Controller and control method for charging and demagnetizing electric permanent magnetic chuck for manipulator

Abstract

The present invention relates to the field of motor control, and discloses a controller for charging and demagnetizing an electric permanent magnetic chuck for a manipulator, comprising a switching power supply module, a rectifier filter module, a main control module, a drive module, an IGBT module, an output circuit, a protection control module, a Hall sensor, and an external control module; the rectifier filter module, the switching power supply module, the main control module, the drive module, and the IGBT module are connected in sequence, the main control module is connected to the Hall sensor through the protection control module, the main control module is also connected to the external control module, and the IGBT module is connected to the electric permanent magnetic chuck for a manipulator through the output circuit. The present invention can monitor the change of output voltage or current in real time and adjust it to achieve the change of the magnetic force of the chuck to control the electric permanent magnetic chuck for a manipulator by changing the circuit control form, so that the output magnetic force of the electric permanent magnetic chuck is stable and reliable, and is used to solve the problem that the controller cannot monitor the change of the magnetic force of the chuck and the conversion speed in real time.

Description

Technical Field

[0001] The invention relates to the field of magnetizing and demagnetizing controllers, and in particular to a magnetizing and demagnetizing controller for an electric permanent magnetic chuck used in a robot and a control method thereof. Background Art

[0002] With the development of society and the progress of science and technology, automated production lines have appeared in many fields and industries, especially in the application environment where the equipment runs at high speed and the speed of transferring workpieces increases rapidly. When some industries transfer iron components, due to the heavy weight of the components and the complex factory environment, the requirements for the manipulators in the automated production line are gradually increasing. At this time, the electric permanent magnetic chuck for manipulators came into being and is widely used in various links of the automated production line.

[0003] According to the different requirements of the production process of the environment, the manipulator has different shapes and different requirements for electrical appliances. The most important indicator is the conversion speed of the manipulator's electric permanent magnetic chuck for charging and demagnetization. The electric permanent magnetic chuck for the manipulator is installed at the front end of the robot wrist, and the workpiece is sucked by electromagnetic suction. Since the electric permanent magnetic chuck is an inductive load, it is necessary to maintain a certain charging and demagnetization time to ensure the magnetic stability of the electric permanent magnetic chuck. The traditional charging and demagnetization controller generally adopts the form of thyristor, and the output current and time are difficult to accurately control, resulting in unstable magnetic force; and because the manipulator runs at high speed on the production line, the safety control of the electric permanent magnetic chuck for the manipulator is also a problem that needs to be paid attention to and solved. Summary of the invention

[0004] In view of this, the purpose of the present invention is to provide a manipulator electric permanent magnetic chuck charging and demagnetization controller and a control method thereof, so as to solve the problem that the traditional manipulator electric permanent magnetic chuck charging and demagnetization controller cannot monitor the chuck magnetic force change and conversion speed in real time.

[0005] To achieve the above object, the technical solution of the present invention is achieved as follows:

[0006] An electric permanent magnetic chuck charging and demagnetization controller for a manipulator, including a switching power supply module, a rectifier filter module, a main control module, a drive module, an IGBT module, an output circuit, a protection control module, a Hall sensor and an external control module;

[0007] The rectifier and filter module, the switch power module, the main control module, the drive module and the IGBT module are connected in sequence, the main control module is connected to the Hall sensor through the protection control module, the main control module is also connected to the external control module, and the IGBT module is connected to the manipulator electric permanent magnetic chuck through the output circuit;

[0008] The switch power supply module is used to supply power to the main control module;

[0009] The rectifier and filter module is used to convert the positive and negative alternating voltage into a unidirectional pulsating voltage and reduce the AC component in the pulsating DC voltage, so as to reduce the output voltage ripple factor, thereby converting the AC power supply into the required DC power supply;

[0010] The main control module is used to calculate and output a PWM signal according to the parameters set by the external control module and the switch signal;

[0011] The driving module is used to respond to the PWM signal of the main control module and output it to the IGBT module;

[0012] The IGBT module is used to control the direction and size of the PWM value to achieve the change of the output voltage or current to control the electric permanent magnetic chuck of the robot;

[0013] The protection control module is used to output an enable drive signal command or a disable drive signal command to protect the safe operation of the controller and the load end according to whether the current working current is abnormal after being logically processed by the RS trigger circuit;

[0014] The Hall sensor is used to detect whether the working current state is normal or not, and send the detected current signal to the main control module;

[0015] The external control module is used to send the instructions issued by the main control module to an externally arranged actuator.

