Gantry equipment and gantry equipment control method

Abstract

The invention discloses gantry equipment and a gantry equipment control method. A cross beam device of the gantry device is erected between the first track device and the second track device, and a working shaft is arranged on the cross beam device; the two sets of beam driving devices are arranged at the two ends of the beam device correspondingly and used for driving the beam device to move along the first track device and the second track device. Cross beam position sensors are arranged on moving shafts of the cross beam driving devices and are used for sensing the positions of the two ends of the cross beam device relative to the first track device and the second track device in real time. According to the gantry equipment, the beam driving devices are arranged at the two ends of the beam device respectively, and the beam position sensors are correspondingly arranged, so that the positions of the two ends of the beam device relative to the first track device and the second track device can be obtained in real time and adjusted according to needs, and hard dragging of one end of the beam device can be avoided; and mechanical transmission can be prevented from being damaged, and the safety of gantry equipment can be improved.

Description

Technical Field

[0001] The present invention relates to the field of lifting equipment, and in particular to a gantry equipment and a gantry equipment control method. Background Art

[0002] The gantry structure is a very common mechanical structure processing device in industrial manufacturing. Its applications range from the construction of large ships to the processing of precision semiconductors. Especially in intelligent manufacturing, large gantry structures such as truss robots and small gantry structures such as three-coordinate rectangular robots are all within the motion control scope of the gantry structure.

[0003] The gantry support structure can also be used as a three-coordinate motion control system with a simple and stable system structure, and can be used as a solution for many industrial automation processing, such as: gantry precision CNC machine tools, semiconductor wafer processing, precision laser cutting and scribing, three-coordinate measuring instruments, wood processing, dispensing machines and punching machines, etc. It can also be used as a large-span gantry crane for lifting equipment, rectangular robot racks, and many other industrial manufacturing fields, especially if it is equipped with an intelligent gantry multi-axis synchronous control system, it can evolve into the basic mechanical structure of a truss robot and a rectangular coordinate robot.

[0004] like Figure 1-Figure 2 As shown, a conventional gantry support 90 is shown in the figure. The gantry support 90 has automatic control of mechanical motion with three degrees of freedom in space, which can be set as XYZ three-coordinates. The gantry support 90 includes a pillar, a first track 91, a second track 92, a beam axis 93, and a working axis 94. The first track 91 and the second track 92 are collectively referred to as double tracks, the first track 91 can be defined as the Y1 axis, and the second track 92 can be defined as the Y2 axis, collectively referred to as the gantry double track axis. The beam axis 93 is mounted on the gantry double track and can move relative to the track. The beam axis 93 and the double tracks on both sides constitute a stable gantry support structure, and can be equipped to move along the direction of the beam axis 93, and the beam axis 93 can be defined as the X axis. A working axis 94 that can move upward and downward is provided on the beam axis 93, and various manipulators or hook devices can be installed on the working axis 94 to drive the workpiece, and the working axis 94 can be defined as the Z axis. The Z axis can also move with the X axis. Various processing equipment can be installed on the Z axis, such as a manipulator or hook installed on a lifting gantry truss robot, or a laser cutting tool installed on a laser processing rectangular coordinate robot, etc. Finally, the processing preparation can be mechanically moved in the rectangular three-coordinate system formed by the gantry support 90 to meet the processing work needs.

[0005] At present, when the gantry structure is in use, the two ends of the beam shaft 93 often become out of sync and deflect. The mechanical movements of the left and right sides of the beam shaft 93 are out of sync, which can easily cause one side of the double-track mechanical part to tilt and drag hard, and the beam shaft 93 to get stuck. Severe damage may be caused to the double-track mechanical structure, such as the screw thread of the screw being broken or the screw being tilted; or the lifting gantry track may jam on the track, the rollers may wear out, etc.

[0006] When the gantry structure is in use, the center of gravity of the working shaft 94 often shakes and sways during acceleration and deceleration, which can easily cause inefficiency in work positioning and, in serious cases, may cause problems in production safety. Summary of the invention

[0007] The technical problem to be solved by the present invention is to overcome the above-mentioned defect that the beam axis of the gantry structure in the prior art is prone to being out of sync, and to provide a gantry device and a gantry device control method.

