Full-automatic transfer system between graphite boat stations

Abstract

The present application relates to a kind of graphite boat maintenance system and its using method.Graphite boat involved in maintenance is provided with two-dimensional code, and graphite boat maintenance system includes: offline station, maintenance station, online station, AGV carrier and computer, and the inside of computer is provided with graphite boat management system and dispatch system;Offline station and online station are provided with camera, offline station, maintenance station, online station are all provided with manipulator and two-dimensional code scanner, the present application increases manipulator, camera, two-dimensional code scanner and AGV carrier on each existing station, and the collaborative control of the dispatch system in computer and graphite boat management system control, the existing graphite boat management paper record is changed into two-dimensional code record, each two-dimensional code is recorded with the corresponding information of a graphite boat, simultaneously, the transfer of graphite boat between each station is changed from existing manual handling to AGV carrier automatic handling.

Description

Technical Field

[0001] This invention relates to a fully automated transfer system, and more particularly to a fully automated transfer system between workstations of a graphite boat. Background Technology

[0002] In the solar photovoltaic field, graphite boats are silicon wafer carriers that can be used multiple times, but require cleaning and maintenance after each use. Currently, all processes from the production line to the maintenance area involve manual handling, and the usage of graphite boats requires manual completion of paper inspection forms. However, as the industry has developed, the output of supporting equipment has continuously increased, and the variety of products has also expanded, making manual handling and statistical work increasingly burdensome. To reduce costs, increase production efficiency, and reduce manpower while increasing automation is a major trend. Summary of the Invention

[0003] This invention provides a fully automated transfer system between graphite boat workstations, solving the problem of low automation in the transfer of graphite boats between different workstations in the prior art.

[0004] The above-mentioned technical problems of the present invention are mainly solved by the following technical solution: a graphite boat maintenance system and its usage method, characterized in that: all graphite boats involved in maintenance are equipped with QR codes, and the graphite boat maintenance system includes: an offline station for receiving old graphite boats from the process line; a maintenance station for maintaining graphite boats; an online station for sending graphite boats back to the process line; an AGV transport vehicle for transferring graphite boats; and a computer, which has a graphite boat management system and a scheduling system installed inside.

[0005] The offline and online workstations are equipped with cameras for capturing the visual features of the graphite boats. The offline, maintenance, and online workstations are all equipped with robotic arms capable of gripping the graphite boats and QR code scanners. The robotic arms, QR code scanners, cameras, and AGV transport vehicles are all connected to a computer for signal transmission. The maintenance system is used as follows:

[0006] S1, the off-line station receives the old graphite boat, the QR code scanner scans the QR code of the graphite boat, and at the same time the camera takes a picture of the graphite boat and sends the image to the computer;

[0007] S2, the image software in the computer can determine the degree of damage of the graphite boat by recognizing the visual features in the image, and send the degree of damage of the graphite boat to the graphite boat management system. The graphite boat management system records the information in the QR code corresponding to the graphite boat.

[0008] S3. After completing the above processes, the scheduling system sends a signal to the AGV transport vehicle via computer. The AGV transport vehicle moves to the unloading point of the off-line station, and then the computer controls the robotic arm to transfer the graphite boat onto the AGV transport vehicle.

[0009] S4. After the graphite boat is transferred, the dispatching system controls the AGV transport vehicle again via computer to move it to the subsequent maintenance station.

[0010] S5. After the AGV transport vehicle is transferred to the loading point of the maintenance station, it feeds the information back to the computer. The computer controls the robotic arm on the maintenance station to transfer the graphite boat from the AGV transport vehicle to the maintenance station. The QR code scanner on the maintenance station scans the QR code of the graphite boat and sends the information to the computer. The graphite boat management system can check whether the graphite boat is consistent with the pre-set graphite boat for transfer. Then the graphite boat is maintained at the maintenance station. After the maintenance is completed, the maintenance station sends the information to the computer. The dispatching system sends a signal to the AGV transport vehicle through the computer. The AGV transport vehicle moves to the unloading point of the maintenance station. Then the computer controls the robotic arm to transfer the graphite boat to the AGV transport vehicle.

