Virtual-real combined full-automatic screw locking industrial robot

Abstract

The invention provides a virtual-real combined full-automatic screw locking industrial robot, which belongs to the technical field of screw locking, and comprises a cabinet, an electric screwdriver bit, a manipulator, a screw arrangement machine, a display, a switch, an emergency stop button and an electric screwdriver torque display, the electric screwdriver bit is arranged at the output end of the mechanical arm, and the screw arranging machine is arranged on one side of the upper portion of the machine cabinet and used for storing screws. According to the scheme, the full-automatic virtual-real linkage screw industrial robot is designed based on the Internet of Things technology such as the embedded system technology and the sensing technology, the mechanical arm and the intelligent screwdriver serve as core components, the PLC is adopted for controlling various electric and pneumatic components, the procedures of automatic feeding, conveying, tightening, alarming and the like of screws are achieved, the manual operation process is reduced, and the production efficiency is improved. And adverse effects caused by artificial factors are reduced, and the production efficiency is remarkably improved.

Description

Technical Field

[0001] The invention belongs to the technical field of screw locking, in particular to a virtual-real combined full-automatic screw locking industrial robot. Background Art

[0002] A screw machine is a mechanical device that automatically or semi-automatically fastens screws. Its basic system consists of a feeding system and a locking system. One machine can be used for screws of various specifications and has a certain adjustment space. Compared with traditional screw disks, the production efficiency of screw machines can reach 6 times that of traditional screw disks. Therefore, it is widely used in electronic industries such as automobiles, electrical appliances, and chips.

[0003] At present, most of the screw locking machines on the market are fully automatic screw locking machines, which are mainly divided into two categories:

[0004] The first is a manual handheld screw locking machine; the second is a modern fully automatic screw locking industrial robot. Traditional manual handheld screw locking machines can realize automatic feeding, without manual screw picking, but the screw locking process still needs to be completed manually, and cannot accept human command, and the efficiency depends entirely on the manual speed, so it is easy to increase the fatigue of workers, and is widely used in the field of automatic production of small electronic products; modern fully automatic screw locking industrial robots add mechanical arms and control consoles on the basis of manual handheld screw locking machines. It can accept human command and run pre-programmed programs, which can assist or replace human work, saving labor costs and improving production efficiency.

[0005] However, most screw machines on the market lack human-machine interaction and actual work demonstrations, and cannot quickly identify the root cause of a fault when a fault occurs, which brings a heavy workload to maintenance work. How to combine the concept of intelligent interaction to increase the degree of virtual-real linkage of equipment and realize unmanned monitoring, multi-directional locking, and fault detection functions in the production process is a major direction for current industrial upgrading, equipment optimization, and intelligent control. Summary of the invention

[0006] In view of the above-mentioned deficiencies in the prior art, the present invention provides a virtual-real fully-automatic screw locking industrial robot by simulating the detailed process of a screw locking assembly line of a robotic arm, aiming to improve the production efficiency and product quality of the enterprise and realize the intelligent display function of machinery and equipment in the screw assembly line locking process.

[0007] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0008] A virtual and real fully automatic screw locking industrial robot, including a cabinet, an electric screwdriver bit, a manipulator, a screw arranging machine, a display, a switch and an emergency stop button, and an electric screwdriver torque display.

[0009] The manipulator is installed on the upper part of the cabinet, and the electric screwdriver bit is arranged at the output end of the manipulator.

[0010] The screw arrangement machine is arranged on one side of the upper part of the cabinet and is used to store the screws.

[0011] The electric screwdriver torque display is arranged inside the cabinet. When the electric screwdriver head drives a screw into a material, the electric screwdriver torque display is used to track the torque of the screw.

[0012] The display is arranged on the other side of the upper part of the cabinet, and is used to display the 3D animation when the screw is driven into the material and record the torque value output by the torque display of the electric screwdriver. When the torque value exceeds the error threshold, it is determined that the screw driving fails.

[0013] As a further improvement of the present invention: the upper part of the cabinet is also provided with a servo motor, a module A, a line drag chain A and a first correction module.

[0014] The first correction module is installed on the upper part of the module A to provide support for the material. The servo motor is used to drive the first correction module to move through the module A and the line drag chain A to correct the position of the material.

[0015] As a further improvement of the present invention: the upper part of the cabinet is also provided with a stepper motor, a module B, a line drag chain B, a transport module and a second correction module.