[0008] The present invention solves the above technical problems through the following technical solutions:

[0009] A gantry device, the gantry device comprises a first track device, a second track device, a beam device, and a working axis device, the first track device and the second track device are arranged in parallel and at intervals, the beam device is erected between the first track device and the second track device, the working axis is arranged on the beam device, the working axis is used to connect processing equipment, and the working axis is also used to adjust the height of the processing equipment; the gantry device also includes two sets of beam driving devices, the two sets of beam driving devices are respectively arranged at the two ends of the beam device, the beam driving devices are used to drive the beam device to move along the first track device and the second track device; beam position sensors are provided on the moving axes of the two sets of beam driving devices, and the beam position sensors are used to sense in real time the positions of the two ends of the beam device relative to the first track device and the second track device respectively.

[0010] In the present solution, by adopting the above structure, the gantry equipment sets a beam driving device at both ends of the beam device and sets a beam position sensor accordingly, so that the positions of the two ends of the beam device relative to the first track device and the second track device can be known in real time and adjusted as needed, thereby avoiding hard dragging of one end of the beam device, avoiding damage to the mechanical transmission, and improving the safety of the gantry equipment.

[0011] Optionally, the two sets of beam driving devices can implement feedback closed-loop control with respect to the positions of the first track device and the second track device.

[0012] In this solution, by adopting the above structure, the beam driving device that can realize feedback closed-loop control can avoid the two ends of the beam device from being out of sync, can avoid the problem of rail gnawing, and can improve the reliability and safety of the gantry equipment.

[0013] Optionally, the beam position sensor also includes a beam absolute multi-turn encoder device, which is used to measure the positions of both ends of the beam device relative to the first track device and the second track device in real time, and realize feedback closed-loop control.

[0014] In this solution, by adopting the above structure, the crossbeam absolute value multi-turn encoder device can more reliably realize closed-loop control, avoid calculator accumulation errors, and eliminate the adverse effects of accumulated data errors. When debugging the gantry equipment, the crossbeam absolute value multi-turn encoder device can also reduce the debugging workload and reduce the debugging cost.

[0015] Optionally, the gantry device also includes a beam edge calculator, which is communicatively connected to the beam position sensor, and is used to process the position signal of the beam position sensor in real time and send a drive signal to the beam drive device.

[0016] In this solution, by adopting the above structure, the beam edge calculator can be used to optimize the calculation in real time, measure the actual return difference on site and store it for a long time.

[0017] Optionally, the beam edge calculator is also used to complete one or more of the self-test, direction, zero point, and resolution re-adjustment of the beam position sensor.

[0018] Optionally, signals from the two sets of beam position sensors are transmitted in parallel to a host computer.

[0019] In this solution, by adopting the above structure, the signals are transmitted in parallel to the host computer, which can reduce the delay time difference between different signals, improve the synchronization of data acquisition feedback, and achieve more precise control.

[0020] Optionally, the gantry device also includes a working shaft drive device and a working shaft position sensor, wherein the working shaft drive device acts on the working shaft to move the working shaft relative to the crossbeam device; the working shaft position sensor is used to sense the position of the working shaft device relative to the crossbeam device in real time.

[0021] In this solution, by adopting the above structure and utilizing the working shaft drive device and the working shaft position sensor, the position of the working shaft device can be known in real time, thereby facilitating the judgment of the load position and further adjusting the driving force of the beam drive device at both ends of the beam device, thereby avoiding hard dragging at one end of the beam device, avoiding damage to the mechanical transmission, and improving the safety of the gantry equipment.

[0022] Optionally, the gantry device also includes a working axis edge calculator, which is communicatively connected to the working axis position sensor, and is used to process the position signal of the working axis position sensor in real time and send a drive signal to the working axis drive device.

[0023] Optionally, the working axis edge processor is also used to calculate the load distribution on the left and right sides of the beam device and generate a load distribution signal. The working axis edge processor is also used to send the distribution signal to the host computer, and the host computer controls the beam drive device according to the distribution signal.

[0024] In this solution, by adopting the above structure and using the distribution signal to judge the load position, and then adjusting the driving force of the beam driving device at both ends of the beam device, hard dragging at one end of the beam device can be avoided, damage to the mechanical transmission can be avoided, and the safety of the gantry equipment can be improved.

[0025] Optionally, the gantry equipment also includes a vertical axis drive device and a vertical axis position sensor, the working axis drive device acts on the working axis to move the processing equipment away from or close to the working axis; the working axis position sensor is used to sense the position of the processing equipment relative to the working axis in real time.

