A controller installation method, apparatus and system

Abstract

The application discloses a controller mounting method, device and system, and belongs to the controller mounting field. When assembling, a mechanical arm is used to grab a control circuit board to a protective shell, at least two target parameters are obtained, and then whether deformation exists and the deformation side on the control circuit board when the deformation exists are determined according to the two target parameters. The rotation direction is determined according to the deformation side, the mechanical arm is controlled to drive the control circuit board to rotate according to the rotation direction, until the control circuit board does not exist deformation, and finally the control circuit board and the protective shell are assembled. The application can detect whether the control circuit board is deformed during the assembling, and does not need to be detected separately. When the deformation is detected, the control circuit board can be adjusted so as to not deform any more. The controller after the assembling does not cause the control circuit board to be excessively deformed, damages components and even breaks, product quality is improved, and production cost is reduced.

Description

TECHNICAL FIELD

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

[0002] An air conditioner controller is usually composed of a protective shell and a control circuit board, and there are two processes of assembling the protective shell and the control circuit board in an automatic production line of the air conditioner controller. In a traditional production line, a mechanical arm is used to pick up a capacitor of the control circuit board for assembly.

[0003] In actual application, the assembly gap between the protective shell and the control circuit board is small. Due to the deformation of the protective shell, the position deviation of the incoming control circuit board and the error of a tooling plate, the control circuit board is pressed against the edge of the protective shell, which causes the control circuit board to be excessively deformed, damages components and even breaks, thereby affecting product quality and increasing production cost. SUMMARY

[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, due to the deformation of the protective shell, the position deviation of the incoming control circuit board and the error of a tooling plate, the control circuit board is pressed against the edge of the protective shell, which causes the control circuit board to be excessively deformed, damages components and even breaks, thereby affecting product quality and increasing production cost.

[0005] The technical scheme adopted by the present application to solve the technical problems is:

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

[0007] obtaining at least two target parameters in the process of picking up the control circuit board by the mechanical arm for assembly to the protective shell;

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

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

[0010] determining the rotation direction according to the deformation side, and controlling the mechanical arm to rotate the control circuit board according to the rotation direction until the control circuit board is not deformed;

[0011] completing the assembly of the control circuit board and the protective shell.

[0012] Further, the step of controlling the mechanical arm to rotate the control circuit board according to the rotation direction until the control circuit board is not deformed comprises:

[0013] According to the rotation direction, the mechanical arm is controlled to move at a preset value, so as to rotate the control circuit board until the control circuit board does not exist deformation;

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

[0015] Further, the control circuit board is determined whether to exist deformation according to the at least two target parameters, comprising:

[0016] The difference between each target parameter and the reference target parameter is obtained to obtain a difference value;

[0017] If all difference values are within a preset difference value range, it is determined that the control circuit board does not exist deformation. If at least one difference value is not within the preset difference value range, it is determined that the control circuit board exists deformation.

[0018] Further, the deformation side of the control circuit board is determined, comprising:

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

[0020] Further, the target parameter is the distance from the preset position on the mechanical arm to the control circuit board.

[0021] Further, the preset positions are uniformly distributed on the mechanical arm.

[0022] Further, the reference target parameter is the distance from the preset position on the mechanical arm to the control circuit board when taking the material.

[0023] Further, the target parameter is the force of the contact position on the mechanical arm and the control circuit board.

[0024] Further, it also comprises:

[0025] If there is no deformation, the control circuit board and the protective shell are continued to be assembled.

[0026] The second aspect provides a controller installation device, comprising:

[0027] A parameter acquisition module is configured to acquire at least two target parameters during the process of assembling the control circuit board to the protective shell by the mechanical arm.

[0028] A deformation judgment module is configured to determine whether the control circuit board exists deformation according to the at least two target parameters.