[0011] S6, the scheduling system controls the AGV transport vehicle to transfer the graphite boat to the loading point of the online station, and feeds the information back to the computer. The computer controls the robotic arm on the online station to transfer the graphite boat on the AGV transport vehicle to the online station.

[0012] S7: The QR code scanner at the workstation scans the QR code on the graphite boat, then the camera takes a picture of the graphite boat and sends the image to the computer. The image software on the computer can identify the integrity of the graphite boat. Because new damage may occur during the maintenance process, this process can be used to detect graphite boats that have not been properly maintained. After the graphite boat passes the inspection, it is sent back to the process line.

[0013] This invention adds robotic arms, cameras, QR code scanners, and AGV transport vehicles to each existing workstation. Through coordinated control of a computer-based scheduling system and a graphite boat management system, the existing paper-based records for graphite boat management are transformed into QR code records. Each QR code corresponds to a specific graphite boat's information. Simultaneously, the transfer of graphite boats between workstations is changed from manual handling to automated transport by AGV transport vehicles. This makes the graphite boat maintenance process more efficient, reduces manpower, minimizes human error, and facilitates real-time monitoring of the maintenance status of each graphite boat.

[0014] Furthermore, the maintenance stations, in sequence according to the process, include: a drying station for cleaning and drying the graphite boat; a replacement station for replacing old or damaged parts of the graphite boat; and a plating station for calibrating and plating the boat.

[0015] Furthermore, the drying and plating stations are mandatory. After obtaining an image of the corresponding graphite boat, the graphite boat management system uses software to determine its degree of wear. If the degree of wear is below a set value, the graphite boat skips the replacement station; otherwise, it needs to be sent to the replacement station. Using computer software to identify the degree of wear in the graphite boat image is more efficient and accurate than manual judgment.

[0016] Furthermore, each of the drying, washing, replacement, and plating stations is equipped with a robotic arm and a QR code scanner, both of which are connected to the computer for signal transmission. With the cooperation of the graphite boat management and scheduling system on the computer, the graphite boat can automatically move between the three stations.

[0017] Furthermore, the processing time for the graphite boat at the three maintenance stations—drying, replacement, and plating—is fixed. The computer can determine whether the graphite boat has been processed based on its dwell time at each station. Preferably, each of the three stations is equipped with corresponding existing automated equipment, facilitating the fixing of the processing time at each station. Compared to determining the status of the graphite boat at the current station through detection devices, judging the status by processing time reduces hardware usage, thereby lowering the overall system cost.

[0018] Furthermore, the AGV carrier is equipped with a support device on its back for carrying the graphite boat. The support device can rotate horizontally, and the posture of the graphite boat can be adjusted by rotating the support device to facilitate the gripping of the robotic arm.

[0019] Furthermore, the supporting device includes a load-bearing platform and two clamping members. The two clamping members are movable, and the graphite boat can be clamped or released by changing the distance between the two clamping members. Specifically, the clamping action of the two clamping members can be achieved by an electric cylinder, a pneumatic cylinder, or a synchronous belt.

[0020] Furthermore, the robotic arm is equipped with a gripping mechanism for holding a graphite boat. This gripping mechanism includes a gripper base and two grippers on it whose spacing can be changed by sliding. The gripping action of the two grippers can be driven by an electric cylinder or a pneumatic cylinder.

[0021] Furthermore, the gripping mechanism is equipped with sensors to detect whether it is holding the graphite boat, preventing situations where the graphite boat cannot be successfully gripped.

[0022] Therefore, this invention has the following characteristics compared with the prior art: 1. This invention uses two hardware devices, a robotic arm and an AGV transport vehicle, in conjunction with a graphite boat management system and a scheduling system, to achieve fully automated transfer of graphite boats between different workstations in the graphite boat maintenance process, eliminating the need for manual handling and effectively improving production efficiency; 2. Each graphite boat is equipped with a unique QR code, which can record the graphite boat's image and maintenance information, transforming the existing paper-based graphite boat management records into QR code records, improving work efficiency and facilitating real-time viewing of the maintenance progress of each graphite boat. Attached Figure Description

[0023] Appendix Figure 1 This is a process flow diagram of the present invention;

[0024] Appendix Figure 2 This is a flowchart of the hardware in the graphite boat maintenance system;

[0025] Appendix Figure 3 This is a schematic diagram of the gripping mechanism;

[0026] Appendix Figure 4 This is a structural schematic diagram of the load-bearing device;

[0027] Appendix Figure 5 This is a diagram showing the interconnection between various hardware components and the computer. Detailed Implementation

[0028] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings.