[0026] In this solution, by adopting the above structure and utilizing the vertical axis drive device and the vertical axis position sensor, the center of gravity position of the processing equipment can be determined, and the negative acceleration during deceleration positioning can be predicted, which can reduce the shaking of the vertical axis device and improve stability.

[0027] Optionally, the gantry device also provides a vertical axis edge calculator, which is communicatively connected to the vertical axis position sensor, and is used to process the position signal of the vertical axis position sensor in real time and send a drive signal to the vertical axis drive device.

[0028] Optionally, the vertical axis edge processor is also used to calculate the height and center of gravity position of the workpiece processed by the processing equipment and generate a swing signal. The vertical axis edge processor is also used to send the swing signal to the host computer, and the host computer controls the beam drive device according to the swing signal.

[0029] A gantry device control method is provided, and the gantry device control method is used to control the gantry device as described above.

[0030] In this solution, by adopting the above method and utilizing the gantry device control method to control the gantry device, it is possible to avoid abrupt dragging of the gantry device, avoid damage to the mechanical transmission, and improve the safety of the gantry device.

[0031] Optionally, the gantry equipment control method includes:

[0032] Using a beam position sensor of the gantry device to sense in real time the positions of the two ends of the beam device relative to the first track device and the second track device, respectively, and using a beam edge calculator of the gantry device to control a beam driving device in real time;

[0033] Using a working axis position sensor to sense the position of the working axis device relative to the crossbeam device in real time, and using a working axis edge calculator to control the working axis driving device in real time;

[0034] A vertical axis position sensor is used to sense the position of the processing equipment relative to the working axis in real time, and a vertical axis edge calculator is used to control a vertical axis driving device.

[0035] On the basis of being in accordance with the common sense in the art, the above-mentioned preferred conditions can be arbitrarily combined to obtain the preferred embodiments of the present invention.

[0036] The positive and progressive effects of the present invention are:

[0037] The gantry device of the present invention respectively arranges beam driving devices at both ends of the beam device and correspondingly arranges beam position sensors, so that the positions of the two ends of the beam device relative to the first track device and the second track device can be known in real time and adjusted as needed, thereby avoiding hard dragging of one end of the beam device, avoiding damage to the mechanical transmission, and improving the safety of the gantry device. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the XYZ three-coordinates of the gantry bracket in the prior art.

[0039] Figure 2 It is a schematic diagram of the asynchronous cross beam axis of the gantry support in the prior art.

[0040] Figure 3 It is a schematic diagram of the three-dimensional structure of the gantry device of the present invention.

[0041] Figure 4 Figure 3 A schematic diagram of the position of the working axis device in the gantry device of the present invention.

[0042] Figure 5 Figure 3 Schematic diagram of the drive device-position sensor in the gantry device of the present invention.

[0043] Figure 6 Figure 3 Another schematic diagram of the drive device-position sensor in the gantry device of the present invention.

[0044] Figure 7 Figure 3 Schematic diagram of a mechanical gear type multi-turn absolute encoder in a gantry device of the present invention.

[0045] Figure 8 Figure 3 Schematic diagram of an edge processor in a gantry device of the present invention.

[0046] Fig. 9 Figure 3 Schematic diagram of data acquisition of absolute value multi-turn encoder in gantry equipment of the present invention.

[0047] Fig.10 Figure 3 Schematic diagram of laser calibration in the gantry device of the present invention.

[0048] Fig.11 Figure 3 A schematic diagram of the position of the crossbeam device in the gantry device of the present invention.

[0049] Fig.12 Figure 3 A schematic diagram of the position of the working axis device in the gantry device of the present invention.

[0050] Fig.13 Figure 3 Schematic diagram of the anti-sway strategy in the gantry device of the present invention.

[0051] Fig.14 Figure 3 A schematic diagram of the center of gravity position of the processing equipment in the gantry equipment of the present invention.

[0052] Fig.15 Figure 3 Schematic diagram of the movement of the rotary encoder measuring wheel in the gantry device of the present invention.

[0053] Fig.16 Figure 3 Schematic diagram of the rotary encoder measuring the gear rack in the gantry device of the present invention.

[0054] Fig.17 Figure 3 Schematic diagram of the host computer operating interface of the gantry device of the present invention.

[0055] Fig.18 Figure 3 Schematic diagram of the return differential zone in the gantry device of the present invention.

