main control unit; The feeding device is connected to the PLC main control unit and is used to realize the automatic feeding and positioning of connector sealing plugs; The XYZ three-axis module is used to drive the pressing module to achieve precise positioning and movement in three-dimensional space; The teaching module, integrated into the PLC main control unit, is used to simulate and store the motion trajectory and pressure parameters of the blind plug insertion machine.

2. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The PLC main control unit adopts the FX3U series programmable controller, which has a built-in high-speed pulse output module and is used to control the XYZ three-axis module servo motor.

3. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The image processing unit uses HALCON image processing software and its algorithm to identify the hole positions on the workpiece.

4. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The force sensor is a strain gauge force sensor with a range of 0-100N and an accuracy of ±0.5N.

5. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The human-machine interface uses a Weintek TK6071IP touch screen and communicates with the PLC main control unit via an RS232 interface. The human-machine interface has an operation interface and alarm display functions.

6. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The XYZ three-axis module adopts high-precision ball screw drive with a transmission efficiency of ≥85%.

7. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The feeding device is equipped with a vibratory feeder, and the vibration frequency and amplitude are controlled by a PLC main control unit to achieve orderly feeding of the sealing plugs.

8. The teaching system for a blind plug insertion machine based on PLC control according to claim 1, characterized in that, The various components of the system transmit data via the EtherNet / IP communication protocol, with a communication rate of ≥10Mbps.

9. A teaching system for a blind plug insertion machine based on PLC control according to claim 4, characterized in that, If the force sensor insertion pressure exceeds the set threshold, the PLC main control unit triggers an emergency stop and records the fault code.

10. A control method for a PLC-controlled blind plug insertion machine teaching system according to any one of claims 1-9, characterized in that, The control method includes the following steps: Step 100, power-on self-test, the sensor transmits the position information of the actuator and the feeding system information to the PLC main control unit; Step 101: The PLC main control unit controls the XYZ three-axis drive module to return to the mechanical zero point and checks whether the feeding device is in place. Step 102: Manually plan the motion path. Select the teaching mode through the human-machine interface and manually plan the motion path and insertion parameters of the pressing module. Step 103: Execute the program. The PLC main control unit parses the teaching data, generates multi-axis collaborative control instructions, and starts the blind plug insertion process. Step 104: Produce the product. The actuator grabs the sealing plug according to the preset path, and the XYZ three-axis is positioned to the target hole. Insertion is completed under the feedback of the force sensor. If the insertion pressure exceeds the set threshold or the position is out of tolerance, the PLC main control unit triggers an emergency stop and records the fault code.

Images