Robotic polishing apparatus and method of polishing

Abstract

The application provides a robot polishing machining device and a machining method thereof, and comprises a supporting module, a robot, a force-position control module, a vision module, a system control module, a tool driving module and a tool magazine module; a steel rail is arranged on the upper portion of the supporting module, the force-position control module, the vision module, the tool driving module and the tool are integrally installed at the tail end of the robot; the system control module can automatically modify the algorithm model of the robot coordinate system, the dynamic searching algorithm model of the welding rib and the robot grinding machining program according to the data information collected by the vision module and the preset data, so that the accurate searching of the welding rib position and the active adaptation of the mechanical position deviation after the steel rail is clamped are realized, the problems of the low searching accuracy of the welding rib, the incapability of the robot polishing track to independently adapt to the welding rib contour form, the incomplete polishing of the welding rib contour and the poor polishing quality of the similar products are solved, and the working efficiency and quality of the steel rail welding rib grinding machining of the device are improved.

Description

Technical Field

[0001] This invention relates to the field of precision machining technology, specifically to a robotic grinding processing device and its processing method. Background Technology

[0002] The high smoothness of high-speed train operation depends on the high smoothness of the appearance quality of the welded joints of the long rails. Objectively, the welded joints of the long rails of high-speed trains not only exhibit complex curved surface features, but also have obvious dimensional deviations. Therefore, the welded rail reinforcement must undergo "weld reinforcement shaping" during the manufacturing process of long rails.

[0003] With the further development of high-speed rail technology, the new requirement of "invisible welds" has been gradually put forward. On the one hand, it is to reduce the abrupt changes and sharp angles in the appearance of the rail welded joint cross-section, so as to reduce or even eliminate stress concentration points. On the other hand, it is to eliminate the occurrence of weld bead waves during the base flaw detection operation and subsequent daily maintenance flaw detection vehicle operation on the line, which may lead to misjudgment or false alarms. It is to reduce manual intervention in judging whether it is a weld bead wave or a damage wave of the rail welded joint, and to achieve the goal of judging damage as soon as there is a wave in the flaw detection operation.

[0004] The shortcomings of existing technologies are: they generally adopt the idea of ​​using a dedicated machine for grinding a given area of ​​the weld bead, or the idea of ​​using a multi-tool rigid contouring full-section machining. Regardless of the approach, they lack the content of robot-anthropomorphic and intelligent grinding operations, and lack multi-process and multi-tool combination configurations. As a result, the equipment cannot achieve automated and high-quality grinding of the entire cross-sectional area of ​​the rail weld bead, and further improvements are urgently needed. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a robotic grinding processing device and its processing method.

[0006] A robotic grinding and processing device according to the present invention includes a support module, a robot, a vision module, a force and position control module, a tool drive module, a system control module, a tool, a tool magazine module, and a robot control cabinet.

[0007] The rails are arranged on the upper part of the support module, so that the rail weld bars on the rails are suspended in the air. The vision module, force and position control module, tool drive module, and tool are integrated and installed at the end of the robot. The system control module controls and connects the vision module, tool drive module, tool magazine module, and robot control cabinet. The system control module has any one or more of the following functions:

[0008] Based on the data collected by the vision module, the robot can automatically locate the position of the rail weld and actively adjust the coordinate system.

[0009] The robot can be controlled to interact with the tool magazine module and complete the automatic tool changing operation under the drive of the tool drive module, according to the system control program preset in the system control module.

[0010] The robot can automatically grind rail welds according to the pre-set robot grinding program in the robot control cabinet and the function of the force and position control module, thereby ensuring that the robot grinding trajectory is compatible with the contour shape of the incoming rail weld.

[0011] A robotic grinding method according to the present invention includes the following steps:

[0012] S1: Fix the rail to the support module and make the rail weld beads on the rail suspended in the air;

[0013] S2: The system control module controls the robot to drive the vision module to collect data information of the rail weld bars;

[0014] S3: The system control module controls the robot to interact with the tool magazine module based on the multi-tool contouring machining process data information preset in itself, and completes the automatic tool changing operation of the tool according to the preset grinding process sequence under the drive of the tool drive module.