[0016] Furthermore, the IGBT module adopts an H-bridge circuit arrangement, and the H-bridge circuit is composed of four groups of IGBT driver chips to control the direction and magnitude of the main circuit output current.

[0017] Furthermore, one end of the rectifier and filter module is connected to the high voltage end of the H-bridge circuit, and the other end is connected to the low voltage end of the H-bridge circuit; the rectifier and filter module includes a three-phase rectifier bridge circuit and a filter capacitor circuit.

[0018] Furthermore, the main control module adopts an MCU chip.

[0019] Furthermore, the IGBT driver chip and the MCU chip are connected via an RS trigger circuit to achieve low voltage protection and current protection.

[0020] Furthermore, the external control module includes a position sensor, which is connected to the electro-permanent magnetic chuck of the manipulator and is used to collect position change information of the electro-permanent magnetic chuck of the manipulator and send it to the main control module.

[0021] Furthermore, the external control module includes a PLC controller.

[0022] Furthermore, the external control module also includes an operation panel, and the operation panel is used to perform output state setting of parameter setting.

[0023] The present invention also provides a control method for a charging and demagnetizing controller of an electric permanent magnetic chuck for a robot, which is characterized in that an input power supply is rectified and filtered by a rectifier and filter module to form a high-voltage direct current, and a variable PWM wave is output through an H-bridge circuit in an IGBT module. By changing the output direction of the H-bridge and the size of the PWM value, a change in the output voltage or current is achieved, thereby controlling the electric permanent magnetic chuck for the robot to achieve a change in the magnetic force of the chuck; a main control module uses parameter settings and a Hall sensor to collect the output quantity to form a closed-loop servo system, and stably and reliably outputs current or voltage to achieve control of the chuck and generate a stable magnetic force.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] The controller for charging and demagnetizing the permanent magnetic chuck for manipulators provided by the present invention can monitor the change of output voltage or current in real time and adjust it to achieve the change of magnetic force of the chuck by changing the circuit control form, so as to control the permanent magnetic chuck for manipulators, so that the output magnetic force of the permanent magnetic chuck is stable and reliable, and the danger of the chuck falling off due to insufficient magnetic force is effectively prevented. The conversion time is reduced from the original second level to the millisecond level, which greatly shortens the operation time, saves labor, improves work efficiency, and realizes the requirement for high-speed conversion of the controller.

[0026] At the same time, it also has the function of current detection and protection for the suction cup and realizes effective communication with the production line. When a fault occurs on the equipment, the entire equipment can be controlled to stop in time through emergency communication with the production line to avoid accidents and achieve safety protection. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a circuit block diagram of the controller for charging and demagnetizing the electric permanent magnetic chuck for the manipulator of the present invention;

[0028] Figure 2 This is a functional block diagram of the charging and demagnetization controller of the electric permanent magnetic chuck for the manipulator of the present invention;

[0029] Figure 3 This is the overall circuit diagram of the controller for charging and demagnetizing the electric permanent magnetic chuck for the manipulator of the present invention;

[0030] Figure 4 This is an internal power supply circuit diagram of the charging and demagnetization controller of the electric permanent magnetic chuck for the robot arm of the present invention;

[0031] Figure 5 The present invention is a circuit diagram of the operating panel of the controller for charging and demagnetizing the electric permanent magnetic chuck for the robot. DETAILED DESCRIPTION

[0032] The present invention will be described in detail below with reference to the accompanying drawings.