[0029] Example 1: See Figure 2 A graphite boat maintenance system and its usage method are disclosed. Each graphite boat involved in the maintenance is equipped with a QR code. The graphite boat maintenance system includes: a loading / unloading station A, used to receive old graphite boats from the process line or to return maintained graphite boats to the process line; a drying / washing station B, used to clean and dry the graphite boats; a replacement station C, used to replace old or damaged parts of the graphite boats; a plating / calibrating station D, used for calibrating and plating the boats; an AGV transport vehicle 2, used to transfer graphite boats; and a computer, which internally contains a graphite boat management system and a scheduling system.

[0030] See Figure 2 and Figure 5 Workstation A is a combined workstation of the offline and online workstations, possessing the functions of two workstations. Each workstation is equipped with a camera 6 for capturing the visual characteristics of the graphite boat. Workstations A, B, C, and D are all equipped with robotic arms 1 capable of gripping graphite boats and QR code scanners 5. Robotic arms 1, QR code scanners 5, cameras 6, and AGV transport vehicles 2 are all connected to a computer for signal transmission. Cameras 6 and QR code scanners 5 are fixed to robotic arms 1. The operating method of the above maintenance system is as follows:

[0031] See Figure 1 S1, the online and offline workstations receive old graphite boats, the QR code scanner scans the QR code on the graphite boat, and at the same time the camera takes a picture of the graphite boat and sends the image to the computer. The software on the computer can perform secondary visual development on the photo using Halcon.

[0032] S2, the image software in the computer can identify the visual features in the image after secondary development to determine the degree of damage to the graphite boat, and send the degree of damage information of the graphite boat to the graphite boat management system. The graphite boat management system records the information in the QR code corresponding to the graphite boat.

[0033] S3. After completing the above processes, the scheduling system sends a signal to the AGV transport vehicle via computer. The AGV transport vehicle moves to the unloading point of the upper and lower line workstations. Then, the computer controls the robotic arm to transfer the graphite boat onto the AGV transport vehicle.

[0034] S4. After the graphite boat is transferred, the dispatching system controls the AGV transport vehicle again via computer to move it to the subsequent maintenance station.

[0035] S5, the maintenance station is divided into a drying station, a replacement station, and a plating station. The steps for each station are as follows: S5.1, the AGV transport vehicle moves the graphite boat to the drying station, the robotic arm transfers the graphite boat to the drying station, and then the QR code scanner scans the QR code of the graphite boat and sends the information to the computer. The graphite boat management system can check whether the graphite boat is consistent with the pre-set graphite boat to be transferred. Then the drying station starts drying. After the drying time reaches the predetermined time, the scheduling system will dispatch the AGV transport vehicle to the unloading point of the drying station, and the robotic arm completes the unloading of the graphite boat.

[0036] S5.2, the AGV transport vehicle moves the graphite boat to the replacement station. The robotic arm transfers the graphite boat to the replacement station, and then the QR code scanner scans the QR code of the graphite boat and sends the information to the computer. The graphite boat management system can check whether the graphite boat is consistent with the pre-set graphite boat to be transferred. Then the replacement station begins the replacement process. After the replacement time reaches the predetermined time, the scheduling system will dispatch the AGV transport vehicle to the unloading point of the replacement station, and the robotic arm will complete the unloading of the graphite boat.