[0029] a deformation side determination module configured to determine a deformation side of the control circuit board if there is deformation;

[0030] a posture adjustment module configured to determine a rotation direction according to the deformation side and control the mechanical arm to rotate the control circuit board according to the rotation direction until there is no deformation of the control circuit board;

[0031] a board combination control module configured to complete combination 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 implement the above method.

[0036] Advantages:

[0037] The technical solution of the present application provides a controller installation method, device and system. The controller is composed of a control circuit board and a protective shell. During assembly, the mechanical arm picks up the control circuit board to install it into the protective shell. At this time, at least two target parameters are obtained. Then, it is determined whether there is deformation according to the two target parameters, and the deformation side of the control circuit board when there is deformation. The rotation direction is determined according to the deformation side. Then, the mechanical arm is controlled to rotate the control circuit board according to the rotation direction until there is no deformation of the control circuit board. Finally, the combination of the control circuit board and the protective shell is completed. The present application can detect whether the control circuit board is deformed during assembly without separate detection. When deformation is detected, adjustment can be made to prevent the control circuit board from deforming further, damaging components or even breaking, thereby improving product quality and reducing production cost. BRIEF DESCRIPTION OF DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments or prior art description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application. Those skilled in the art can obtain other drawings according to these drawings without creative labor.

[0039] Figure 1 is a control circuit board installation method flowchart provided by the present application;

[0040] Figure 2 is a specific control circuit board installation method flowchart provided by the present application;

[0041] Figure 3 is a structural schematic diagram of a distance sensor mounted on a mechanical arm provided by an embodiment of the present application;

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

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

[0044] Figure 6 is a structural schematic diagram of a controller mounting device provided by an embodiment of the present application;

[0045] Figure 7 is a structural schematic diagram of a controller mounting system provided by an embodiment of the present application.

[0046] Legend of reference signs:

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

[0048] To make the purpose, technical solutions and advantages of the present application clearer, the technical solutions of the present application are described in detail below in combination with the drawings and embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of the present application.

[0049] The traditional detection method is to detect whether the protective shell and the control circuit board are flat respectively, but in the assembly process, even if the protective shell and the control circuit board are qualified, the installation process may cause the rupture of components due to factors such as material taking. Conventional cameras and the like can only detect after rupture, and cannot detect in advance.

[0050] To solve this problem, with reference to Figure 1 The present application provides a controller mounting method, comprising:

[0051] S11: acquiring at least two target parameters in the process of assembling the mechanical arm grabbing the control circuit board to the protective shell;

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

[0053] As a preferred implementation manner of the embodiment, the preset positions are uniformly distributed on the mechanical arm. The preset positions are uniformly distributed on the mechanical arm, so that the distances from the control circuit board to the mechanical arm at different positions can be obtained, and then the positions where deformation occurs can be determined. For example, if two target parameters are obtained, the distances from the mechanical arm to the left and right sides of the control circuit board are obtained as the target parameters.

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

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

[0056] The more target parameters, the more accurately the deformation of the control circuit board at different positions can be reflected, but the more target parameters, the more sensors are needed, and the cost is high. Therefore, two sensors are generally used to obtain two target parameters.

[0057] S12: determining whether the control circuit board is deformed according to the at least two target parameters;

[0058] The determination of whether the control circuit board is deformed according to the at least two target parameters comprises:

[0059] obtaining a difference value by subtracting each target parameter from a reference target parameter;

[0060] If all the difference values are within a preset difference value range, it is determined that the control circuit board is not deformed, and if at least one difference value is not within the preset difference value range, it is determined that the control circuit board is deformed.

[0061] The reference target parameter is a preset fixed value. When the preset fixed value is used, each mechanical arm needs to be measured in advance to determine the reference target parameter.

[0062] As a preferred implementation manner of the embodiment, when the target parameter is the distance from the preset position on the mechanical arm to the control circuit board, the reference target parameter is the distance from the preset position on the mechanical arm to the control circuit board when the material is taken. Because the control circuit board is not deformed when the material is taken, the distance at this time is used as the reference target parameter, and there is no need to be preset in advance.