[0015] S4: The system control module automatically completes the location search of the rail weld bar and the autonomous coordinate system correction of the robot based on the data information;

[0016] S5: The system control module controls the cutting tool and superimposes the function of the force position control module to ensure that the robot grinding trajectory is autonomously compatible with the outline shape of the rail weld bar of the current material and uses different cutting tools in sequence according to the grinding process sequence preset in the robot control cabinet to realize the full-section automated grinding operation of the rail weld bar.

[0017] Preferably, the system includes a safety module, which comprises a safety fence and a safety lock and a safety button box arranged on the safety fence. The support module, robot, vision module, force and position control module, tool drive module, tool, and tool magazine module are all located inside the safety fence.

[0018] The system control module can control the safety lock and safety button box to achieve human-machine safe interaction function.

[0019] Preferably, the force position control module enables the tool to perform processing in a constant force and flexible grinding state through the tool drive module, wherein the tool processes the rail weld bar in a radial force processing manner.

[0020] Preferably, the tool drive module is equipped with a water chiller that can maintain its own temperature within a set range, and the water chiller can achieve automatic cooling under the control of the system control module.

[0021] Preferably, the rail is fixed to the support module by tooling and clamps, wherein the clamps are capable of automatically clamping the rail after it stops under the control of the system control module.

[0022] Preferably, the data information includes first data and second data. The first data is the comparison data of the first and second positions collected on the bottom edge of the rail after the rail is clamped, compared with the preset data of the corresponding positions. Based on the comparison data, the position deviation is obtained, and the preset algorithm model in the system control module can automatically complete the adjustment of the robot's preset coordinate system, thereby realizing the autonomous correction of the coordinate system. The second data is the protrusion shape data of the weld seam area at the bottom edge of the rail weld after the rail is clamped.

[0023] Preferably, the dynamic search for the rail weld reinforcement is achieved by identifying the continuous trapezoidal pattern of the weld area; during data sampling, the filtering function in the system control module is used to eliminate interference factors from discontinuous convex points. The filtering parameters of the filtering function are manually input by the operator and recorded by the system in the form of statistical curves and displayed on the human-machine interface, so that the user can accurately set the current filtering parameters from historical pattern curves and thus continuously optimize the accuracy to achieve the dynamic search.

[0024] Preferably, the system control module has a memory function. After the robot completes the teaching programming of the ideal trajectory of the rail weld, the robot control cabinet can use the ideal trajectory of the weld as the grinding operation trajectory and, with the help of the tool drive module, enable the tool to actively adapt to the contour shape change of the rail weld.

[0025] Preferably, the robot has a multi-joint serial structure, which enables the multi-process combined contouring tool to reach any position of the rail weld in an anthropomorphic manner.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. This invention uses a vision module and data collected by the vision module to construct an automatic coordinate system correction algorithm model for the robot and a dynamic search algorithm model for rail weld bars. This solves the problems of low weld bar search accuracy and unqualified grinding quality caused by the inability of the robot coordinate system to actively adjust, achieving active compatibility and matching of mechanical position deviations when the rail is stopped and clamped. It meets the positioning accuracy requirements of the tooling fixtures of this device for robot grinding operations and greatly improves the accuracy of the device in finding rail weld bars.

[0028] 2. This invention, by adopting a compact, integrated, and active fully closed-loop force and position control device structure, solves the problem that similar products cannot actively adapt to changes in the outline size of rail weld bars, which leads to unqualified grinding quality. It achieves the effect of automatically accommodating and matching changes in the outline size of rail weld bars while meeting the grinding quality process requirements. It also effectively avoids the impact of reverse impact force on the robot during grinding operations and automatically eliminates the impact of dimensional changes in the wheel diameter caused by wear and tear on the grinding tools.

[0029] 3. After the robot is programmed with the "ideal trajectory of weld rebar" in this invention, the standard grinding trajectory program will be pre-set in the system control module and the controller in the robot control cabinet. With the help of the force position control module, it can actively adapt to the changes in the outline size of the rail weld rebar, which greatly optimizes and reduces the difficulty of robot programming.

[0030] 4. By adopting a structure of tool drive module, tool and tool magazine module, this invention solves the problem that similar products cannot effectively realize the combined application of multiple processes and multiple tools. It eliminates the problem of tool interference and the inability to perform symmetrical grinding operations on the left, right sides, bottom and top surfaces of the rail weld reinforcement area. It achieves the effect of using different tools to perform "lateral" multi-segment small straight line fitting and contour grinding operations on different areas of the rail weld reinforcement.