[0056] Fig.19 Figure 3 Schematic diagram of edge calculator logic switches in the gantry device of the present invention.

[0057] Fig. 20 Figure 3 Schematic diagram of the Y1 position switch in the gantry device of the present invention.

[0058] Fig.21 Figure 3 Another schematic diagram of the host computer operating interface in the gantry device of the present invention.

[0059] Fig. 22 Figure 3 A third schematic diagram of the operating interface of the host computer in the gantry device of the present invention.

[0060] Fig.23 Figure 3 Schematic diagram of the absolute position of the mechanical end in the gantry device of the present invention.

[0061] Fig.24 Fig.23 Schematic diagram of absolute encoder feedback at the mechanical end.

[0062] Fig.25 Figure 3 Schematic diagram of edge computing and providing spindle strategy selection according to load position in the gantry device of the present invention.

[0063] Fig.26 Figure 3 Schematic diagram of the Z-axis center of gravity height and swing in the gantry device of the present invention.

[0064] Fig. 27 Figure 3 A fourth schematic diagram of the upper computer operating interface in the gantry device of the present invention.

[0065] Fig.28 Figure 3 Schematic diagram of the logical sequence of the four-axis edge calculator in the gantry device of the present invention.

[0066] Fig.29 Figure 3 Schematic diagram of the output data format of the edge calculator in the gantry device of the present invention.

[0067] Fig.30 Figure 3 Schematic diagram of dual-track synchronous control in the gantry device of the present invention.

[0068] Fig.31 Figure 3 Schematic diagram of digital cloud migration of gantry equipment of the present invention.

[0069] Description of reference numerals:

[0070] Gantry equipment 100

[0071] The first track device 11

[0072] The second track device 12

[0073] Beam device 13

[0074] Working axis device 14

[0075] Gantry bracket 90

[0076] First Track 91

[0077] Second track 92

[0078] Beam axis 93

[0079] Working axis 94 DETAILED DESCRIPTION

[0080] The present invention will be described more clearly and completely below by way of embodiments in conjunction with the accompanying drawings, but the present invention is not limited to the scope of the embodiments.

[0081] like Figure 3-Figure 31 As shown, this embodiment includes a gantry device 100 and a control method of the gantry device 100 , wherein the control method of the gantry device 100 uses the gantry device 100 .

[0082] The gantry device includes a first track device 11, a second track device 12, a beam device 13, and a working axis device 14. The first track device 11 and the second track device 12 are arranged in parallel and spaced apart. The beam device 13 is erected between the first track device 11 and the second track device 12. The working axis is arranged on the beam device 13. The working axis is used to connect the processing equipment, and the working axis is also used to adjust the height of the processing equipment. The gantry device 100 also includes two sets of beam driving devices, which are respectively arranged at both ends of the beam device 13, and the beam driving devices are used to drive the beam device 13 to move along the first track device 11 and the second track device 12. The moving axes of the two sets of beam driving devices are provided with beam position sensors, and the beam position sensors are used to sense the positions of the two ends of the beam device 13 relative to the first track device 11 and the second track device 12 in real time. The gantry device 100 is provided with beam driving devices at both ends of the beam device 13, and beam position sensors are provided accordingly, so that the positions of the two ends of the beam device 13 relative to the first track device 11 and the second track device 12 can be known in real time and adjusted as needed, thereby avoiding hard dragging of one end of the beam device 13, avoiding damage to the mechanical transmission, and improving the safety of the gantry device 100.

[0083] The gantry equipment 100 may be understood to include equipment having a gantry-shaped structure, which may specifically include a crane in a workshop, and may also include other gantry-shaped equipment. The processing equipment may include hoists, welding equipment, and the like.

[0084] The first track device 11 and the second track device 12 can be understood as a component set including a column, a track and a corresponding driving device. The crossbeam device 13 can be understood as a crossbeam erected between the first track device 11 and the second track device 12 and a driving device arranged on the crossbeam. The working axis device 14 can be understood as a component set including a component capable of driving a processing device in a vertical direction.

[0085] In some of the drawings, the first track device 11 is marked as Y1, the second track device 12 is marked as Y2, the crossbeam device 13 is marked as X, and the working axis device 14 is marked as Z.

[0086] The two sets of beam driving devices can realize feedback closed-loop control with respect to the positions of the first track device 11 and the second track device 12. The beam driving device capable of realizing feedback closed-loop control can avoid the asynchronism of the two ends of the beam device 13, avoid the problem of gnawing the rails, and improve the reliability and safety of the gantry device 100.

