A method and system for mass production of robots

Abstract

The purpose of this application is to provide a method and system for mass production of robots. This application connects a PLC device to an industrial computer and a robotic arm to the industrial computer on an assembly line. When the industrial computer receives a signal that the robotic arm has completed its task, it sends a command signal to the PLC device, thereby controlling the robotic arm assembly process based on the command signal. A wireless access point module is installed on the assembled robot, and component information is uploaded to the production system via the wireless access point module. When the assembly line status in the production system indicates that assembly is complete, the assembled robot automatically proceeds to a test waiting area for testing. A docking station is provided at the end of the assembly line. When a robot carrier flows to the end of the assembly line, the docking station transports the robot carrier to the beginning of the assembly line, completing the docking and flow of the robot carrier. This achieves automation of robot production and assembly, reduces costs, facilitates replication, and facilitates scalability.

Description

Technical Field

[0001] The present application relates to the field of robotics, and in particular to a method and system for mass production of robots. Background Art

[0002] As service robot products mature and market demand grows, robot production plants must be capable of large-scale mass production. Currently, the assembly line in the robot production process requires manual supervision, resulting in low production efficiency, error-proneness, difficulty in replicability, and high labor costs. Furthermore, the assembly line's carriers are heavy, making manual handling inefficient and prone to injury. Summary of the Invention

[0003] One purpose of the present application is to provide a method and system for mass production of robots to solve the problems in the prior art of requiring manual defense, low production efficiency, difficulty in replication, low handling efficiency and easy injury.

[0004] According to one aspect of the present application, a method for mass production of robots is provided, the method comprising:

[0005] Connecting a PLC device to an industrial computer on an assembly line, and connecting a robotic arm to the industrial computer; when the industrial computer receives a signal indicating that the robotic arm has completed its task, sending a command signal to the PLC device, and controlling the assembly process of the robotic arm based on the command signal;

[0006] A wireless access point module is installed on the assembled robot, and component information is uploaded to the production system through the wireless access point module. When the assembly line status in the production system is assembly completed, the assembled robot automatically goes to the test waiting area for testing;

[0007] A docking station is provided at the tail end of the assembly line. When the robot carrier flows to the tail end of the assembly line, the robot carrier is transported to the head end of the assembly line through the docking station, completing the docking and flow of the robot carrier.

[0008] Optionally, before the industrial computer sends a command signal to the PLC device upon receiving the robot arm operation task completion signal, the process includes:

[0009] The PLC device is used to collect data on the assembly line and to control the rotation of the crawler, the raising and lowering of the lifting platform and the raising and lowering of the docking platform.

[0010] Optionally, controlling the robotic arm assembly process based on the command signal includes:

[0011] Determine whether the current robot arm assembly station is idle through a control program on the industrial computer, and start assembly work at the current robot arm assembly station based on the determination result;

[0012] When the assembly operation is completed at the current robot arm assembly station, a message of assembly completion is sent to the industrial computer. The industrial computer records the assembly time and related data of the current robot arm station and reports them to the production system.

[0013] Optionally, starting an assembly operation at the current robot arm assembly station based on the judgment result includes:

[0014] If the current robotic arm assembly station is idle, the control program sends a message to the PLC device to enable the PLC device to unlock the conveyor belt so that the belt rotates forward to perform assembly operations, and lock the conveyor belt after the robot carrier moves to the next robotic arm assembly station.

[0015] Optionally, when the assembly line status in the production system is assembly completed, the assembled robot automatically goes to a test waiting area for testing, including:

[0016] A pressure sensor is installed under the lifting platform of the assembly line. When the robot is in position, the lifting platform descends to the bottom.

[0017] The industrial computer uploads the message that the lifting platform has reached the bottom to the production system. Based on the information that the lifting platform is at the bottom read from the production system, the robot walks down the assembly line and goes to the test waiting area for testing.

[0018] Optionally, self-directed to the testing holding area after testing, including:

[0019] When the infrared sensor senses that the robot has left, the lifting platform automatically rises and transfers the robot carrier to the docking platform via the conveyor belt.