[0033] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0034] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0035] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0036] The present invention provides a controller for charging and demagnetizing an electric permanent magnetic chuck for a manipulator, referring to Figure 1 , Figure 2, a charging and demagnetizing controller for an electric permanent magnetic chuck for a manipulator, comprising a switching power supply module, a rectifying and filtering module, a main control module, a driving module, an IGBT module, an output circuit, a protection control module, a Hall sensor and an external control module; the rectifying and filtering module, the switching power supply module, the main control module, the driving module and the IGBT module are connected in sequence, the main control module is connected to the Hall sensor through the protection control module, the main control module is also connected to the external control module, and the IGBT module is connected to the electric permanent magnetic chuck for the manipulator through the output circuit; the switching power supply module is used to supply power to the main control module; the rectifying and filtering module is used to convert the positive and negative changing AC voltage into a unidirectional pulsating voltage and reduce the AC component in the pulsating DC voltage, so that the output voltage ripple coefficient is reduced, thereby converting the AC power supply into the required DC power supply; The main control module is used to calculate and output PWM signals according to the parameters set by the external control module and the switch signal; the drive module is used to respond to the PWM signal of the main control module and output it to the IGBT module; the IGBT module is used to control the direction and size of the PWM value to achieve the change of the output voltage or current to control the electric permanent magnetic sucker of the manipulator; the protection control module is used to output the enable drive signal command or disable drive signal command to protect the safe operation of the controller and the load end according to whether the current working current detected is abnormal or not, after the RS trigger circuit performs logic processing; the Hall sensor is used to detect whether the working current state is normal or not, and send the detected current signal to the main control module; the external control module is used to send the instructions issued by the main control module to the externally set actuator. Among them, the main control module is used to calculate the frequency and duty cycle of the PWM signal according to the rated current, release demagnetization starting current, release demagnetization delay time, single-step demagnetization pulse number and other parameters set by the external control module and each take-up switch signal, and output the PWM signal according to the output time.

[0037] The electric permanent magnetic suction cup charging and demagnetization controller for manipulators provided by the present invention can monitor the change of output voltage or current in real time and adjust it to achieve the change of suction cup magnetic force by changing the circuit control form, so as to control the electric permanent magnetic suction cup for manipulators, so that the output magnetic force of the electric permanent magnetic suction cup is stable and reliable, and the danger of the suction cup falling off due to insufficient magnetic force is effectively prevented. The conversion time is reduced from the original second level to the millisecond level, which greatly shortens the operation time, saves labor, improves work efficiency, and realizes the requirement for high-speed conversion of the controller. At the same time, it also has the current detection protection function of the suction cup and realizes effective communication with the production line. When a fault occurs on the equipment, the entire equipment can be controlled to stop in time through emergency communication with the production line to avoid accidents and realize safety protection.

[0038] Preferably, the IGBT module adopts an H-bridge circuit arrangement, and the H-bridge circuit is composed of four groups of IGBT driver chips to control the direction and magnitude of the main circuit output current.

[0039] More preferably, one end of the rectifier and filter module is connected to the high voltage end of the H-bridge circuit, and the other end is connected to the low voltage end of the H-bridge circuit; the rectifier and filter module includes a three-phase rectifier bridge circuit and a filter capacitor circuit. The main control module uses an MCU chip.

[0040] like Figure 3 As shown, the present invention provides the main control circuit part of the electric permanent magnetic chuck demagnetization controller for manipulators, the input power R, S, T forms a +500V high voltage direct current after passing through the three-phase rectifier bridge D1, filter capacitors C2, C3 and voltage divider resistors R01, R02, and inputs to the +500V high voltage end (positive pole) and GND low voltage end (negative pole) of the H bridge composed of four IGBT driver chips Q1, Q2, Q3, Q4, and controls the two-phase H bridge loop to make the U and V ends output a DC PWM wave with a variable size and direction: the H bridge is controlled by four groups of isolated IGBT driver chips U4, U5, U6, and U3, wherein the U-phase upper arm of the H bridge is controlled by the driver chip U4, the lower arm is controlled by U5, the V-phase upper bridge arm is controlled by U6, and the lower arm is controlled by U3. The IGBT driver chip has the functions of low voltage protection, high voltage UCE protection, overcurrent protection, etc.

[0041] During operation, the working principle of the H bridge is as follows, refer to Figure 3 , the signal is calculated by MCU chip U1 and output PWM1-PWM4 signal to IGBT driver chip U4, U5, U6 and U3, and then output to IGBT Q1, Q2, Q3 and Q4 driver terminals after high and low voltage isolation. When magnetizing, PWM1 inputs high level, PWM2 inputs low level, PWM3 inputs low level, PWM4 inputs high level, U terminal outputs high level, V terminal outputs low level, forming a positive voltage from U to V; when demagnetizing, a negative voltage is first formed from U terminal to V terminal (PWM1 inputs low level, PWM2 inputs high level, PWM3 inputs high level, PWM4 inputs low level). By adjusting the duty cycle of PWM1 and PWM4, the output voltage is adjusted to achieve the purpose of controlling the output current.

[0042] In addition, if Figure 3 The IGBT driver chips U4, U5, U6, U3 and the MCU chip U1 are connected via an RS trigger U2 circuit to achieve low voltage protection and current protection.