[0037] S5.3, the AGV transport vehicle moves the graphite boat to the plating station. The robotic arm transfers the graphite boat to the plating station, and then the QR code scanner scans the QR code of the graphite boat and sends the information to the computer. The graphite boat management system can check whether the graphite boat is consistent with the pre-set graphite boat to be transferred. Then the plating station starts the plating process. After the plating time reaches the predetermined time, the scheduling system will dispatch the AGV transport vehicle to the unloading point of the plating station, and the robotic arm will complete the unloading of the graphite boat.

[0038] When the graphite boat management system determines that the graphite boat needs to be replaced based on the degree of wear recorded in the graphite boat's QR code, the graphite boat needs to go through S5.1, S5.2 and S5.3 in sequence; otherwise, the graphite boat only needs to go through S5.1 and S5.3 in sequence.

[0039] S6. After the AGV transport vehicle is transferred to the loading point of the upper and lower line workstations, it feeds the information back to the computer. The computer controls the robotic arms on the upper and lower line workstations to transfer the graphite boat on the AGV transport vehicle to the upper and lower line workstations.

[0040] S7: The QR code scanner at the upstream and downstream workstations scans the QR code on the graphite boat, and then the camera takes a picture of the graphite boat. The image is sent to the computer, and the image software on the computer can identify the integrity of the graphite boat. Because new damage may occur during the maintenance process, this process can be used to detect graphite boats that have not been properly maintained. After the graphite boat passes the inspection, it is sent back to the process line.

[0041] This embodiment adds robotic arms, cameras, QR code scanners, and AGV transport vehicles to each existing workstation. Through collaborative control of the computer's scheduling system and the graphite boat management system, the existing paper-based records of graphite boat management are transformed into QR code records. Each QR code corresponds to the information of a graphite boat. Simultaneously, the transfer of graphite boats between workstations is changed from manual handling to automated transport by AGV transport vehicles. This makes the graphite boat maintenance process more efficient, reduces manpower, minimizes human error, and facilitates real-time monitoring of the maintenance status of each graphite boat.

[0042] See Figure 2 The AGV carrier 2 has a support device 3 on its back for carrying the graphite boat. The support device 3 can rotate horizontally, and by rotating, it can adjust the posture of the graphite boat to facilitate the gripping of the robotic arm 1. The AGV carrier is an existing mature product, and its back support device can be customized to control the overall horizontal rotation. The specific structure will not be described in detail here.

[0043] See Figure 4 The bearing device 3 includes a load-bearing platform 31 and two clamping parts 32. The load-bearing platform 31 is equipped with a synchronous belt 33. The two clamping parts 32 are synchronously engaged with the two sides of the synchronous belt 33 respectively. When the synchronous belt 33 rotates, it will synchronously drive the two clamping parts 32 to move in opposite directions.

[0044] See Figure 3 In this embodiment, the robotic arm 1 is a readily available and mature industrial six-axis robotic arm. The robotic arm is equipped with a gripping mechanism 4 for holding a graphite boat. The gripping mechanism 4 includes a gripper base 41 and two grippers 42 on it whose spacing can be changed by sliding. The gripping action of the two grippers can be driven by an electric cylinder.

[0045] See Figure 3 The gripping mechanism 4 is also equipped with a sensor 43 for detecting whether it is holding the graphite boat, to prevent the graphite boat from being unsuccessfully gripped.

[0046] It will be apparent to those skilled in the art that the present invention can be modified in various ways, and such modifications are not considered to depart from the scope of the invention. All such modifications that are obvious to those skilled in the art are included within the scope of the claims.