[0020] Optionally, when the robot carrier flows to the end of the assembly line, the robot carrier is transported to the head of the assembly line through the docking station, including:

[0021] The robot carrier is transported to the docking station via the transport crawler, and the transport robot sends a docking start command based on the information received from the production system indicating that the robot carrier is located at the docking station;

[0022] The docking station at the tail end of the assembly line descends to load the robot carrier onto the pallet of the transport robot, and the transport robot moves to the head of the assembly line on its own.

[0023] Optionally, the transport robot moves to the head of the assembly line by itself, including:

[0024] The transport robot enters the docking station at the head of the assembly line through the operation of aligning the QR code, and returns the robot carrier to the assembly line through the rising operation of the docking station.

[0025] According to another aspect of the present application, a system for robot mass production is also provided, the system comprising: an assembly line module, an assembly module and a flow module, wherein:

[0026] The assembly line module is used to connect the PLC device to the industrial computer and the robotic arm to the industrial computer on the assembly line. When the industrial computer receives the task completion signal of the robotic arm, it sends a command signal to the PLC device, and controls the assembly process of the robotic arm based on the command signal.

[0027] The assembly module is used to install a wireless access point module on the assembled robot, and upload the component information to the production system through the wireless access point module. When the assembly line status in the production system is assembly completed, the assembled robot automatically goes to the test waiting area for testing;

[0028] The transfer module is used to provide a docking station at the tail end of the assembly line. When the robot carrier flows to the tail end of the assembly line, the robot carrier is transported to the head end of the assembly line through the docking station to complete the docking and transfer of the robot carrier.

[0029] According to another aspect of the present application, a computer-readable medium is provided, on which computer-readable instructions are stored. The computer-readable instructions can be executed by a processor to implement the method described above.

[0030] Compared with the existing technology, the present application connects a PLC device to an industrial computer and a robotic arm to the industrial computer on the assembly line. When the industrial computer receives a signal that the robotic arm has completed its task, it sends a command signal to the PLC device, and controls the robotic arm assembly process based on the command signal. A wireless access point module is installed on the assembled robot, and component information is uploaded to the production system through the wireless access point module. When the assembly line status in the production system is assembly completed, the assembled robot automatically goes to the test waiting area for testing. A docking station is provided at the end of the assembly line. When the robot carrier flows to the end of the assembly line, the docking station transports the robot carrier to the head of the assembly line to complete the docking and flow of the robot carrier. This enables the automation and unmanned production and assembly of robots, reduces labor costs during production, and is easy to replicate and scale up. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Other features, objects and advantages of the present application will become more apparent upon reading the detailed description of non-limiting embodiments made with reference to the following drawings:

[0032] Figure 1 A schematic flow chart of a method for mass production of robots according to one aspect of the present application is shown;

[0033] Figure 2 A framework diagram of an automated assembly line for robot mass production according to an embodiment of the present application is shown;

[0034] Figure 3 A schematic diagram showing the process of assembling a robotic arm in one embodiment of the present application is shown;

[0035] Figure 4 A schematic diagram showing the process of completing assembly by a robot in one embodiment of the present application is shown;

[0036] Figure 5 A schematic diagram showing the process of docking and circulation of a robot carrier in one embodiment of the present application is shown;

[0037] Figure 6 A schematic structural diagram of a system for robot mass production provided according to another aspect of the present application is shown.

[0038] The same or similar reference numerals in the drawings represent the same or similar components. DETAILED DESCRIPTION

[0039] The present application is described in further detail below with reference to the accompanying drawings.

[0040] In a typical configuration of the present application, the terminal, the device of the service network and the trusted party all include one or more processors (eg, a central processing unit (CPU)), an input / output interface, a network interface and a memory.

[0041] Memory may include non-permanent storage in a computer-readable medium, random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of a computer-readable medium.

