Controller installation method, device and system

Abstract

The invention discloses a controller installation method, device and system, and belongs to the field of controller installation. During assembly, the mechanical arm grabs the control circuit board to install the protective shell, at the moment, at least two target parameters are obtained, then whether deformation exists or not is determined according to the two target parameters, and the deformation side on the control circuit board when deformation exists is determined. And the rotation direction is determined according to the deformation side, then the mechanical arm is controlled to drive the control circuit board to rotate according to the rotation direction until the circuit board does not deform, and finally board combination of the control circuit board and the protection shell is completed. According to the scheme, whether the control circuit board deforms or not can be detected during assembly, independent detection is not needed, and when deformation is detected, adjustment can be carried out to enable the control circuit board not to deform any more, so that the controller after board combination does not enable the control circuit board to deform excessively to damage components or even break, and the product quality is improved. The product quality is improved; and the production cost is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of controller installation, and in particular, to a controller installation method, device and system. Background Art

[0002] Air conditioner controllers are usually composed of a protective shell and a control circuit board. There are two processes for assembling the protective shell and the control circuit board in the automatic production line of air conditioner controllers. The traditional production line uses a robotic arm to grab the capacitor of the control circuit board for assembly.

[0003] In actual applications, the assembly gap between the protective shell and the control circuit board is small. Due to factors such as the deformation of the protective shell, the position deviation of the control circuit board, and the error of the tooling board, the control circuit board squeezes the edge of the protective shell, causing the control circuit board to deform excessively, damaging components or even breaking, affecting product quality and increasing production costs. Summary of the invention

[0004] In order to overcome the shortcomings of the prior art, the present application provides a controller installation method, device and system to solve the problem that when the protective shell and the control circuit board are assembled, the control circuit board is squeezed against the edge of the protective shell due to factors such as deformation of the protective shell, position deviation of the incoming material of the control circuit board and error of the tooling board, causing the control circuit board to be excessively deformed, damaging components or even breaking, thereby affecting product quality and increasing production costs.

[0005] The technical solution adopted by this application to solve its technical problem is:

[0006] In a first aspect, a controller installation method is provided, comprising:

[0007] Obtaining at least two target parameters in a process in which a robot arm grabs a control circuit board and assembles it into a protective housing;

[0008] Determining whether the control circuit board is deformed according to the at least two target parameters;

[0009] If there is deformation, determining the deformed side of the control circuit board;

[0010] Determining a rotation direction according to the deformed side, and controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed;

[0011] The control circuit board and the protective housing are assembled.

[0012] Further, controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed includes:

[0013] Controlling the robot arm to move by a preset value according to the rotation direction, so as to rotate the control circuit board until there is no deformation of the control circuit board;

[0014] The preset value is a fixed value, or the preset value is determined according to the degree of deformation of the control circuit board. The greater the degree of deformation of the control circuit board, the greater the preset value.

[0015] Further, the determining whether the control circuit board is deformed according to the at least two target parameters includes:

[0016] Subtract each target parameter from the reference target parameter to obtain a difference value;

[0017] If all the differences are within the preset difference range, it is determined that the control circuit board has no deformation; if at least one difference is not within the preset difference range, it is determined that the control circuit board has deformation.

[0018] Further, the determining the deformation side of the control circuit board includes:

[0019] The deformation side is determined according to a position corresponding to a difference value that is not within a preset difference value range.

[0020] Furthermore, the target parameter is the distance from a preset position on the robot arm to the control circuit board.

[0021] Furthermore, the preset positions are evenly distributed on the robotic arm.

[0022] Furthermore, the reference target parameter is the distance from the preset position on the robot arm to the control circuit board when picking up materials.

[0023] Furthermore, the target parameter is the force at the contact position of the robot arm with the control circuit board.

[0024] Furthermore, it also includes:

[0025] If there is no deformation, continue to complete the assembly of the control circuit board and the protective housing.

[0026] In a second aspect, a controller installation device is provided, comprising:

[0027] A parameter acquisition module, used to acquire at least two target parameters in the process of the robot arm grabbing the control circuit board and assembling it into the protective housing;

[0028] A deformation judgment module, used for determining whether the control circuit board has deformation according to the at least two target parameters;

[0029] A deformation side determination module, used for determining the deformation side of the control circuit board if there is deformation;

[0030] A posture adjustment module, used for determining a rotation direction according to the deformed side, and controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed;

[0031] The assembly control module is used to complete the assembly of the control circuit board and the protective shell.