[0031] 5. By employing special tooling and fixture structures, this invention solves the problem of horizontal deviation of the left and right positions of similar products from the center line of the roller conveyor during the conveying of steel rails. It achieves effective support, guidance, and centering of the steel rail clamping and stopping position, and minimizes its horizontal deviation to the greatest extent.

[0032] 6. By adopting a structure of safety fence, safety lock and safety button box, this invention solves the problems of low safety protection level or even lack of physical isolation protection of similar products. This makes the device not only have the automation function of one-button operation, but also achieve the effect of meeting the level requirements of absolute product safety.

[0033] 7. This invention solves the problems of large footprint and high manufacturing cost of similar products by using a robot mounting base with a "straddling" structure to stack and fix the robot on the system mounting base. This allows the device to effectively perform full-section symmetrical grinding operations on the left, right, bottom and top surfaces of the rail weld area by configuring only one robot and integrating a vision module, force position control module, tool drive module or electric spindle assembly at the robot end. Attached Figure Description

[0034] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0035] Figure 1 This is a schematic diagram of the structure of the present invention when viewed from a side and above;

[0036] Figure 2 A schematic diagram of the structure during robot grinding operations;

[0037] Figure 3 This is a structural schematic diagram of a rail tooling fixture;

[0038] Figure 4 This is a schematic diagram of the outline structure of the rail weld reinforcement.

[0039] Figure 5 This is a structural diagram of the back of the tool magazine module;

[0040] Figure 6 This is a structural diagram of the front of the tool magazine module, in which the upper and lower sliding doors of the tool magazine are pulled down and are in the open state.

[0041] The diagram shows:

[0042] System control module 1

[0043] Safety Fence 2

[0044] Safety Lock 3

[0045] Safety button box 4

[0046] Tooling 5

[0047] Tool magazine module 6

[0048] Tool magazine frame 61

[0049] Tool magazine with 62 tool positions

[0050] Tool magazine and tool holder 63

[0051] Tool holder 64

[0052] 65 Tool position sensor; 66 Tool holder spring; 67 Tool magazine sliding door; 68 Tool magazine electrical control module; 69 Tool magazine sliding door cylinder; 610 Tool magazine pneumatic control module; 611 Tool magazine safety door.

[0053] Robot control cabinet 7

[0054] Water chiller 8

[0055] Storage cabinet 9

[0056] System mounting base 10 Robot mounting base 11 Robot 12

[0057] Visual Module 13

[0058] 14 Force position control module, 15 Tool drive module or electric spindle, 16 Tool

[0059] 17 rail weld bars

[0060] Fixture 18

[0061] Clamp support 181

[0062] Left clamping arm 182

[0063] Right clamping arm 183

[0064] Clamp drive mechanism 184

[0065] Rail 19 Detailed Implementation

[0066] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0067] Example 1:

[0068] This invention provides a robotic grinding processing device capable of performing anthropomorphic and intelligent grinding processing on the rail weld ribs 17 on a rail 19, achieving an invisible weld seam. The device includes a support module, a robot 12, a system control module 1, a tool magazine module 6, and a robot control cabinet 7. The rail 19 is arranged on the upper part of the support module, preferably fixed to the support module by a rail clamp 18 and tooling 5. The robot 12 integrates a vision module 13, a force and position control module 14, a cutting tool 16, and a cutting tool drive module. The rail weld ribs 17 on the rail 19 are suspended, allowing the cutting tool 16 to reach various positions of the rail weld ribs 17 without interference during grinding. Furthermore, the robot 12 preferably has a multi-joint serial structure, enabling the multi-process combined contour cutting tool 16 to reach any position of the rail weld ribs 17 in an anthropomorphic manner, thereby achieving grinding operations on various parts of the rail weld ribs 17.

[0069] Specifically, the system control module 1 controls the connected vision module 13, tool drive module, tool magazine module 6, robot control cabinet 7, safety lock 3, safety button box 4, water chiller 8, and fixture 18. The system control module 1 can control the vision module 13 to collect data information of the rail 19 and rail weld 17. The system control module 1 can automatically locate the position of the rail weld 17 and actively correct and adjust the coordinate system of the robot 12 based on the data information collected by the vision module 13. In addition, the system control module 1 can also determine the tool 16 required for the grinding operation according to the process sequence of multi-tool contouring operation according to the preset control program, and then control the robot 12 to drive the tool 16 to interact with the tool magazine module 6 to complete the tool change. Specifically, during the tool change process, the tool drive module provides the driving force for the tool change, and the automatic tool change operation is completed under the drive of the tool drive module.