[0042] Computer-readable media include permanent and non-permanent, removable and non-removable media that can be used to store information by any method or technology. Information can be computer-readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase-change RAM (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile disk (DVD) or other optical storage, magnetic cassettes, tape disk storage or other magnetic storage devices or any other non-transmission medium that can be used to store information that can be accessed by a computing device. According to the definition in this article, computer-readable media does not include non-transitory media such as modulated data signals and carrier waves.

[0043] To solve the above technical problems, this application proposes a method for an automated assembly line with robots. This method can operate unmanned, record the information of each assembly step, and cooperate with a transport robot to achieve the recycling of carriers. The specific implementation steps are as follows:

[0044] Figure 1 A schematic flow chart of a method for mass production of robots according to one aspect of the present application is shown, the method comprising: steps S11 to S13,

[0045] Step S11: Connect a PLC device to an industrial computer and a robotic arm to the industrial computer on the assembly line. When the industrial computer receives a signal that the robotic arm has completed its task, it sends a command signal to the PLC device, and controls the assembly process of the robotic arm based on the command signal. Here, the assembly line is an automatic assembly line for producing robots, and a PLC device (Programmable Logic Controller), an industrial computer, and a robotic arm are installed on the assembly line. Figure 2As shown, the assembly line is controlled by a PLC device using the Modbus communication protocol. The PLC is connected to an industrial computer via a network cable. The computer runs an automated scheduling program, controls the assembly line, and simultaneously uploads real-time status to the production system. The robotic arm on the assembly line is connected to the IPC via a serial port. When the IPC receives a task completion signal from the robotic arm, it sends a command signal to the PLC device, including unlocking the tracks and forwarding signals. The robotic arm at the next station receives the command signal and begins its work, continuing the assembly process. The IPC can receive and send Modbus messages used by the PLC device, communicate with the robotic arm via the serial port, and receive and send HTTP messages to the production system, achieving unified message forwarding.

[0046] In step S12, a wireless access point module is installed on the assembled robot, and component information is uploaded to the production system through the wireless access point module. When the assembly line status in the production system is assembly completed, the assembled robot automatically goes to the test waiting area for testing. Here, a wireless access point module (wifi module) is installed on the assembled robot, which can access the factory network and conduct two-way communication with the production system on the server side, upload component information to the production system, and receive the assembly line status from the production system. When the status is assembly completed, the robot automatically walks off the assembly line and goes to the test waiting area for testing.

[0047] Step S13: A docking station is provided at the end of the assembly line. When the robot carrier reaches the end of the assembly line, it is transported to the beginning of the assembly line via the docking station, completing the docking and transfer of the robot carrier. Because the robot carrier is relatively heavy, a handling robot carries it when it reaches the end of the assembly line and then transports it to the beginning of the assembly line. After the carrier is lifted to the beginning of the assembly line, the handling robot returns to the docking station at the end of the assembly line. The docking station and the handling robot achieve automated docking. This enables automated and unmanned robot production and assembly, reduces labor costs during production, and facilitates replication and scalability.

[0048] In one embodiment of the present application, the PLC device is used to collect data from the assembly line and control the rotation of the crawler belt, the raising and lowering of the lifting platform, and the raising and lowering of the docking platform. The PLC device collects data from the assembly line, such as the assembly line status, robot arm position information, and robot installation information, so that the industrial computer can analyze the data collected by the PLC device and information received from other devices such as the robot arm to control the assembly line. The PLC device controls the assembly line by controlling the forward and backward rotation of the crawler belt, the raising and lowering of the upgrading platform, and the raising and lowering of the docking platform.

[0049] In this application, a unified information system is established for the automated assembly line to control the operations and flows of each link: the moment when the robotic arm starts and ends operation; the moment when the crawler track locks, starts to rotate, and stops rotating; the moment when the robot is assembled, the lifting platform descends to the bottom, the robot walks off the assembly line, and the lifting platform rises again; the moment when the docking platform descends and docks with the handling robot; the moment when the handling robot leaves the rear docking station, goes to the front of the assembly line, enters the front docking station, and raises the docking platform after docking. Through the control program on the industrial computer, it can connect and forward messages with the PLC, robotic arm, and production system, realize the sharing of status information and achieve automated control.