[0063] In addition, the reason for setting the preset difference range is that the control circuit board will inevitably be deformed to a certain extent during assembly, but as long as the deformation does not exceed a certain value, the components will not be broken.

[0064] S13: If there is deformation, determine the deformation 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 shell.

[0066] The determination of the deformation side of the control circuit board includes:

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

[0068] S14: Determine the rotation direction according to the deformation side, and control the mechanical arm to rotate the control circuit board according to the rotation direction until there is no deformation in the control circuit board.

[0069] S15: Complete the assembly of the control circuit board and the protective shell.

[0070] The controller installation method provided by the embodiments of the present application is composed of a control circuit board and a protective shell. During assembly, the mechanical arm grasps the control circuit board to install it into the protective shell. At this time, at least two target parameters are obtained, and then it is determined whether there is deformation according to the two target parameters, and the deformation side of the control circuit board when there is deformation. According to the deformation side, the rotation direction is determined, and then the mechanical arm is controlled to rotate the control circuit board according to the rotation direction until there is no deformation in the control circuit board. Finally, the assembly of the control circuit board and the protective shell is completed. The present application can detect whether the control circuit board is deformed during assembly without the need for separate detection. When deformation is detected, adjustment can be made to prevent the control circuit board from deforming again, so that 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 cost.

[0071] In order to more clearly illustrate the scheme of the present application, a specific implementation manner is provided as follows: Figure 2

[0072] The hardware of the present scheme mainly includes three parts: a programmable controller (PLC), a mechanical arm, and a high-precision distance sensor.

[0073] As shown in Figure 3 ​As shown, two high-precision distance sensors 1 are mounted on the grippers of the robotic arm 2. They contact the control circuit board 3 when the grippers grasp it. This is because they are used to detect locations where deformation is most pronounced when pressure occurs. Since the control circuit board 3 typically presses against the edge of the protective housing 4, it is mounted near the edge of the protective housing 4.

[0074] Workflow:

[0075] 1. Material Retrieval: such as Figure 4 As shown, the robotic arm 2 moves to the control circuit board 3, ensuring that the gripper of the robotic arm 2 stably grasps the control circuit board 3 while the high-precision distance sensor 1 measures contact with the control circuit board 3. Data α1 and α2 are then sent to the programmable controller and recorded.

[0076] 2. Assembly: such as Figure 5 As shown, after the protective shell 4 is in place, the robotic arm 2 begins assembly. First, the control circuit board 3l1 is inserted into the clips of the protective shell 4. The robotic arm 2 uses l1 as a rotation axis and rotates downwards at a low speed to complete the assembly. The protective shell 4 has two clips on the side of the control circuit board 3l1 (and the assembly of the protective shell 4 and the control circuit board 3 has directional requirements). When installing the control circuit board 3, it must first be inserted into the clips.

[0077] 3. During assembly, the high-precision distance sensor sends data to the programmable controller in real time, recording the data as β1 and β2. The deformation range of the control circuit board during normal assembly 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 If β1-α1 and β2-α2 are within the allowable error range, then the board assembly process can proceed normally; if the data difference (β1-α1 and β2-α2) is within the allowable error range, then the board assembly process can proceed normally. x -α x If β1-α1 and β2-α2 exceed the allowable error range, then the data comparison is performed to determine the interference position. That is, by comparing β1-α1 and β2-α2, the extrusion position is determined. The data with a larger difference indicates a larger deformation, and the side with a larger deformation is the side of extrusion.

[0079] 5. Once the side to be squeezed is determined, the robotic arm moves in the opposite direction to adjust it, moving at a fixed value while detecting the difference. When the difference returns to the error range, it indicates that the normal position has been reached, and the plate-closing process continues, using l1 as the rotation axis to continue rotating.