[0032] In a third aspect, a controller installation system is provided, comprising:

[0033] at least one processor and at least one memory;

[0034] The memory stores executable instructions of the processor;

[0035] The processor is configured to perform the above method.

[0036] Beneficial effects:

[0037] The technical solution of the present application provides a controller installation method, device and system. The controller consists of a control circuit board and a protective shell. During assembly, a robotic arm grabs the control circuit board and installs it on the protective shell. At this time, at least two target parameters are obtained, and then the presence of deformation and the deformation side of the control circuit board when deformation exist are determined based on the two target parameters. The rotation direction is determined based on the deformation side, and then the robotic arm is controlled to drive the control circuit board to rotate based on the rotation direction until the circuit board is no longer deformed, and finally the control circuit board and the protective shell are assembled. The solution of the present application can complete the detection of whether the control circuit board is deformed during assembly without the need for separate detection, and when deformation is detected, adjustments can be made so that the control circuit board is no longer deformed. In this way, the controller after assembly will not cause excessive deformation of the control circuit board to damage components or even break, thereby improving product quality and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0039] Figure 1 is a flow chart of a controller installation method provided in an embodiment of the present application;

[0040] Figure 2 is a flow chart of a specific controller installation method provided in an embodiment of the present application;

[0041] Figure 3 It is a schematic diagram of a structure in which a distance sensor provided in an embodiment of the present application is installed on a mechanical arm;

[0042] Figure 4 It is a structural schematic diagram of a robot arm grabbing control circuit board provided in an embodiment of the present application;

[0043] Figure 5 It is a schematic diagram of an assembly of a control circuit board and a protective housing provided in an embodiment of the present application;

[0044] Figure 6 It is a schematic diagram of the structure of a controller installation device provided in an embodiment of the present application;

[0045] Figure 7 It is a schematic diagram of the structure of a controller installation system provided in an embodiment of the present application.

[0046] Description of reference numerals:

[0047] 1- distance sensor, 2- robotic arm, 3- control circuit board, 4- protective shell. DETAILED DESCRIPTION

[0048] In order to make the purpose, technical scheme and advantages of the present application clearer, the technical scheme of the present application is described in detail below in conjunction with the accompanying drawings and embodiments. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other implementation methods obtained by ordinary technicians in the field without making creative work belong to the scope of protection of the present application.

[0049] The traditional inspection method is to check whether the protective shell and the control circuit board are flat. However, during the assembly process, even if the protective shell and the control circuit board are qualified, the components may be broken during the installation process due to factors such as material removal. Conventional cameras can only detect after the breakage, and cannot detect in advance.

[0050] To solve this problem, refer to Figure 1 , an embodiment of the present application provides a controller installation method, comprising:

[0051] S11: obtaining at least two target parameters in a process in which the robot arm grasps and controls the circuit board to be assembled into the protective housing;

[0052] In one embodiment, the target parameter is the distance from a preset position on the robot arm to the control circuit board.

[0053] As a preferred implementation method of the embodiment of the present application, the preset positions are evenly distributed on the robotic arm. The preset positions are evenly distributed on the robotic arm, which can fully obtain the distance from each part of the control circuit board to the robotic arm, thereby facilitating the subsequent confirmation of the deformation location. Exemplarily, if there are two target parameters, the distance from the robotic arm to the left and right sides of the control circuit board are obtained as target parameters.

[0054] In addition, when deformation occurs, the most serious deformation is generally at the edges of the control circuit board and the protective housing, so the sensor installed on the robot arm generally obtains the distance to the edge of the control circuit board.

[0055] In another embodiment, the target parameter is the force on the position of the robot arm in contact with the control circuit board. In the prior art, there is a torque feedback robot arm, which reflects the force of the robot arm through the torque of each axis motor of the robot arm when it moves. When assembled normally, there is an upper limit to the force on the robot arm, and when the assembly is deformed, the force on the robot arm exceeds the upper limit, and the torque is relatively large at this time.

[0056] The more target parameters there are, the more accurately the deformation of each part of the circuit board can be controlled. However, the more target parameters there are, the more sensors are needed, which is more expensive. Therefore, two sensors are generally used to obtain two target parameters.