[0050] In one embodiment of the present application, the robot assembly process includes: judging whether the current robot assembly station is idle through the control program on the industrial computer, and starting the assembly operation at the current robot assembly station based on the judgment result; when the assembly operation is completed at the current robot assembly station, a message of assembly completion is sent to the industrial computer, and the industrial computer records the assembly time and related data of the current robot station and reports it to the production system. Figure 3 As shown, the control program on the working condition machine confirms through the serial port whether the next robot assembly station is idle. The next robot assembly station is the current robot assembly station that needs to be assembled. Based on the judgment result, the assembly operation is started at the current robot assembly station that needs to be assembled. That is, if the next robot assembly station is idle, the assembly operation is performed at that station. Specifically: if the current robot assembly station is idle, the control program sends a message to the PLC device to cause the PLC device to unlock the conveyor track so that the track rotates forward to perform the assembly operation, and lock the conveyor track after the robot carrier moves to the next robot assembly station. Here, if the current robot arm assembly station is idle, the control program sends a modbus message to the PLC device. Based on the received message, the PLC device unlocks the track to rotate forward, and locks the conveyor track when the carrier moves to the next station. The robot arm completes the assembly operation at the station and sends the message to the industrial computer through the serial port. The industrial computer records the assembly time and related data of the station, reports it to the production system, and enters the process again to confirm whether the next robot arm assembly station is idle.

[0051] In one embodiment of the present application, after the robot is assembled, a pressure sensor is installed under the lifting platform of the assembly line. When the robot is in position, the lifting platform descends to the bottom. The industrial computer uploads the message that the lifting platform has reached the bottom to the production system. After the robot reads the information that the lifting platform is at the bottom from the production system, it goes down the assembly line and goes to the test waiting area for testing. Figure 4As shown, a pressure sensor is installed under the assembly line lifting platform. When it senses that the robot is in position, the upgrading platform descends to the bottom. The industrial computer then uploads the message that the lifting platform has reached the bottom to the production system. The robot obtains the current lifting platform status from the production system as the bottom, walks down the assembly line, and goes to the test waiting area.

[0052] Following the above embodiment, after going to the test waiting area for testing, the infrared sensor senses that the robot has left, the lifting platform automatically rises, and the robot carrier is transferred to the docking station via the conveyor belt. Figure 4 , the infrared sensor senses that the robot has left, the lifting platform automatically rises, and the robot carrier is transferred to the docking platform via the conveyor belt, entering the carrier docking and flow process.

[0053] The carrier docking and flow process is as follows: the robot carrier is transported to the docking platform via the conveyor belt, and the handling robot sends a start docking command based on the information received from the production system that the robot carrier is already at the docking platform; the docking platform at the end of the assembly line descends to load the robot carrier onto the pallet of the handling robot, and the handling robot goes to the head of the assembly line on its own. The handling robot enters the docking platform at the head of the assembly line by aligning the QR code, and returns the robot carrier to the assembly line by raising the docking platform. Here, as Figure 5 As shown, the carrier is transported to the docking station via tracks, and the handling robot obtains from the production system that the carrier is located at the docking station and sends a command to start docking; the docking station at the end of the assembly line descends, so that the carrier is loaded onto the tray of the handling robot, and the robot exits the docking station and goes to the head of the assembly line by itself, where it goes to a factory map that can be pre-established in the robot's memory and goes to the target point by itself through a path-finding algorithm; the handling robot aligns with the QR code and enters the docking station at the head of the assembly line. If it fails, it repeatedly exits and tries again. The docking accuracy requirement is high. If successful, the handling robot exits the head docking station and goes to the docking station at the end of the assembly line by itself; the handling robot aligns with the QR code and enters the docking station at the end of the assembly line. If it fails, it repeatedly exits and tries again. If successful, the handling robot stands by at the docking station at the end of the assembly line, waiting for the carrier to be transported to the tail docking station. The docking accuracy between the robot carrier and the assembly line guide rail is required to be at the centimeter level. The handling robot also needs centimeter-level docking accuracy when entering the docking platform. This docking accuracy cannot be achieved by conventional lidar map matching. In the embodiment of the present application, the camera at the front end of the robot is used to dock with the QR code placed under the docking platform to achieve this.