[0043] In addition, the external control module includes a position sensor, which is connected to the electro-permanent magnetic chuck of the manipulator and is used to collect position change information of the electro-permanent magnetic chuck of the manipulator and send it to the main control module.

[0044] It is understandable that the external control module includes a PLC controller. The PLC controller is connected to the production line and uses relay contacts to transmit the fault status signal of the controller to the production line, wherein two relay switch signals are used to transmit the success and failure signals of the demagnetization and the demagnetization, and one relay switch signal is used to transmit the fault signal inside the controller.

[0045] Reference Figure 2 The external control module also includes an operation panel, which is used to set the output state of the parameter setting. The operation panel uses a key switch to complete parameter setting and adjustment, such as Figure 5 As shown, U18 is a four-digit digital tube for displaying parameters and fault codes, and U17 drives the digital tube segment code display. For example, E06 indicates a load fault, which may be a load short circuit or leakage fault. Q8-Q11 is used for dynamic bit code display; buttons K1, K2, K3, and K4 are used for password, function setting, and parameter adjustment. In terms of parameters, multiple parameters such as magnetizing voltage, demagnetization time, and interlocking protection point can be set.

[0046] The power supply inside the controller, such as Figure 4 As shown, the main control chip of the 500V high-voltage DC switching power supply is U7. Through the oscillator Q5, an oscillation frequency of 70K is formed to form a flyback switching power supply, and multiple voltage outputs are formed through the transformer T1; the voltage generated by the winding T1E is stabilized by the rectifier tubes D13, L1, and C61 to generate a 12V voltage output, and the optocoupler OP1 and U9 form a voltage feedback to form a constant voltage main power supply 12V, and the 5V (VCC) voltage generated after the voltage stabilization by U8 is used to power the MCU chip; after the voltage is divided by D21 and R53, R54, the VOL voltage is generated for the MCU chip to sample and detect the power supply voltage. Winding T1C generates +15V2 and -5V2 voltages after rectification by D17, filtering by C46 and C47, and stabilization by D7 to provide positive and negative power supplies to the H-bridge U-phase upper arm driver chip U4; winding T1D generates +15V3 and -5V3 voltages to provide positive and negative power supplies to the H-bridge V-phase upper arm driver chip U6; winding T1B generates +15V1 and -5V1 voltages to provide positive and negative power supplies to the H-bridge lower arm driver chips U5 and U3; winding T1F generates +12V0 and GND0 to provide 12V power supply to the external terminal.

[0047] Reference Figure 3, PWM regulation is through AD sampling of VOL voltage and AD sampling of Iu1 current detected by Hall sensor IC3, and PWM output is controlled by internal PID algorithm to form a closed-loop control system. The PID control process can be divided into voltage loop and current loop. The voltage loop outputs PWM according to the set output voltage value, and compares the sampled voltage value VOL with the set voltage value, and uses the difference to correct the PWM output value to achieve the purpose of constant output voltage. The current loop is the current output by Hall sensor IC3, IGBTU, V phase, and the detection signal Iu1 enters the MCU chip U1 for AD sampling, and compares the sampled value with the set current value. When the sampled value is greater than the set value, the output PWM value decreases, and the output current value also decreases, so that the actual output value and the set value are consistent; when the sampled current value is less than the set current value, the output PWM value increases, and the output current value also increases, so that the set value and the output value are equal, so as to achieve the purpose of constant current output. In the actual circuit, the current loop or voltage loop can be used according to the characteristics of the load.

[0048] The present invention also provides a control method for a controller for charging and demagnetizing an electric permanent magnetic chuck for a robot, which is characterized in that the input power is rectified and filtered by a rectifier and filter module to form a high-voltage direct current, and a variable PWM wave is output through an H-bridge circuit in an IGBT module. By changing the output direction of the H-bridge and the size of the PWM value, the output voltage or current is changed to control the electric permanent magnetic chuck for the robot to achieve a change in the magnetic force of the chuck; the main control module uses parameter settings and Hall sensors to collect the output quantity to form a closed-loop servo system, and stably and reliably outputs current or voltage to achieve control of the chuck and generate a stable magnetic force. The controller for charging and demagnetizing an electric permanent magnetic chuck for a robot provided by the present invention has a complete low-voltage protection and current protection circuit, such as Figure 3 As shown, when any end of the IGBT driver chip U3, U4, U5, and U6 detects a fault signal, the F01 signal is set low, which will trigger the RS trigger U2 and generate a SD high-level signal. The high-level SD signal locks U3-U6 and prohibits the PWM signal output. The SD signal is simultaneously transmitted to the MCU chip U1 drive signal fault detection pin. The MCU chip U1 immediately terminates the IGBT driver chip output signal and sends out an alarm signal to play a protective role.