[0070] Specifically, the system control module 1 analyzes the complex curved surface of the rail weld 17 based on data information and, in conjunction with the grinding trajectory and according to the grinding process sequence, interacts with the tool magazine module 6 to achieve automatic tool changing. During the grinding process, the system control module 1 can autonomously correct the preset coordinate system of the robot 12 based on data information and control the tool drive module to automatically correct the position of the tool 16 accordingly. It can also dynamically search for the position of the rail weld 17 and actively match the positions of the tooling 5 and fixture 18 to achieve adaptive grinding of the rail weld 17, thereby executing the automated grinding trajectory of the tool 16 on the rail weld 17.

[0071] The robot 12 integrates a force position control module 14 and a cutting tool 16. The adaptive grinding of the rail weld reinforcement 17 is achieved under the drive of the force position control module 14. The force position control module 14, through the cutting tool drive module, enables the cutting tool 16 to perform grinding in a constant force and flexible grinding state. It should be noted that the system control module 1 has a memory function. After the ideal trajectory of the weld reinforcement is taught and programmed by the robot 12, the system control module 1 can store the ideal trajectory as the grinding operation trajectory through the robot control cabinet 7. During each processing operation, the cutting tool drive module drives the cutting tool 16 to execute the ideal trajectory of the weld reinforcement and actively adapts to changes in the contour shape of the rail weld reinforcement 17. In the actual grinding operation, the cutting tool 16 processes the rail weld reinforcement 17 by applying radial force, easily enabling the cutting tool 16 to perform grinding operations along the transverse direction of the rail weld reinforcement 17, achieving better grinding quality.

[0072] The data information in this invention includes first data and second data. The first data is the comparison data obtained by comparing the data of the first and second positions collected on the lower bottom edge of the rail 19, where it is relatively easy to sample, after the rail 19 is clamped, with the preset data of the corresponding positions. Based on the comparison data, the position deviation is obtained. Through the preset algorithm model in the system control module 1, the preset coordinate system of the robot 12 can be automatically adjusted and the tool 16 can be adjusted accordingly to achieve automatic coordinate system correction. Specifically, based on the position deviation of the data of the first and second positions relative to the corresponding reference points, the system control module 1 can automatically adjust the original coordinate system of the robot 12 through the preset algorithm model and drive the robot control cabinet 7, thereby realizing the function of automatic coordinate system correction.

[0073] The second data is the protrusion shape data of the rail weld bead 17 at the bottom edge of the weld seam area after the rail 19 is clamped. Based on the automated grinding trajectory and the grinding program preset in the robot 12, the type of tool used and the process sequence are automatically retrieved. The dynamic search of the rail weld bead 17 is achieved by identifying the protrusion shape in the weld seam area, which is represented by data of regular, continuous trapezoidal patterns. During data sampling, the filtering function in the system control module 1 eliminates interference from discontinuous protrusion points. The filtering parameters are manually input by the operator and recorded by the system as statistical curves, displayed on the human-machine interface. This allows the user to accurately set the current filtering parameters from historical patterns and continuously optimize the accuracy to achieve the purpose of dynamic search.

[0074] The present invention also provides a robotic grinding method, which can be implemented using the robotic grinding device of the present invention, and includes the following steps:

[0075] S1: Fix the rail 19 to the support module using tooling 5 and clamp 18, and make the rail weld bar 17 on the rail 19 suspended in the air.

[0076] S2: The system control module 1 controls the robot 12 to carry the vision module 13 integrated on its end flange to collect data information of the rail 19 and the rail weld bar 17;

[0077] S3: The system control module 1 controls the robot 12 to drive the tool 16 to interact with the tool magazine module 6 based on the multi-tool contouring process data information preset therein, and completes the automatic tool changing operation of the tool 16 under the drive of the tool drive module.

[0078] S4: The system control module 1 automatically locates the position of the rail weld 17 based on the data information and actively corrects and adjusts the position of the robot 12 in the preset coordinate system and drives the tool 16 to make corresponding position adjustments; thereby achieving self-adaptation of the grinding operation position of the rail weld 17 to obtain the automated grinding trajectory of the tool 16 on the rail weld 17.