[0054] Figure 6A structural schematic diagram of a system for mass production of robots provided according to another aspect of the present application is shown, the system comprising: an assembly line module 11, an assembly module 12 and a transfer module 13, wherein the assembly line module 11 is used to connect a PLC device to an industrial computer and a robotic arm to the industrial computer on the assembly line, and when the industrial computer receives a signal that the robotic arm has completed its task, it sends a command signal to the PLC device, and controls the assembly process of the robotic arm based on the command signal; the assembly module 12 is used to install a wireless access point module on the assembled robot, and upload component information to the production system through the wireless access point module, and when the assembly line status in the production system is assembly completed, the assembled robot goes to the test waiting area for testing on its own; the transfer module 13 is used to set up a docking station at the tail of the assembly line, and when the robot carrier flows to the tail of the assembly line, the robot carrier is transported to the head of the assembly line through the docking station to complete the docking and transfer of the robot carrier.

[0055] It should be noted that the contents executed by the pipeline module 11, the assembly module 12 and the flow module 13 are respectively the same as or corresponding to the contents in the above steps S11, S12 and S13, and are not repeated here for the sake of simplicity.

[0056] In addition, an embodiment of the present application also provides a computer-readable medium on which computer-readable instructions are stored. The computer-readable instructions can be executed by a processor to implement the aforementioned method for mass production of robots.

[0057] Obviously, those skilled in the art may make various changes and modifications to this application without departing from the spirit and scope of this application. Thus, if these modifications and variations of this application fall within the scope of the claims of this application and their equivalents, this application is intended to include these modifications and variations.

[0058] It should be noted that the application can be implemented in software and / or a combination of software and hardware, for example, can be implemented using an application specific integrated circuit (ASIC), a general purpose computer or any other similar hardware device. In one embodiment, the software program of the application can be executed by a processor to realize the steps or functions described above. Similarly, the software program of the application (including relevant data structures) can be stored in a computer-readable recording medium, for example, a RAM memory, a magnetic or optical drive or a floppy disk and similar devices. In addition, some steps or functions of the application can be implemented using hardware, for example, as a circuit that cooperates with a processor to perform each step or function.

[0059] In addition, a part of the present application may be applied as a computer program product, such as computer program instructions, which, when executed by a computer, can call or provide the method and / or technical solution according to the present application through the operation of the computer. The program instructions for calling the method of the present application may be stored in a fixed or removable recording medium, and / or transmitted through a data stream in a broadcast or other signal-carrying medium, and / or stored in a working memory of a computer device that runs according to the program instructions. Here, according to an embodiment of the present application, a device is included, which includes a memory for storing computer program instructions and a processor for executing program instructions, wherein, when the computer program instructions are executed by the processor, the device is triggered to run the method and / or technical solution based on the aforementioned multiple embodiments of the present application.

[0060] It is obvious to those skilled in the art that the present application is not limited to the details of the above-mentioned exemplary embodiments, and that the present application can be implemented in other specific forms without departing from the spirit or basic characteristics of the present application. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive, and the scope of the present application is defined by the appended claims rather than the above description, and it is intended that all changes that fall within the meaning and scope of the equivalent elements of the claims are included in the present application. Any figure mark in the claims should not be regarded as limiting the claims involved. In addition, it is obvious that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units or devices stated in the device claim can also be implemented by one unit or device through software or hardware. Words such as first and second are used to indicate names and do not indicate any particular order.