[0057] S12: Determining whether the control circuit board has deformation according to the at least two target parameters;

[0058] Determining whether the control circuit board is deformed according to the at least two target parameters includes:

[0059] Subtract each target parameter from the reference target parameter to obtain a difference value;

[0060] If all the differences are within the preset difference range, it is determined that the control circuit board has no deformation; if at least one difference is not within the preset difference range, it is determined that the control circuit board has deformation.

[0061] The reference target parameters are preset fixed values. When the preset fixed values ​​are used, each robot arm needs to be measured in advance to determine the reference target parameters.

[0062] As a preferred implementation of the embodiment of the present application, when the target parameter is the distance from the preset position on the robot arm to the control circuit board, the reference target parameter is the distance from the preset position on the robot arm to the control circuit board when picking up materials. Because the control circuit board must not be deformed when picking up materials, the distance at this time is used as the reference target parameter and does not need to be preset in advance.

[0063] In addition, the reason for setting the preset difference range is that during the assembly process, the control circuit board will inevitably have a certain degree of deformation, but as long as the deformation does not exceed a certain value, it will not cause the components to break.

[0064] S13: If there is deformation, determining the deformed side of the control circuit board;

[0065] If there is no deformation, continue to complete the assembly of the control circuit board and the protective housing.

[0066] Wherein, determining the deformation side of the control circuit board includes:

[0067] The deformation side is determined according to the position corresponding to the difference that is not within the preset difference range. For example, if the target parameter is to control the distance between the left and right sides of the circuit board, if the difference on the left side is larger, the left side is the deformation side.

[0068] S14: determining a rotation direction according to the deformed side, and controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed;

[0069] S15: completing the assembly of the control circuit board and the protective housing.

[0070] The controller installation method provided in the embodiment of the present application is composed of a control circuit board and a protective shell. During assembly, a robotic arm grabs the control circuit board and installs it on the protective shell. At this time, at least two target parameters are obtained, and then the presence of deformation and the deformation side of the control circuit board when deformation exist are determined based on the two target parameters. The rotation direction is determined based on the deformation side, and then the robotic arm is controlled to drive the control circuit board to rotate based on the rotation direction until the circuit board is no longer deformed, and finally the control circuit board and the protective shell are assembled. The present application scheme can complete the detection of whether the control circuit board is deformed during assembly without the need for separate detection, and when deformation is detected, adjustments can be made so that the control circuit board is no longer deformed. In this way, the controller after assembly will not cause excessive deformation of the control circuit board to damage components or even break, thereby improving product quality and reducing production costs.

[0071] In order to more clearly illustrate the solution of the present application, a specific implementation method is provided below. Figure 2 As shown:

[0072] The hardware of this solution mainly includes three parts: programmable controller (PLC), robotic arm, and high-precision distance sensor.

[0073] like Figure 3As shown, two high-precision distance sensors 1 are installed on the grippers of the robot arm 2. When the grippers grip the control circuit board 3, they contact the control circuit board 3. Because it is necessary to detect the position where the deformation amount is obvious when the extrusion occurs. Generally, the control circuit board 3 is extruded against the edge of the protective shell 4, so it is installed at a position close to the edge of the protective shell 4.

[0074] Workflow:

[0075] 1. Material collection: Figure 4 As shown, the robot arm 2 is moved to the control circuit board 3 to ensure that the gripper of the robot arm 2 stably grips the control circuit board 3 while the high-precision distance sensor 1 can measure the contact with the control circuit board 3. Send to the programmable controller to record data α1 and α2.

[0076] 2. Assembly: Figure 5 As shown, after the protective shell 4 is in place, the robot arm 2 starts to assemble, first inserting the control circuit board 3l1 side into the protective shell 4 buckle, and the robot arm 2 uses l1 as the rotation axis and rotates downward at a low speed to complete the board assembly. Among them, the protective shell 4 has two buckles on the control circuit board 3l1 side (at the same time, the assembly of the protective shell 4 and the control circuit board 3 has direction requirements). When installing the control circuit board 3, the control circuit board 3 must be installed into the buckle first.

[0077] 3. During the assembly process, the high-precision distance sensor sends data to the programmable controller in real time, and the data is recorded as β1 and β2. The deformation range of the normal assembly of the control circuit board is converted into the error allowable range δ1 and δ2 of the high-precision distance sensor.

[0078] 4. The programmable controller calculates and compares the measured data. If the data difference (β x -α x ) means that β1-α1 and β2-α2 are within the allowable error range, and the panel closing work can be carried out normally; if the data difference (β x -α x ) That is, β1-α1 and β2-α2 exceed the allowable error range, then the data comparison is performed to determine the interference position, that is, the extrusion position is determined by comparing β1-α1 and β2-α2, that is, the data with a larger difference indicates a larger deformation, and the side with a larger deformation is the extruded side.