[0079] S5: The system control module 1 controls the cutting tool 16 and superimposes the function of the force position control module 14 to ensure that the grinding trajectory of the robot 12 is autonomously compatible with the outline shape of the rail weld bar 17 currently in the material and uses different cutting tools 16 in sequence according to the grinding process sequence preset in the robot control cabinet 7 to realize the automated grinding operation of the entire cross section of the rail weld bar 17.

[0080] It should be noted that this invention employs a multi-process, multi-tool combination for multi-segment small straight-line fitting and contouring when grinding the rail weld reinforcement 17. The multi-process approach is based on multiple tools or grinding wheels. Specific tools or grinding wheels include brazed grinding wheels with a diameter of φ90mm, resin grinding wheels with a diameter of φ150mm, resin grinding wheels with a diameter of φ200mm, flap wheels with a diameter of φ200mm, etc. The multi-tool combination refers to the tools in this invention being pre-set in the tool magazine module 6, such as... Figure 5 As shown. However, only one tool is used in a single grinding operation. The size and style of each tool are customized based on the near-straight-line shape presented after analyzing the complex curved surface of the rail 19, such as... Figure 4 As shown, this ensures that the physical dimensions of the tool 16 perfectly fit the rail weld bead 17 without any accessibility interference issues. Furthermore, only one tool is carried per machining operation, thus eliminating mechanical positional interference issues between tools that would occur when multiple tools are used together.

[0081] Example 2:

[0082] This embodiment is a preferred example of Embodiment 1, providing a robotic grinding processing device. The support module includes a system mounting base 10 and a robot mounting base 11. The system mounting base 10 is an integrated design and is fixed to the ground with chemical bolts. The robot mounting base 11 is bolted onto the system mounting base 10. A fixture 5 for fixing and clamping the rail 19 is bolted onto the system mounting base 10, and a clamp 18 is bolted onto the fixture 5. When the rail 19 is conveyed to the production station of this device via the automatic roller conveyor in the previous process, the fixture 5 provides support and guidance for the rail 19, and the clamp 18 provides automatic clamping and fixing for the rail 19. The fixture 5 can be equipped with the support roller and guide roller structure disclosed in patent document CN213896582U to achieve a guiding function. The robot mounting base 11 has a "straddle" structure and is bolted onto the system mounting base 10, serving as the mounting and fixing base for the robot 12.

[0083] like Figure 3 As shown, the clamp 18 includes a clamp support 181, a left clamping arm 182 and a right clamping arm 183 rotatably arranged on the clamp support 181, and a clamp drive mechanism 184 capable of switching the left clamping arm 182 and the right clamping arm 183 between a clamping state and a releasing state. The left clamping arm 182 and the right clamping arm 183 are both rotatably arranged on the clamp support 181 via a pivot. When the clamp drive mechanism 184 drives the left clamping arm 182 and the right clamping arm 183... When the bottom ends move away, the top ends of the left clamping arm 182 and the right clamping arm 183 move closer together, clamping the rail 19. At this time, the left clamping arm 182 and the right clamping arm 183 are in a clamping state. When the clamping drive mechanism 184 drives the bottom ends of the left clamping arm 182 and the right clamping arm 183 to move closer together, the top ends of the left clamping arm 182 and the right clamping arm 183 move away, releasing the rail 19. At this time, the left clamping arm 182 and the right clamping arm 183 are in a released state. It should be noted that the clamping drive mechanism 184 can be implemented using a motor, cylinder, or other drive structure. This drive structure can also adopt other existing drive methods, which will not be elaborated here.