Claims

1. A method for mass production of robots, characterized in that: The method comprises: Connecting a PLC device to an industrial computer on an assembly line, and connecting a robotic arm to the industrial computer; when the industrial computer receives a signal indicating that the robotic arm has completed its task, sending a command signal to the PLC device, and controlling the assembly process of the robotic arm based on the command signal; A wireless access point module is installed on the assembled robot, and component information is uploaded to the production system through the wireless access point module. The assembly line status from the production system is received. When the assembly line status in the production system is assembly completed, the assembled robot automatically moves off the assembly line and goes to the test waiting area for testing; A docking station is provided at the tail end of the assembly line. When the robot carrier flows to the tail end of the assembly line, the robot carrier is transported to the head end of the assembly line through the docking station, completing the docking and flow of the robot carrier.

2. The method according to claim 1, characterized in that When the industrial computer receives the robot arm operation task completion signal and sends a command signal to the PLC device, the process includes: The PLC device is used to collect data on the assembly line and to control the rotation of the crawler, the raising and lowering of the lifting platform and the raising and lowering of the docking platform.

3. The method according to claim 1, characterized in that Controlling the robotic arm assembly process based on the command signal includes: Determine whether the current robot arm assembly station is idle through a control program on the industrial computer, and start assembly work at the current robot arm assembly station based on the determination result; When the assembly operation is completed at the current robot arm assembly station, a message of assembly completion is sent to the industrial computer. The industrial computer records the assembly time and related data of the current robot arm station and reports them to the production system.

4. The method according to claim 3, characterized in that Based on the judgment result, the assembly operation is started at the current robot arm assembly station, including: If the current robotic arm assembly station is idle, the control program sends a message to the PLC device to enable the PLC device to unlock the conveyor belt so that the belt rotates forward to perform assembly operations, and lock the conveyor belt after the robot carrier moves to the next robotic arm assembly station.

5. The method according to claim 1, wherein When the assembly line status in the production system is assembly completed, the assembled robot automatically goes to the test waiting area for testing, including: A pressure sensor is installed under the lifting platform of the assembly line. When the robot is in position, the lifting platform descends to the bottom. The industrial computer uploads the message that the lifting platform has reached the bottom to the production system. Based on the information that the lifting platform is at the bottom read from the production system, the robot walks down the assembly line and goes to the test waiting area for testing.

6. The method according to claim 5, characterized in that After you go to the test waiting area on your own for testing, including: When the infrared sensor senses that the robot has left, the lifting platform automatically rises and transfers the robot carrier to the docking platform via the conveyor belt.

7. The method according to claim 1, characterized in that When the robot carrier flows to the end of the assembly line, the robot carrier is transported to the head of the assembly line through the docking station, including: The robot carrier is transported to the docking station via a conveyor belt, and the transport robot sends a docking start command based on the information received from the production system indicating that the robot carrier is located at the docking station; The docking station at the tail end of the assembly line descends to load the robot carrier onto the pallet of the transport robot, and the transport robot moves to the head of the assembly line on its own.

8. The method according to claim 7, characterized in that The transport robot moves to the head of the assembly line by itself, including: The transport robot enters the docking station at the head of the assembly line through the operation of aligning the QR code, and returns the robot carrier to the assembly line through the rising operation of the docking station.

9. A system for mass production of robots, characterized in that The system includes: an assembly line module, an assembly module and a circulation module, wherein: The assembly line module is used to connect the PLC device to the industrial computer and the robotic arm to the industrial computer on the assembly line. When the industrial computer receives the task completion signal of the robotic arm, it sends a command signal to the PLC device, and controls the assembly process of the robotic arm based on the command signal. The assembly module is used to install a wireless access point module on the assembled robot, upload component information to the production system through the wireless access point module, and receive the assembly line status from the production system. When the assembly line status in the production system is assembly completed, the assembled robot automatically moves off the assembly line and goes to the test waiting area for testing; The transfer module is used to provide a docking station at the tail end of the assembly line. When the robot carrier flows to the tail end of the assembly line, the robot carrier is transported to the head end of the assembly line through the docking station to complete the docking and transfer of the robot carrier.

10. A computer-readable medium having computer-readable instructions stored thereon, wherein the computer-readable instructions can be executed by a processor to implement the method according to any one of claims 1 to 8.

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