[0016] The second correction module is connected to the line drag chain B through the transportation module, and the line drag chain B is connected to the stepping motor through the module B.

[0017] As a further improvement of the present invention: the first correction module and the second correction module have the same structure, both including a correction cylinder A and a correction cylinder B, and a built-in air compressor is arranged inside the cabinet.

[0018] As a further improvement of the present invention: the transport module includes a module slider, a lifting cylinder, a clamping cylinder and a clamping claw,

[0019] The module slider is slidably matched with the module B, the lifting cylinder is installed on one side of the module slider, the clamping claw cylinder is installed at the output end of the lifting cylinder, and the clamping claw is arranged at the output end of the clamping claw cylinder.

[0020] As a further improvement of the present invention: a recycling box is also provided on the upper part of the cabinet, and the recycling box is used to store screws that have failed to be locked.

[0021] As a further improvement of the present invention: it also includes a PLC, and the PLC is used to control the actions of the servo motor, the stepper motor, the correction cylinder A, the correction cylinder B, the lifting cylinder and the clamping cylinder.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] This solution is designed based on Internet of Things technologies such as embedded system technology and sensor technology, with manipulators and intelligent screwdrivers as core components. It uses PLC to control various electric and pneumatic components of a fully automatic virtual-real linkage screw industrial robot to realize automatic feeding, transportation, tightening, alarm and other processes of screws, reducing the manual operation process, reducing the adverse effects of human factors, and significantly improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural diagram of a virtual-real combination of fully automatic screw-fastening industrial robot;

[0025] Figure 2 It is a structural schematic diagram of a transport module in a virtual-real fully automatic screw-fastening industrial robot;

[0026] Figure 3 This is a structural schematic diagram of a correction module in a virtual-real combination of fully automatic screw-locking industrial robots. DETAILED DESCRIPTION

[0027] The technical solution of the present invention is further described in detail below in conjunction with specific implementation methods.

[0028] See also Figure 1 , Figure 2 as well as Figure 3 The present embodiment provides a virtual-real combination fully automatic screw locking industrial robot, including a cabinet, an electric screwdriver bit 1, a manipulator 2, a screw arranging machine 4, a display 5, a switch and an emergency stop button 6, and an electric screwdriver torque display 12. The manipulator 2 is installed on the upper part of the cabinet, the electric screwdriver bit 1 is arranged at the output end of the manipulator 2, the screw arranging machine 4 is arranged on one side of the upper part of the cabinet for storing screws, the electric screwdriver torque display 12 is arranged inside the cabinet, when the electric screwdriver bit 1 drives the screw into the material 22, the electric screwdriver torque display 12 is used to track the torque of the screw, the display 5 is arranged on the other side of the upper part of the cabinet, and is used to display a 3D animation when the screw is driven into the material 22 and record the torque value output by the electric screwdriver torque display 12. When the torque value exceeds the error threshold, it is determined that the screw driving fails.

[0029] When simulating the action scene of the screw locking process, the switch and the emergency stop button 6 are pressed, the robot 2 drives the electric screwdriver bit 1 to the screw arrangement machine 4 to take the screw, and then returns to the locking position. The electric screwdriver bit 1 rotates to drive the obtained screw into the material 22. At this time, the electric screwdriver torque display 12 is used to track the torque of the screw. The display 5 displays a 3D animation of the screw being driven into the material 22 and records the torque value output by the electric screwdriver torque display 12. When the torque value exceeds the error threshold, it is determined that the current screw driving fails.

[0030] See also Figure 1 In one embodiment, a servo motor 7, a module A8, a line drag chain A9 and a first correction module 10 are further provided on the upper part of the cabinet. The first correction module 10 is installed on the upper part of the module A8 to provide support for the material 22. The servo motor 7 is used to drive the first correction module 10 to move through the module A8 and the line drag chain A9 to correct the position of the material 22, so that the electric screwdriver bit 1 can accurately drive the screw into the material 22.