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

[0081] The specific controller mounting method provided in the embodiments of the present application detects the deformation of the control circuit board in real time through two high-precision distance sensors, calculates the abnormally extruded side by comparing the data fed back by the two sensors, automatically adjusts the posture of the mechanical arm, and ensures that the board assembly proceeds smoothly. The working precision of the mechanical arm is improved, the qualified rate of the board assembly of the equipment is improved, the production efficiency is ensured, and the scrap rate of the control circuit board is reduced (the production cost is reduced).

[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 mechanical arm can be used for force feedback to determine whether there is interference. There is a torque feedback mechanical arm in the prior art, which reflects the force condition of the mechanical arm through the torque of each shaft motor of the mechanical arm when the motor moves. When the control circuit board and the protective shell are normally assembled, the mechanical arm is stably stressed, and there is an upper limit A of the torque of the mechanical arm.

[0084] When the control circuit board and the protective shell are extruded, the mechanical arm is subjected to enhanced resistance to reach the predetermined point, and the required torque exceeds A, that is, the work is stopped, and an alarm is fed back. The mechanical arm can be set by the user to set the upper limit of the torque.

[0085] Based on the same inventive concept, as shown in Figure 6 The present application also provides a controller mounting device 60, which comprises:

[0086] A parameter acquisition module 61 is configured to acquire at least two target parameters in the process of assembling the control circuit board grabbed by the mechanical arm into the protective shell.

[0087] In one embodiment, the target parameters are distances from preset positions on the mechanical arm to the control circuit board.

[0088] As a preferred implementation manner of the embodiments of the present application, the preset positions are uniformly distributed on the mechanical arm.

[0089] In another embodiment, the target parameters are forces at positions on the mechanical arm in contact with the control circuit board.

[0090] A deformation judgment module 62 is configured to determine whether the control circuit board is deformed according to the at least two target parameters.

[0091] The determining whether the control circuit board is deformed according to the at least two target parameters comprises:

[0092] The difference between each target parameter and the reference target parameter is obtained to obtain a difference value.

[0093] If all the difference values are within the preset difference value range, it is determined that the control circuit board is not deformed; if at least one difference value is not within the preset difference value range, it is determined that the control circuit board is deformed.

[0094] The reference target parameter is a preset value.

[0095] Optionally, when the target parameter is the distance from the preset position on the mechanical arm to the control circuit board, the reference target parameter is the distance from the preset position on the mechanical arm to the control circuit board when taking the material.

[0096] The deformation side determining module 63 is configured to determine the deformation side of the control circuit board if there is deformation.

[0097] The determining of the deformation side of the control circuit board comprises:

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

[0099] The posture adjusting module 64 is configured to determine a rotation direction according to the deformation side, and control the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is not deformed.

[0100] The control of the mechanical arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is not deformed comprises:

[0101] The mechanical arm is controlled to move by a preset value according to the rotation direction, so that the control circuit board is rotated until the control circuit board is not deformed.

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

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

[0104] The board combining module 65 is configured to complete the combination of the control circuit board and the protective shell.

[0105] It should be noted that if there is no deformation, the combination of the control circuit board and the protective shell is continued.

[0106] The controller mounting device provided by the embodiment of the application is composed of a control circuit board and a protective shell. When assembling, a mechanical arm is used to pick up the control circuit board to mount the protective shell. At this time, at least two target parameters are obtained. Then, whether there is deformation and the deformation side on the control circuit board when the deformation exists are determined according to the two target parameters. 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 control circuit board does not exist deformation. Finally, the assembly of the control circuit board and the protective shell is completed. The scheme provided by the application can complete the detection of whether the control circuit board is deformed during assembly, without the need for separate detection. When deformation is detected, adjustment can be performed to prevent the control circuit board from deforming again. In this way, the controller after assembly does not cause the control circuit board to be excessively deformed, damage components, or even be broken, thereby improving product quality and reducing production cost.

[0107] Based on the same inventive concept, as shown in Figure 7 The application further provides a controller mounting system 70, which comprises:

[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 mounting method provided by the above-mentioned embodiments.