Claims

1. A graphite boat maintenance system and its usage method, characterized in that: Each graphite boat involved in the maintenance is equipped with a QR code. The graphite boat maintenance system includes: The off-line station is used to receive old graphite boats from the production line. Maintenance station, used for maintaining the graphite boat; The online workstation is used to send the graphite boat back to the production line; AGV transport vehicles are used to transfer graphite boats; The computer contains a graphite boat management system and a scheduling system. The offline and online workstations are equipped with cameras for capturing the visual features of the graphite boats. The offline, maintenance, and online workstations are all equipped with robotic arms capable of gripping the graphite boats and QR code scanners. The robotic arms, QR code scanners, cameras, and AGV transport vehicles are all connected to a computer for signal transmission. The maintenance system is used as follows: S1, the off-line station receives the old graphite boat, the QR code scanner scans the QR code of the graphite boat, and at the same time the camera takes a picture of the graphite boat and sends the image to the computer; S2, the image software in the computer can determine the degree of damage of the graphite boat by recognizing the visual features in the image, and send the degree of damage of the graphite boat to the graphite boat management system. The graphite boat management system records the information in the QR code corresponding to the graphite boat. S3. After completing the above processes, the scheduling system sends a signal to the AGV transport vehicle via computer. The AGV transport vehicle moves to the unloading point of the off-line station, and then the computer controls the robotic arm to transfer the graphite boat onto the AGV transport vehicle. S4. After the graphite boat is transferred, the dispatching system controls the AGV transport vehicle again via computer to move it to the subsequent maintenance station. S5. After the AGV transport vehicle is transferred to the loading point of the maintenance station, it feeds the information back to the computer. The computer controls the robotic arm on the maintenance station to transfer the graphite boat from the AGV transport vehicle to the maintenance station. The QR code scanner on the maintenance station scans the QR code of the graphite boat and sends the information to the computer. The graphite boat management system can check whether the graphite boat is consistent with the pre-set graphite boat for transfer. Then the graphite boat is maintained at the maintenance station. After the maintenance is completed, the maintenance station sends the information to the computer. The dispatching system sends a signal to the AGV transport vehicle through the computer. The AGV transport vehicle moves to the unloading point of the maintenance station. Then the computer controls the robotic arm to transfer the graphite boat to the AGV transport vehicle. S6, the scheduling system controls the AGV transport vehicle to transfer the graphite boat to the loading point of the online station, and feeds the information back to the computer. The computer controls the robotic arm on the online station to transfer the graphite boat on the AGV transport vehicle to the online station. S7, the QR code scanner at the workstation scans the QR code on the graphite boat, then the camera takes a picture of the graphite boat and sends the image to the computer. The image software on the computer can identify the integrity of the graphite boat. After the graphite boat passes the inspection, it is sent back to the process line.

2. The graphite boat maintenance system and its method of use according to claim 1, characterized in that: The maintenance workstations, in sequence according to the work process, include: The drying station is used to clean and dry the graphite boats. The new workstation is used to replace old and damaged parts on the graphite boat. The plating station is used for calibrating and plating boats.

3. The graphite boat maintenance system and its method of use according to claim 2, characterized in that: The drying and cleaning station and the plating and calibration station are mandatory stations. After obtaining the image of the corresponding graphite boat, the graphite boat management system uses software to determine its degree of wear. When the degree of wear is lower than the set value, the graphite boat skips the replacement station; otherwise, it needs to be sent to the replacement station.

4. The graphite boat maintenance system and its method of use according to claim 3, characterized in that: The drying, washing, replacement, and plating stations are all equipped with robotic arms and QR code scanners, and the corresponding robotic arms and QR code scanners can transmit signals to the computer.

5. The graphite boat maintenance system and its method of use according to claim 4, characterized in that: The processing time for the graphite boat is fixed at the three stations in the maintenance station: the drying and washing station, the replacement station, and the plating and calibration station. The computer can determine whether the graphite boat has been processed based on the dwell time of the graphite boat at each station.

6. The graphite boat maintenance system and its method of use according to claim 1, characterized in that: The AGV carrier is equipped with a support device on its back for carrying the graphite boat, and the support device can rotate horizontally.

7. The graphite boat maintenance system and its method of use according to claim 6, characterized in that: The bearing device includes a load-bearing platform and two clamping components. The two clamping components are movable, and the graphite boat can be clamped or released by changing the distance between the two clamping components.

8. The graphite boat maintenance system and its method of use according to claim 7, characterized in that: The robotic arm is equipped with a gripping mechanism that can hold a graphite boat. The gripping mechanism includes a gripper base and two grippers on it whose spacing can be changed by sliding.

9. The graphite boat maintenance system and its method of use according to claim 8, characterized in that: The gripping mechanism is also equipped with sensors to detect whether it is holding the graphite boat.

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