[0084] It should be noted that the tool drive module can adopt various drive methods. In this embodiment, the tool drive module adopts an electric spindle 15. The electric spindle 15 is cooled by a water chiller 8 to maintain the normal operating temperature of the electric spindle 15. The tool magazine module 6 includes a tool magazine frame 61, a tool magazine sliding door 67 mounted on the tool magazine frame 61, a tool magazine sliding door cylinder 69, a tool magazine electrical control module 68, a tool magazine pneumatic control module 610, a tool magazine safety door 611, a tool magazine tool rack 63, and eight tool magazine positions 62 respectively mounted on the tool magazine tool rack 63. Each tool magazine position 62 is equipped with an independent tool holder 64, a tool holder spring 66, and a tool presence sensor 65. Figure 5 , Figure 6 As shown. During the tool change process, the robot 12 drives the electric spindle 15 and tool 16 integrated at its end to actively move to the tool magazine module 6 according to the preset control program in the system control module 1 and wait for the system control module 1 to issue an automatic opening command for the tool magazine module 6. When the tool magazine upper and lower sliding door cylinder 69 receives the opening command and drives the tool magazine upper and lower sliding door 67 to open to the correct position, the main control program issues a control command to control the tool 16 to move into the tool magazine. First, the tool 16 currently connected to the electric spindle 15 is automatically placed into the tool magazine tool position 62 on the tool magazine tool holder 63 on the tool magazine module 6. During this process, the tool holder spring 66 can provide force to the tool position. The tool holder 64 provides sufficient cushioning force to absorb the impact when the tool 16 is placed into the tool magazine position 62. Then, according to the instructions of the main control program, the electric spindle 15 is driven to automatically grab another tool 16 pre-positioned in the tool magazine position 62 and remove it from the tool magazine. During this process, the tool holder spring 66 provides sufficient cushioning force to the tool holder 64 to absorb the pulling force when the tool 16 is removed from the tool magazine position 62. At the same time, the tool magazine module 6 executes the main control program's instruction to automatically close the door. The tool magazine up-and-down sliding door cylinder 19 receives the closing instruction and drives the tool magazine up-and-down sliding door 67 to automatically close. At this point, the entire automatic tool changing operation is completed. If there is no pre-positioned tool 16 in some tool magazine positions 62, the tool presence sensor 65 will provide real-time feedback information to the system control module 1 and trigger it to modify the currently issued instruction to grab the tool 16 in the tool magazine position 62, and this process will be repeated cyclically. When some tools 16 are used up and need to be replaced, the operator can easily replace them through the tool magazine safety door 611 on the tool magazine module 6.

[0085] The vision module 13 is mounted on the force position control module 14 by bolts. The vision module 13 in this invention can adopt the laser vision dynamic measurement device disclosed in patent document CN1776364A to realize the acquisition of data information. It can also adopt other laser vision structures in the prior art to realize the acquisition of data information, which will not be described in detail here.

[0086] The force position control module 14 can adopt the active, fully closed-loop constant force compliant force position control device disclosed in patent document US5448146A. One end of the force position control module 14 is bolted to the end flange of the robot 12, and the other end is bolted to the electric spindle 15. When the rail 19 is conveyed to this device via the automatic roller conveyor, after being supported and guided by the tooling 5 and automatically clamped and fixed by the fixture 18, the robot 12 drives the vision module 13, the force position control module 14, the electric spindle 15, and the tool 16 to complete the pre-programmed operation. The control program automatically moves to the vicinity of the rail 19, and constructs an automatic coordinate system correction algorithm model for the robot 12 and a dynamic search algorithm model for the rail weld 17 based on the data information collected by the vision module 13 and the vision module 13. It actively matches the positions of the tooling 5 and the fixture 18 to achieve adaptive operation of the grinding position of the rail weld 17, and superimposes the function of the force and position control module 14 to meet the requirements of the robot 12's automated grinding trajectory for the accuracy of the stopping and clamping position of the rail 19 and the active compatibility and matching of the changes in the contour shape of the rail weld 17.

[0087] This embodiment also includes a safety module, comprising a safety fence 2, a safety lock 3, and a safety button box 4. The entire device is housed inside the safety fence 2, which has a safety door. The safety door is equipped with the safety lock 3 and the safety button box 4. The safety fence 2 is a physical isolation fence, fixed to the ground by anchors and expansion bolts. The safety lock 3 is a safety lock with electromagnetic interlocking. The safety button box 4 is a multi-functional button assembly with an emergency stop button, as well as door opening, closing, and reset functions. The safety lock 3 and the safety button box 4 are bolted to the safety fence 2. When an operator wants to enter the isolated space formed by the safety fence 2, they must use the door opening button on the safety button box 4 to send an opening request to the system control module 1. When the system control module 1 processes the request from the safety button box 4 according to the preset control program and returns an unlock signal, the safety lock 3 will release the electromagnetic interlock signal. At this time, the operator can manually open the safety lock 3 and enter the safety fence 2. Conversely, after the operator exits from safety fence 2, they must use the closing button on safety button box 4 to request to close the door. When system control module 1 processes the request from safety button box 4 according to the preset control program and returns a locking signal, safety lock 3 will lock the electromagnetic interlock signal, completing the locking process. Immediately afterward, the operator presses the reset button on safety button box 4, and the device will enter a safe standby state, awaiting work instructions from the system. In any case, if the emergency stop button on safety button box 4 is triggered, the device will immediately stop operating.