[0087] The crossbeam position sensor also includes a crossbeam absolute value multi-turn encoder device, which is used to measure the positions of the two ends of the crossbeam device 13 relative to the first track device 11 and the second track device 12 in real time, and realize feedback closed-loop control. The use of the crossbeam absolute value multi-turn encoder device can more reliably realize closed-loop control, avoid calculator accumulation errors, and eliminate the adverse effects of accumulated data errors. When debugging the gantry device 100, the crossbeam absolute value multi-turn encoder device can also reduce the debugging workload and reduce the debugging cost.

[0088] The gantry device 100 also includes a beam edge calculator, which is in communication with the beam position sensor. The beam edge calculator is used to process the position signal of the beam position sensor in real time and send a drive signal to the beam drive device. The beam edge calculator can be used to optimize the calculation in real time, measure the actual return difference on site, and store it for a long time.

[0089] The beam edge calculator is also used to complete self-test, direction, zero point, resolution or one or more re-adjustment of the beam position sensor.

[0090] The signals of the two sets of beam position sensors are transmitted in parallel to the host computer. The parallel transmission of signals to the host computer can reduce the delay time difference between different signals, improve the synchronization of data acquisition feedback, and achieve more precise control.

[0091] The gantry device 100 also includes a working shaft driving device and a working shaft position sensor. The working shaft driving device acts on the working shaft to move the working shaft relative to the crossbeam device 13. The working shaft position sensor is used to sense the position of the working shaft device 14 relative to the crossbeam device 13 in real time. By using the working shaft driving device and the working shaft position sensor, the position of the working shaft device 14 can be known in real time, so as to facilitate the judgment of the load position, and then adjust the driving force of the crossbeam driving device at both ends of the crossbeam device 13, so as to avoid hard dragging of one end of the crossbeam device 13, avoid damage to the mechanical transmission, and improve the safety of the gantry device 100.

[0092] The gantry device 100 also includes a working axis edge calculator, which is communicatively connected to the working axis position sensor. The working axis edge calculator is used to process the position signal of the working axis position sensor in real time and send a driving signal to the working axis driving device.

[0093] The working axis edge processor is also used to calculate the load distribution on the left and right sides of the beam device 13 and generate a load distribution signal. The working axis edge processor is also used to send the distribution signal to the host computer, and the host computer controls the beam drive device according to the distribution signal. The distribution signal is used to judge the load position, and then adjust the driving force of the beam drive device at both ends of the beam device 13, so as to avoid hard dragging at one end of the beam device 13, avoid damage to the mechanical transmission, and improve the safety of the gantry device 100.

[0094] The gantry device 100 also includes a vertical axis driving device and a vertical axis position sensor. The working axis driving device acts on the working axis to move the processing device away from or close to the working axis. The working axis position sensor is used to sense the position of the processing device relative to the working axis in real time. The vertical axis driving device and the vertical axis position sensor can be used to determine the center of gravity of the processing device and predict the negative acceleration during deceleration and positioning, thereby reducing the shaking of the vertical axis device and improving stability.

[0095] The gantry device 100 also provides a vertical axis edge calculator, which is in communication with the vertical axis position sensor. The vertical axis edge calculator is used to process the position signal of the vertical axis position sensor in real time and send a drive signal to the vertical axis drive device.

[0096] The vertical axis edge processor is also used to calculate the height and center of gravity position of the workpiece processed by the processing equipment and generate a swing signal. The vertical axis edge processor is also used to send the swing signal to the host computer, and the host computer controls the beam drive device according to the swing signal.

[0097] This embodiment also includes a gantry device 100 control method, which is used to control the above gantry device 100. Using the gantry device 100 control method to control the gantry device 100 can avoid the gantry device 100 from being dragged stiffly, can avoid damage to the mechanical transmission, and can improve the safety of the gantry device 100.

[0098] The control method of the gantry device 100 includes:

[0099] The beam position sensor of the gantry device 100 is used to sense the positions of the two ends of the beam device 13 relative to the first track device 11 and the second track device 12 in real time, and the beam edge calculator of the gantry device 100 is used to control the beam driving device in real time;

[0100] A working axis position sensor is used to sense the position of the working axis device 14 relative to the crossbeam device 13 in real time, and a working axis edge calculator is used to control the working axis driving device in real time;

[0101] The vertical axis position sensor is used to sense the position of the processing equipment relative to the working axis in real time, and the vertical axis edge calculator is used to control the vertical axis drive device.