[0079] 5. Determine the extruded side, and the robot arm moves and adjusts in the opposite direction, moving with a fixed value, and detecting the difference at the same time. When the difference returns to the error range, it means that it has reached the normal position, then continue to close the plate, and continue to rotate with l1 as the rotation axis.

[0080] 6. A closed-loop control is formed between step 4 and step 5 to ensure that the data of the entire process of the assembly is within the allowable error range, ensuring that there is no interference between the protective shell and the control circuit board, so that the control circuit board can be relatively flexibly assembled into the protective shell, ensuring the quality of the product.

[0081] The specific controller installation method provided in the embodiment of the present application detects the deformation of the control circuit board in real time through two high-precision distance sensors, compares and calculates the abnormally squeezed edge using the data feedback from the two sensors, and automatically adjusts the posture of the mechanical arm to ensure smooth assembly of the board. The working accuracy of the mechanical arm is improved, the qualified rate of the equipment board assembly is improved, the production efficiency is guaranteed, and the scrap rate of the control circuit board is reduced (reducing production costs).

[0082] Among them, a high-precision laser ranging sensor can be used instead of a high-precision distance sensor.

[0083] In addition, a torque feedback manipulator can be used for force feedback to determine whether there is interference. In the prior art, there is a torque feedback manipulator that reflects the force of the manipulator through the torque of each axis motor of the manipulator. When the control circuit board and the protective shell are assembled normally, the force of the manipulator is stable, and there is an upper limit A of the torque of the manipulator.

[0084] When the control circuit board is squeezed with the protective shell, the mechanical arm encounters increased resistance to reach the predetermined point, and the required torque exceeds A, and the work stops and an alarm is fed back. The user can set the upper limit of the torque of the mechanical arm.

[0085] Based on the same inventive concept, Figure 6 As shown, the present application also provides a controller installation device 60, comprising:

[0086] A parameter acquisition module 61, used to acquire at least two target parameters in the process of the robot arm grabbing and controlling the circuit board to assemble it into the protective housing;

[0087] In one embodiment, the target parameter is the distance from a preset position on the robot arm to the control circuit board.

[0088] As a preferred implementation method of the embodiment of the present application, the preset positions are evenly distributed on the robotic arm.

[0089] In another embodiment, the target parameter is the force at the contact position of the robot arm with the control circuit board.

[0090] A deformation judging module 62, configured to determine whether the control circuit board has deformation according to the at least two target parameters;

[0091] Wherein, determining whether the control circuit board is deformed according to the at least two target parameters includes:

[0092] Subtract each target parameter from the reference target parameter to obtain a difference value;

[0093] If all the differences are within the preset difference range, it is determined that the control circuit board has no deformation; if at least one difference is not within the preset difference range, it is determined that the control circuit board has deformation.

[0094] Among them, the benchmark target parameters are preset values.

[0095] Optionally, when the target parameter is the distance from the preset position on the robot arm to the control circuit board, the reference target parameter is the distance from the preset position on the robot arm to the control circuit board when picking up materials.

[0096] A deformation side determination module 63, used to determine the deformation side of the control circuit board if there is deformation;

[0097] Wherein, determining the deformation side of the control circuit board includes:

[0098] The deformation side is determined according to a position corresponding to a difference value that is not within a preset difference value range.

[0099] a posture adjustment module 64, configured to determine a rotation direction according to the deformed side, and control the robot arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed;

[0100] Wherein, controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed includes:

[0101] Controlling the robot arm to move by a preset value according to the rotation direction, so as to rotate the control circuit board until there is no deformation of the control circuit board;

[0102] In one embodiment, the preset value is a fixed value.

[0103] In another embodiment, the preset value is determined according to the degree of deformation of the control circuit board. The greater the degree of deformation of the control circuit board, the greater the preset value.

[0104] The board assembly control module 65 is used to complete the assembly of the control circuit board and the protective housing.

[0105] It should be noted that if there is no deformation, the control circuit board and the protective housing are continued to be joined.