[0031] See also Figure 1 In one embodiment, the upper part of the cabinet is further provided with a stepper motor 13, a module B14, a line drag chain B15, a transport module 16 and a second correction module 17. The second correction module 17 is connected to the line drag chain B15 through the transport module 60, and the line drag chain B15 is connected to the stepper motor 13 through the module B14. When the display 5 determines that the current screw locking fails, the material 22 of the material that fails to be screwed is transferred from the first correction module 10 to a position flush with the second correction module 17. Then, the stepper motor 13 operates to drive the module B14 to move the transport module 16 to the top of the first correction module 10. Then, the module B14 operates to transfer the material 22 from the unloading area to the second correction module 17, and the second correction module 17 transfers the material 22 to the temporary storage area.

[0032] See also Figure 3 In one embodiment, the first correction module 10 and the second correction module 17 have the same structure, both including a correction cylinder A23 and a correction cylinder B24. A built-in air compressor 11 is arranged inside the cabinet. When the manipulator 2 drives the electric screwdriver bit 1 to the screw arrangement machine 4 to take the screws, the servo motor 7 operates to drive the module A8 to make the first correction module 10 move to the screw locking area. At this time, the correction cylinder A23 and the correction cylinder B24 included in the first correction module 10 are in an open state. After the middle infrared sensor senses that the material 22 reaches the plane, the built-in air compressor 11 starts to output negative pressure to make the correction cylinder A23 and the correction cylinder B24 in a closed state, thereby correcting the position of the material 22.

[0033] See also Figure 1 as well as Figure 2 In one embodiment, the transport module 16 includes a module slider 18, a lifting cylinder 19, a clamping cylinder 20 and a clamping claw 21. The module slider 18 slides with the module B14. The lifting cylinder 19 is installed on one side of the module slider 18. The clamping claw cylinder 20 is installed at the output end of the lifting cylinder 19. The clamping claw 21 is arranged at the output end of the clamping claw cylinder 20. A recovery box 3 is also provided on the upper part of the cabinet, and the recovery box 3 is used to store screws that have failed to lock.

[0034] When the material 22 of the screw that failed to be locked is transferred from the first correction module 10 to a position flush with the second correction module 17, the stepper motor 13 operates to drive the module B14 to move the transport module 16 to the top of the first correction module 10. At this time, the clamping cylinder 20 drives the clamping claw 21 to expand, and the lifting cylinder 19 drives the clamping claw cylinder 20 and the clamping claw 21 to move down. The clamping claw 21 moves to both sides of the material 22, and then the clamping claw cylinder 20 drives the clamping claw 21 to close to clamp the material 22, and then the correction cylinder A23 and the correction cylinder B24 are expanded, so that The material 22 is released, and then the lifting cylinder 19 drives the clamping cylinder 20, the clamping claw 21 and the material 22 clamped by the clamping claw 21 to move up, and the module B14 operates to transfer the material 22 from the unloading area to the second correction module 17, and the correction cylinder A23 and the correction cylinder B24 included in the second correction module 17 are unfolded, and the clamping claw cylinder 20 drives the clamping claw 21 to unfold to place the material 22 in the temporary storage area, and then the correction cylinder A23 and the correction cylinder B24 included in the second correction module 17 are closed, and the robot 2 operates to put the screws that failed to lock into the recycling box 3.

[0035] In one embodiment, a fully automatic virtual-real linkage screw locking industrial robot designed based on embedded system technology and IoT technology such as 0 sensor technology is used as the main component to perform the above series of actions. The entire locking process obtains the signal status of each component through the bus expansion module to execute the corresponding motion trajectory and reach certain specific positions. The intelligent screwdriver and the PLC-controlled fixture are used to realize the entire screw locking process. The specific locking process is as follows:

[0036] (1) Run the pre-programmed program, in which the PLC controls the rotation of the stepper motor 13 through the preset program, transports the fixture to the preset position through the synchronous belt, controls the cylinder to fix the fixture, and feeds back the status of each component after movement to the robot controller through the I / O control module. The PLC uploads the motor running distance data to the IOT acquisition module through the Device Net communication method.

[0037] (2) This type of industrial robot designed based on IoT technology controls various types of machinery or processes through digital or analog input / output. The PLC realizes the rotation and stop of the screwdriver through the I / O control mode.

[0038] (3) This type of industrial robot designed based on the Internet of Things technology uses the modbus RTU protocol to communicate with the screwdriver controller to collect the screwdriver torque.

[0039] (4) This type of industrial robot designed based on Internet of Things technology communicates with the IOT acquisition module through SOCKET, uploads the motion data of each joint of the robot in real time, and converts analog signals into digital signals to meet computer processing.