[0049] The content of the present invention is not limited to the embodiments listed, and any equivalent changes made to the technical solution of the present invention by ordinary technicians in this field after reading the description of the present invention are covered by the claims of the present invention.

Claims

1. A control method for a charging and demagnetizing controller of an electric permanent magnetic chuck for a manipulator, characterized in that: The controller includes a switching power supply module, a rectifier filter module, a main control module, a drive module, an IGBT module, an output circuit, a protection control module, a Hall sensor and an external control module; The rectifier and filter module, the switch power module, the main control module, the drive module and the IGBT module are connected in sequence, the main control module is connected to the Hall sensor through the protection control module, the main control module is also connected to the external control module, and the IGBT module is connected to the manipulator electric permanent magnetic chuck through the output circuit; The main control module adopts MCU chip; The switch power supply module is used to supply power to the main control module; The rectifier and filter module is used to convert the positive and negative alternating voltage into a unidirectional pulsating voltage and reduce the AC component in the pulsating DC voltage, so as to reduce the output voltage ripple factor, thereby converting the AC power supply into the required DC power supply; The main control module is used to calculate and output a PWM signal according to the parameters set by the external control module and the switch signal; The driving module is used to respond to the PWM signal of the main control module and output it to the IGBT module; The IGBT module is used to control the direction and size of the PWM value to achieve the change of the output voltage or current to control the electric permanent magnetic chuck of the robot; The IGBT module adopts an H-bridge circuit arrangement, which is composed of four groups of IGBT driver chips to control the direction and magnitude of the output current of the main circuit; the IGBT driver chip is connected to the MCU chip through an RS trigger circuit to achieve low voltage protection and current protection; The protection control module is used to output an enable drive signal command or a disable drive signal command to protect the safe operation of the controller and the load end according to whether the current working current is abnormal after being logically processed by the RS trigger circuit; The Hall sensor is used to detect whether the working current state is normal or not, and send the detected current signal to the main control module; The external control module is used to send the instructions issued by the main control module to the externally arranged actuator; The input power is rectified and filtered by the rectifier and filter module to form a high-voltage direct current, and a variable PWM wave is output through the H-bridge circuit in the IGBT module. By changing the output direction of the H-bridge and the size of the PWM value, the output voltage or current is changed to control the electric permanent magnetic chuck for the robot to achieve the change of the magnetic force of the chuck; the main control module uses parameter settings and Hall sensors to collect the output quantity to form a closed-loop servo system, and stably and reliably output current or voltage to control the chuck and generate stable magnetic force; When any end of the IGBT driver chip U3, U4, U5, and U6 detects a fault signal, the F01 signal is set low, which will trigger the RS trigger U2 and generate a SD high-level signal. The high-level SD signal locks U3-U6 and prohibits the PWM signal output. At the same time, the SD signal is transmitted to the MCU chip U1 drive signal fault detection pin. The MCU chip U1 immediately terminates the IGBT driver chip output signal and sends an alarm signal to play a protective role.

2. The control method of the electric permanent magnetic chuck charging and demagnetization controller for a manipulator according to claim 1 is characterized in that: One end of the rectifier and filter module is connected to the high voltage end of the H-bridge circuit, and the other end is connected to the low voltage end of the H-bridge circuit; the rectifier and filter module includes a three-phase rectifier bridge circuit and a filter capacitor circuit.

3. The control method of the electric permanent magnetic chuck charging and demagnetization controller for a manipulator according to claim 2 is characterized in that: The external control module includes a position sensor, which is connected to the manipulator's electric permanent magnetic chuck and is used to collect position change information of the manipulator's electric permanent magnetic chuck and send it to the main control module.

4. The control method of the electric permanent magnetic chuck charging and demagnetization controller for a manipulator according to claim 3 is characterized in that: The external control module includes a PLC controller.

5. The control method of the electric permanent magnetic chuck charging and demagnetization controller for a manipulator according to claim 4 is characterized in that: The external control module further comprises an operation panel connected to the main control module, and the operation panel sends an operation instruction to the main control module.

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