[0102] The gantry device 100 of this embodiment includes an edge calculator for real-time perception and parallel calculation of the movement of each axis; it can simultaneously and in real time be connected in parallel to the sensors installed at the mechanical ends of each movement axis of the gantry, so as to perceive the on-site process end in real time and quickly perform process edge computing processing on the on-site perception data.

[0103] Each sensor signal completes self-checking, direction, zero point, and resolution re-adjustment in the edge calculator. For on-site calibration of mechanical transmission errors, measurement of return difference and memory and current position calculation in the edge calculator; process functions of gantry synchronization control, reference of gantry anti-sway perception data; and other specific process functions of gantry structure mechanical motion control. All of the above perception and calculation data are optimized, packaged, compressed and merged, and uploaded to the host computer controller using the industrial Ethernet, which has the fastest signal transmission technology at present. Only one communication address is occupied during online transmission, saving online resources for fast communication output.

[0104] The control method of the gantry equipment 100 can help with the synchronous control of the gantry. First, it can achieve real-time perception on the mechanical end, data optimization and compression, on-site process functionalization, and fast industrial Ethernet communication output that saves online resources. The upper computer only needs to receive these signals, and through simple calculations, it can control the synchronous control of the drive device and the anti-sway of the gantry working axis.

[0105] The four axes of the gantry support are all driven by independent power, such as servo drive and servo motor or frequency converter and frequency converter motor. The four axes of the gantry support are all equipped with position sensing sensors at the mechanical end to achieve real-time sensing feedback. Absolute multi-turn encoders can be used to form real-time feedback of the absolute position of each axis and the absolute position will not be lost over time, which can help the controller to achieve reliable and deterministic closed-loop control.

[0106] Figure 5 The implementation of the motor-screw absolute multi-turn encoder position closed loop is shown. Figure 6 The closed-loop implementation of the absolute multi-turn encoder at the end of the variable frequency motor reducer is shown. The connection method and signal output of the absolute multi-turn encoder for the perception of the power machinery of each motion axis of the gantry: The various power devices on the gantry structure are mainly motors, such as variable frequency motors and servo motors. For example: The installation method of the absolute multi-turn encoder for the perception of the mechanical movement of the variable frequency motor is as follows Figure 6 The absolute value multi-turn encoder can be installed on the power output shaft end of the variable frequency motor reducer device and rotate together with the power output shaft to obtain the sensory measurement of the power mechanical movement.

[0107] exist Figure 7 In the absolute value multi-turn encoder, a mechanical gearbox type multi-turn absolute value encoder is used, and each position inside it is defined by a mechanical gear structure, which has nothing to do with the counter and time. After the encoder is initialized and debugged to zero point alignment, the zero point definition relationship will no longer change, and the position will not be lost due to interference or power failure. These absolute value multi-turn encoders have intelligent microprocessors inside, which can be used for motion control length conversion, motion direction setting, zero point definition reference position pre-set, and the reference position is already set before the gantry bracket is installed, without the need to enter the cumbersome zeroing procedure when the gantry bracket is debugged. The output signal of the absolute value encoder is in RS485 active transmission format, and the refresh cycle is 2ms.

[0108] Combination Figure 8The signal acquisition of the absolute multi-turn encoder involved in the dual-axis synchronous control is performed by an edge calculator, which collects encoder signals in parallel at the same time. The feedback information of the absolute multi-turn encoder of each motion axis sensor has no time difference and delay. This sensor data collector also has an intelligent microprocessor inside. It is based on the ARM core and has integrated industrial Ethernet communication ASIC chip. It has internal calculation CPU programming function and ROM memory. The memory can also contain non-lost memory parameter storage. It includes a two-way communication function, which can fill in the field application parameters in the parameter window of program programming, and it is not lost and permanently saved. This is an edge calculator with edge data calculation function for fast on-site calculation and processing of specific processes of gantry structure. The calculated and processed data is then quickly processed and synthesized, converted into industrial Ethernet signals for fast transmission and output, such as: Ethercat, Profinet, or CC-Link IE, etc., which are standard industrial Ethernet communication interfaces required by market users. Each sensor absolute value multi-turn encoder signal is input in parallel to this edge calculator to optimize the calculation, measurement and long-term memory of the actual return difference on site; the RS485 digital signal cable of the gantry 4-axis absolute value multi-turn encoder is connected in parallel to the ① parallel input interface end of the gantry device 100. Among them, the 1# input interface is the absolute value multi-turn encoder for mechanical motion perception called spindle Y1.