[0040] The above steps are used to realize the whole process of screw locking. All the above-mentioned components are modeled by webgl, and the built models are debugged and matched with the data collected by IOT, so that the animation can be synchronized with the actual movement, and the Internet of Things technology with embedded system technology and sensor technology is used as the feature to realize the fully automatic interaction between reality and virtuality.

[0041] In one embodiment, the reliability and working efficiency of the device are tested and described.

[0042] (1) Performance test of fully automatic virtual-real linkage screw locking equipment

[0043] This solution is based on embedded system technology and traditional device technology. The switch control of the manipulator, cylinder, and motor in the fully automatic virtual-real linkage screw locking industrial robot is realized through PLC. To ensure the reliable operation of the control system, we must first provide a suitable working environment for the PLC. Therefore, we set the ambient temperature to 0-55 degrees Celsius in the reliability test. To ensure the insulation performance of the PLC, the ambient air humidity is adjusted to less than 85%, and shock-absorbing glue is installed.

[0044] According to actual requirements, the plan sets the full-automatic virtual-real linkage screw locking industrial robot as qualified if its excellence rate is greater than 99%. The number of successful locking, excellence rate, number of failures and working cycle are recorded through hard disk processing to compare and verify the excellence rate and efficiency of this type of industrial robot.

[0045] (2) Results Analysis

[0046] Goodness-of-fit test

[0047] As shown in Table 1, 7 samples were selected. Each sample set included the number of hard disks, the number of failures, the superiority rate, and the number of failed screws for the failed hard disks. The superiority rate of the screw industrial robot in screw locking was calculated by setting up the inspection method, and the T test method was specifically used.

[0048] Assume that p represents the actual average excellence rate of the screw industrial robot in this paper (combined with the average calculation of Table 1, it is 99.21%). Now test the hypothesis H0: μ0 = 99%, where h0 is the ideal excellence rate that the screw industrial robot can achieve statistically, and μ is the specific excellence value. Then the statistics of the existing samples are:

[0049]

[0050] Among them, T is the individual total test value, which is used to test whether the difference between a sample mean and a known population mean is significant; n is the number of samples, and this paper takes n=7, which is the number of tests. S can be determined by the following formula:

[0051]

[0052] S is the sample standard deviation, p i The calculated superiority rate for seven tests, i = 1, 2, ... 7, is S = 1.46. Assume that T follows a t distribution with n-1 degrees of freedom: T ~ t α (n-1), so for α = 0.01:

[0053] t α (6) = 3.707 (4-2)

[0054] Among them, t α (6) represents the critical value of the T test when the sample number n = 7 (obtained from the table). α is the difference level. Since the ideal superiority rate μ0 selected in this paper is 99%, α = 1-0.99 = 0.01.

[0055] Substituting the above data into formula 3-1, we can get

[0056]

[0057] Therefore, the hypothesis that |T|<3.707 and μ0=99 is not rejected and is less than the critical value of the test. It can be considered that the superiority rate of the screw industrial robot designed in this paper can reach 99% statistically.

[0058] Table 1 The superiority rate and fault samples of screw industrial robots

[0059]

[0060] Efficiency test

[0061] The total time for locking 1000 M5*16 screws was 2106 seconds, and a single screw took 2.02 seconds. About 30 screws can be locked every minute. Among the 1000 screws, 998 were locked properly and with appropriate torque, and 2 were abnormally locked, with an excellent rate of 99.8%. One of them was that the drive stroke was too long, causing the firmware position to shift and the screw could not be aligned; the other was that the locking torque was less than the preset value. Both abnormal screws triggered alarm prompts, and the system displayed the problem on the display screen, making it easier for operators to find the problem.