[0088] The working principle of this invention is as follows:

[0089] To meet the requirements for machining and grinding the complex curved surface features of the rail weld rib 17, the electric spindle 15 will automatically interact with the tool magazine module 6 on the ground to perform tool changing operations according to the control program preset in the system control module 1, and perform grinding operations on different areas of the rail weld rib 17 according to the control program preset in the robot control cabinet 7. This invention employs a multi-process, multi-tool combination to perform multi-segment small straight-line fitting and contouring operations, such as... Figure 4 As shown, during the processing, the tool 16 grinds the rail weld bead 17 by applying radial force. The size and shape of the tool 16 in this invention are customized based on the near-straight-line shape presented after analyzing the complex curved surface of the rail, thus ensuring that the physical dimensions of the tool 16 can perfectly fit the rail weld bead 17. The rail weld bead 17 can be regarded as a weld bead structure with multiple small straight lines arranged sequentially. During processing, the tool 16 grinds the rail weld bead 17 according to the grinding trajectory by applying radial force. Objectively, the rail weld bead 17 not only exhibits complex curved surface features, but also has obvious dimensional deviations. In order to meet the grinding quality requirements, it is necessary to use the force position control module 14 to provide an active closed-loop force position control function to achieve constant force and flexible grinding operations. Meanwhile, since the cutting tool 16 can be selected from different styles and weights, when the electric spindle 15 automatically replaces the cutting tool 16 from the tool magazine module 6, the force-position control module 14 will automatically read the weight of the cutting tool 16 at this time and actively balance the influence caused by the weight of the cutting tool 16 through its built-in algorithm control model, thereby ensuring that a constant force output is always maintained. In addition, the electric spindle 15 must be cooled by the water chiller 8 when it is working; otherwise, the electric spindle 15 will experience excessive temperature rise, leading to an alarm and shutdown. The robot control cabinet 7 and the water chiller 8 are placed on the placement cabinet 9, making the module structure compact and easy to move.

[0090] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0091] Those skilled in the art will understand that, in addition to implementing the system, apparatus, and their modules provided by this invention in purely computer-readable program code, the same program can be implemented in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers by logically programming the method steps. Therefore, the system, apparatus, and their modules provided by this invention can be considered a hardware component, and the modules included therein for implementing various programs can also be considered structures within the hardware component; alternatively, modules for implementing various functions can be considered both software programs implementing the method and structures within the hardware component.

[0092] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A robotic grinding process, characterized in that, The steps include the following: S1: Fix the rail (19) to the support module and make the rail weld (17) on the rail (19) suspended in the air; S2: The system control module (1) controls the robot (12) to drive the vision module (13) to collect data information of the rail (19) and rail weld (17); S3: The system control module (1) controls the robot (12) to drive the tool (16) to interact with the tool magazine module (6) according to the multi-tool contouring process data information preset in itself, and completes the automatic tool changing operation of the tool (16) according to the preset grinding process sequence under the drive of the tool drive module. S4: The system control module (1) automatically completes the location search of the rail weld bar (17) and the coordinate system autonomous correction of the robot (12) based on the data information; S5: The system control module (1) controls the cutting tool (16) and superimposes the function of the force position control module (14) to ensure that the grinding trajectory of the robot (12) is autonomously compatible with the contour shape of the rail weld bar (17) of the current material and uses different cutting tools (16) in sequence according to the grinding process sequence preset in the robot control cabinet (7) to realize the full-section automated grinding operation of the rail weld bar (17); The data information includes first data and second data. The first data is the comparison data of the first position and the second position data collected on the bottom edge of the rail (19) after the rail (19) is clamped, and the corresponding preset data. The position deviation is obtained based on the comparison data. The preset algorithm model in the system control module (1) can automatically complete the adjustment of the preset coordinate system of the robot (12) and thus realize the autonomous correction of the coordinate system. The second data is the protrusion shape data of the bottom edge weld area of ​​the rail weld bead (17) after the rail (19) is clamped. The force position control module (14) is integrated and installed at the end of the robot (12).