[0111] The controller mounting system provided by the embodiment of the application stores executable instructions of the processor in the memory. When the executable instructions are executed, the processor can pick up the control circuit board to mount the protective shell by the mechanical arm during assembly. At this time, at least two target parameters are obtained. Then, whether there is deformation and the deformation side on the control circuit board when the deformation exists are determined according to the two target parameters. 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 control circuit board does not exist deformation. Finally, the assembly of the control circuit board and the protective shell is completed. The scheme provided by the application can complete the detection of whether the control circuit board is deformed during assembly, without the need for separate detection. When deformation is detected, adjustment can be performed to prevent the control circuit board from deforming again. In this way, the controller after assembly does not cause the control circuit board to be excessively deformed, damage components, or even be broken, thereby improving product quality and reducing production cost.

[0112] It can be understood that the same or similar parts in the above-mentioned embodiments can be mutually referred to, and the content not described in detail in some embodiments can be referred to the same or similar content in other embodiments.

Claims

1. A controller installation method, characterized in that, include: Acquire at least two target parameters during the assembly process of the robotic arm gripping control circuit board into the protective housing; Determine whether the control circuit board is deformed based on the at least two target parameters; If deformation exists, the deformed side of the control circuit board is determined; The rotation direction is determined based on the deformed side, and the robotic arm is controlled to rotate the control circuit board according to the rotation direction until the control circuit board is no longer deformed. Complete the assembly of the control circuit board and the protective housing; Determining whether the control circuit board has deformation based on the at least two target parameters includes: The difference is obtained by subtracting each target parameter from the baseline target parameter. If all differences are within the preset difference range, it is determined that the control circuit board is not deformed; if at least one difference is not within the preset difference range, it is determined that the control circuit board is deformed.

2. The method according to claim 1, characterized in that, The step of controlling the robotic arm to rotate the control circuit board according to the rotation direction until the control circuit board is no longer deformed includes: The robotic arm is controlled to move by a preset value according to the rotation direction, so that the control circuit board rotates until the control circuit board is no longer deformed; The preset value is either a fixed value or determined based on the degree of deformation of the control circuit board; the greater the degree of deformation of the control circuit board, the larger the preset value.

3. The method according to claim 1, characterized in that: Determining the deformation side of the control circuit board includes: The deformation side is determined based on the position corresponding to the difference that is not within the preset difference range.

4. The method according to claim 1, characterized in that: The target parameter is the distance from a preset position on the robotic arm to the control circuit board.

5. The method according to claim 4, characterized in that: The preset positions are evenly distributed on the robotic arm.

6. The method according to claim 4, characterized in that: The benchmark target parameter is the distance from the preset position on the robotic arm to the control circuit board during material handling.

7. The method according to claim 1, characterized in that, Also includes: If there is no deformation, continue to complete the assembly of the control circuit board and the protective housing.

8. A controller mounting device, characterized in that, include: The parameter acquisition module is used to acquire at least two target parameters during the assembly process of the robotic arm gripping control circuit board onto the protective shell. A deformation determination module is used to determine whether the control circuit board is deformed based on the at least two target parameters. The step of determining whether the control circuit board is deformed based on the at least two target parameters includes: subtracting each target parameter from a reference target parameter to obtain a difference value; if all differences are within a preset difference value range, then it is determined that the control circuit board is not deformed; if at least one difference value is not within the preset difference value range, then it is determined that the control circuit board is deformed. A deformation side determination module is used to determine the deformation side of the control circuit board if deformation exists. The attitude adjustment module is used to determine the rotation direction based on the deformation side, and control the robotic arm to drive the control circuit board to rotate according to the rotation direction until the control circuit board is no longer deformed; The board assembly control module is used to complete the assembly of the control circuit board and the protective housing.

9. A controller installation system, characterized in that, include: At least one processor and at least one memory; The memory stores the executable instructions of the processor; The processor is configured to perform the method according to any one of claims 1-7.

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