[0062] After the above-mentioned virtual-real combination of fully automatic screw locking equipment industrial robot is started, the PLC first receives operation instructions from input devices (such as touch screens, buttons, etc.). These instructions are transmitted to the input module of the PLC through the signal transmission system, and then trigger the corresponding control logic. The PLC analyzes and processes the received instructions according to the preset program, and outputs the corresponding control signal to the actuator. The actuator includes key components such as servo motor 7, stepper motor 13, correction cylinder A23, correction cylinder B24, lifting cylinder 19, and clamping cylinder 20, which are responsible for converting the control signal of the PLC into actual action. When the PLC outputs the control signal to drive the stepper motor 13, the stepper motor 13 will start and drive the screw arrangement machine 4 to operate, and transport the screws to the specified position according to the preset path and speed. Subsequently, the PLC controls the manipulator 2 to move the electric screwdriver head 1 to the screw arrangement machine 4 to take the screws, and then the electric screwdriver head 1 drives the taken screws back and drives the screws into the material 22 to complete the locking action. During the screw locking process, the PLC monitors the operating status and locking quality of the equipment in real time through sensors. The sensors can detect key parameters such as the position, angle, torque, etc. of the screws in real time, and feed this information back to the PLC. The PLC compares the feedback information with the preset parameters to determine whether the locking action meets the standards. If an abnormal situation occurs (such as the screws are not tightened, the threads are slipped, etc.), the PLC will immediately issue an alarm signal and trigger corresponding emergency treatment measures, such as shutdown and reset, to ensure the safety and stability of the equipment.

[0063] In addition, the fully automatic screw locking equipment also has intelligent management and data analysis functions. By connecting to the host computer or cloud platform, the equipment can upload real-time operation data to the server to achieve remote monitoring and management. Managers can use the host computer or cloud platform to monitor the equipment in real time, adjust parameters and analyze data, providing strong support for optimizing production processes and improving production efficiency. At the same time, the equipment can also perform self-learning and adaptive adjustments based on historical data and operating conditions to further improve the stability and reliability of the equipment.

[0064] The preferred embodiments of the present invention are described in detail above, but the present invention is not limited to the above embodiments. Various changes can be made within the knowledge scope of ordinary technicians in this field without departing from the purpose of the present invention.

Claims

1. A virtual and real fully automatic screw locking industrial robot, characterized in that: It includes a cabinet, electric screwdriver bits, a manipulator, a screw arranging machine, a display, a switch and an emergency stop button, and an electric screwdriver torque display. The manipulator is installed on the upper part of the cabinet, and the electric screwdriver bit is arranged at the output end of the manipulator. The screw arrangement machine is arranged on one side of the upper part of the cabinet and is used to store the screws. The electric screwdriver torque display is arranged inside the cabinet. When the electric screwdriver head drives a screw into a material, the electric screwdriver torque display is used to track the torque of the screw. The display is arranged on the other side of the upper part of the cabinet, and is used to display the 3D animation when the screw is driven into the material and record the torque value output by the torque display of the electric screwdriver. When the torque value exceeds the error threshold, it is determined that the screw driving fails.

2. The virtual-real combination fully automatic screw locking industrial robot according to claim 1, characterized in that: The upper part of the cabinet is also provided with a servo motor, a module A, a line drag chain A and a first correction module. The first correction module is installed on the upper part of the module A to provide support for the material. The servo motor is used to drive the first correction module to move through the module A and the line drag chain A to correct the position of the material.

3. The virtual-real fully automatic screw-fastening industrial robot according to claim 2 is characterized in that: The upper part of the cabinet is also provided with a stepper motor, module B, line drag chain B, a transport module and a second correction module. The second correction module is connected to the line drag chain B through the transportation module, and the line drag chain B is connected to the stepping motor through the module B.

4. The virtual-real combination fully automatic screw locking industrial robot according to claim 3 is characterized in that: The first correction module and the second correction module have the same structure, both including a correction cylinder A and a correction cylinder B, and a built-in air compressor is arranged inside the cabinet.

5. The virtual-real fully automatic screw-fastening industrial robot according to claim 4 is characterized in that: The transport module includes a module slider, a lifting cylinder, a clamping cylinder and a clamping claw. The module slider is slidably matched with the module B, the lifting cylinder is installed on one side of the module slider, the clamping claw cylinder is installed at the output end of the lifting cylinder, and the clamping claw is arranged at the output end of the clamping claw cylinder.

6. The virtual-real combination fully automatic screw locking industrial robot according to claim 1, characterized in that: A recycling box is also provided on the upper part of the cabinet, and the recycling box is used to store screws that fail to be locked.

7. The virtual-real fully automatic screw-fastening industrial robot according to claim 5, characterized in that: It also includes a PLC, which is used to control the actions of the servo motor, the stepper motor, the correction cylinder A, the correction cylinder B, the lifting cylinder and the clamping cylinder.

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