2. The method according to claim 1, characterized in that, It has a safety module, which includes a safety fence (2) and a safety lock (3) and a safety button box (4) arranged on the safety fence (2). The support module, robot (12), vision module (13), force position control module (14), tool drive module, tool (16), and tool magazine module (6) are all located inside the safety fence (2). The system control module (1) can control the safety lock (3) and the safety button box (4) to realize the human-machine safe interaction function.

3. The method according to claim 1, characterized in that, The force position control module (14) enables the tool (16) to process in a constant force and flexible grinding state through the tool drive module, wherein the tool (16) processes the rail weld bar (17) in a radial force processing manner.

4. The method according to claim 1, characterized in that, The tool drive module is equipped with a water chiller (8) that can keep its own temperature within a set range, and the water chiller (8) can achieve automatic cooling under the control of the system control module (1).

5. The method according to claim 1, characterized in that, The rail (19) is fixed on the support module by tooling (5) and clamp (18), wherein the clamp (18) can automatically clamp the rail (19) after it stops under the control of the system control module (1).

6. The method according to claim 1, characterized in that, The dynamic search for the rail weld reinforcement (17) is achieved by identifying the continuous trapezoidal pattern of the weld area; when sampling data, the filtering function in the system control module (1) is used to eliminate the interference factors of discontinuous convex points. The filtering parameters of the filtering function are manually input by the operator and recorded by the system in the form of statistical curves and displayed on the human-machine interface, so that the user can accurately set the current filtering parameters from the historical regular curves and thus continuously optimize the accuracy to achieve the dynamic search.

7. The method according to claim 1, characterized in that, The system control module (1) has a memory function. After the robot (12) completes the teaching programming of the ideal trajectory of the rail weld (17), the robot control cabinet (7) can use the ideal trajectory of the rail weld (17) as the grinding operation trajectory and, with the help of the tool drive module, make the tool (16) actively adapt to the contour shape change of the rail weld (17).

8. The method according to claim 1, characterized in that, The robot (12) has a multi-joint serial structure, which enables the multi-process combined contour cutting tool (16) to reach any position of the rail weld bar (17) in an anthropomorphic operation.

9. The method according to claim 1, characterized in that, The force position control module (14) is mounted on the end flange of the robot (12) via a flange and is screwed to the tool drive module or electric spindle (15); the vision module (13) is fixedly mounted on the force position control module (14) via screw bolts.

10. A robotic grinding and processing device, characterized in that, The robot grinding process according to any one of claims 1 to 9 includes a support module, a robot (12), a vision module (13), a force position control module (14), a tool drive module, a system control module (1), a tool (16), a tool magazine module (6), and a robot control cabinet (7). The rail (19) is arranged on the upper part of the support module so that the rail weld (17) on the rail (19) is suspended. The vision module (13), force position control module (14), tool drive module, and tool (16) are integrated and installed at the end of the robot (12). The system control module (1) controls and connects the vision module (13), tool drive module, tool magazine module (6), and robot control cabinet (7). The system control module (1) can automatically find the position of the rail weld (17) according to the data information collected by the vision module (13) and actively perform coordinate system correction adjustment of the robot (12). It can control the robot (12) to drive the tool (16) to interact with the tool magazine module (6) according to the system control program preset in the system control module (1) and complete the automatic tool change operation under the drive of the tool drive module; and / or The robot (12) can automatically grind the rail weld bar (17) according to the pre-set grinding program of the robot (12) in the robot control cabinet (7) and superimpose the function of the force position control module (14), thereby ensuring that the grinding trajectory of the robot (12) is compatible with the contour shape of the rail weld bar (17) of the current material, and thus realize the automated grinding operation of the rail weld bar (17). The data information includes first data and second data. The first data is the comparison data of the first position and the second position data collected on the bottom edge of the rail (19) after the rail (19) is clamped, and the corresponding preset data. The position deviation is obtained based on the comparison data. The preset algorithm model in the system control module (1) can automatically complete the adjustment of the preset coordinate system of the robot (12) and thus realize the autonomous correction of the coordinate system. The second data is the protrusion shape data of the bottom edge weld area of ​​the rail weld bead (17) after the rail (19) is clamped.

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