[0106] The controller installation device provided in the embodiment of the present application, the controller consists of a control circuit board and a protective shell. During assembly, the robotic arm grabs the control circuit board and installs it on the protective shell. At this time, at least two target parameters are obtained, and then the presence of deformation and the deformation side on the control circuit board when deformation exist are determined based on the two target parameters. The rotation direction is determined based on the deformation side, and then the robotic arm is controlled to drive the control circuit board to rotate according to the rotation direction until the circuit board is no longer deformed, and finally the control circuit board and the protective shell are assembled. The present application scheme can complete the detection of whether the control circuit board is deformed during assembly without the need for separate detection, and when deformation is detected, adjustments can be made so that the control circuit board is no longer deformed. In this way, the controller after assembly will not cause excessive deformation of the control circuit board to damage components or even break, thereby improving product quality and reducing production costs.

[0107] Based on the same inventive concept, Figure 7 As shown, the present application also provides a controller installation system 70, including:

[0108] at least one processor 71 and at least one memory 72;

[0109] The memory stores executable instructions of the processor;

[0110] The processor is configured to execute the controller installation method provided in the above embodiment.

[0111] The controller installation system provided by the embodiment of the present application stores the executable instructions of the processor in the memory. When the executable instructions are executed, the processor can, during assembly, have the mechanical arm grab the control circuit board and install it on the protective shell. At this time, at least two target parameters are obtained, and then the presence of deformation and the deformation side of the control circuit board when deformation exist are determined based on the two target parameters. The rotation direction is determined based on the deformation side, and then the mechanical arm is controlled to drive the control circuit board to rotate based on the rotation direction until the circuit board is no longer deformed, and finally the control circuit board and the protective shell are assembled. The present application scheme can complete the detection of whether the control circuit board is deformed during assembly without the need for separate detection, and when deformation is detected, adjustments can be made so that the control circuit board is no longer deformed. In this way, the controller after assembly will not cause the control circuit board to deform excessively, damage components, or even break, thereby improving product quality and reducing production costs.

[0112] It can be understood that the same or similar parts of the above embodiments can be referenced to each other, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

Claims

1. A controller installation method, characterized in that: include: Obtaining at least two target parameters in a process in which a robot arm grabs a control circuit board and assembles it into a protective housing; Determining whether the control circuit board is deformed according to the at least two target parameters; If there is deformation, determining the deformed side of the control circuit board; Determining a rotation direction according to the deformed side, and controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed; The control circuit board and the protective housing are assembled.

2. The method according to claim 1, characterized in that The step of controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed includes: Controlling the robot arm to move by a preset value according to the rotation direction, so as to rotate the control circuit board until there is no deformation of the control circuit board; The preset value is a fixed value, or the preset value is determined according to the degree of deformation of the control circuit board. The greater the degree of deformation of the control circuit board, the greater the preset value.

3. The method according to claim 1, characterized in that: The determining whether the control circuit board is deformed according to the at least two target parameters includes: Subtract each target parameter from the reference target parameter to obtain a difference value; If all the differences are within the preset difference range, it is determined that the control circuit board has no deformation; if at least one difference is not within the preset difference range, it is determined that the control circuit board has deformation.

4. The method according to claim 3, characterized in that: The step of determining the deformation side of the control circuit board comprises: The deformation side is determined according to a position corresponding to a difference value that is not within a preset difference value range.

5. The method according to claim 3, characterized in that: The target parameter is the distance from a preset position on the robot arm to the control circuit board.

6. The method according to claim 5, characterized in that: The preset positions are evenly distributed on the mechanical arm.

7. The method according to claim 3, characterized in that: The reference target parameter is the distance from the preset position on the robot arm to the control circuit board when picking up materials.

8. The method according to claim 3, characterized in that: The target parameter is the force at the position on the robot arm that contacts the control circuit board.

9. The method according to claim 3, characterized in that: Also includes: If there is no deformation, continue to complete the assembly of the control circuit board and the protective housing.

10. A controller installation device, characterized in that: include: A parameter acquisition module, used to acquire at least two target parameters in the process of the robot arm grabbing the control circuit board and assembling it into the protective housing; A deformation judgment module, used for determining whether the control circuit board has deformation according to the at least two target parameters; A deformation side determination module, used for determining the deformation side of the control circuit board if there is deformation; A posture adjustment module, used for determining a rotation direction according to the deformed side, and controlling the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed; The assembly control module is used to complete the assembly of the control circuit board and the protective shell.

11. A controller installation system, characterized in that: include: at least one processor and at least one memory; The memory stores executable instructions of the processor; The processor is configured to execute the method according to any one of claims 1 to 9.

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