[0109] The signal of the absolute multi-turn encoder of the gantry 4-axis is an RS485 active mode signal, which is connected to the gantry device 100 in parallel, that is, the data acquisition time of each absolute encoder is simultaneous, and the time difference of the refresh delay of all sensors is the same as 2ms or 8ms for the longer transmission distance requirement.

[0110] Figure 8 It also includes ② multi-section isolated working power supply, and the surrounding electromagnetic interference is isolated in sections without affecting each other.

[0111] At the 1# encoder connector of the ① input port, an external computer ⑧ can be connected during the debugging phase to the human-machine interface software for setting parameters required by the on-site process, such as Fig.17 As shown, ⑧ can preset the parameters of each encoder sensor, the logical switch planning of each encoder sensor, and the logical switch planning between multiple encoder sensors. This peripheral human-machine interface can be connected to a laptop computer by a commercially available RS485 to USB device, and provides a computer human-machine interface setting software. There is a setting window on this software interface, which can preset the numerical parameters required by the on-site process.

[0112] exist Fig. 9In the process, taking the linear module as an example, the data of the absolute multi-turn encoder is collected, and the signal is connected in parallel to the synchronous edge calculator. In the edge calculator, the direction, resolution and zero position of each input signal are first reset and calibrated according to the on-site process requirements.

[0113] During the on-site commissioning process, the length calibration device available on the market can be used in combination with Fig.10 For example, for high-precision laser displacement sensors, each absolute multi-turn encoder signal is calibrated with the actual mechanical position. The main purpose is to measure the error in mechanical transmission, such as the "return difference" of the return gap, and record this calibrated return difference in segmented positions and input it into the memory of the edge calculator. It is then output to the host computer along with the encoder signal output of each axis. The host computer will choose to add this return difference according to the walking direction and current position to compensate for the mechanical gap error. After the equipment has been in operation for a long time, such on-site calibration measurement of the return difference can be repeated. This return difference is measured and recorded again, and is permanently memorized in the memory of the edge calculator. In the output signal of the edge calculator, the return difference records of each axis are simultaneously output, so that the host computer can compensate for the recorded return difference when calculating motion control. The absolute multi-turn encoder can be installed on the coaxial rotation at the top of the linear module to achieve the perception and measurement of the mechanical movement of the servo motor power.

[0114] Each input absolute value multi-turn encoder signal represents a physical position axis. Each axis can be divided into position zones in the edge calculator according to the on-site process requirements, and the current position value is compared by logical calculation, and the electronic digital switch is output as 1 or 0. Fig.11 As shown, the gantry beam device 13 has protection switches at the extreme positions at both ends when walking on the first track device 11 and the second track device 12.

[0115] The sensing sensors of the dual-track Y1 and Y2 dual-axis data are connected in parallel and synchronously collected. The internal microprocessor will perform fast position comparison, calculate the position difference of the dual axes, the positive and negative vector axes containing the sign bit, and set the synchronous correction switch quantity based on the position deviation calculation. The switch quantity can be corrected at the first time when the host computer scans.

[0116] Combination Fig.12 While collecting the sensor data of the X-axis, the internal microprocessor can quickly calculate the left and right load distribution, calculate the partition switch of heavy load and light load, and quickly transmit it to the upper controller via industrial Ethernet to allocate and adjust the driving strategies of the heavy load and light load of the dual-track drive on which side, which is similar to the partition switch of the gear position of a car;

[0117] exist Fig.13 , Fig.14In the process, while the absolute value sensor data of the Z axis is being collected, the internal microprocessor can quickly calculate the height and center of gravity position of the workpiece, separate the anti-sway partition switch, and quickly transmit it to the host controller via industrial Ethernet. The host controller can plan a flexible segmented deceleration and stop positioning strategy based on the real-time position perception record, time, and Z-axis center of gravity height at the startup state to adjust the anti-sway strategy from rapid movement to stop.

[0118] The swing of the Z-axis is related to the following factors: the shape of the S-curve of initial acceleration, the shape of the S-curve during deceleration, the mechanical characteristics of the on-site deceleration brake, the height of the center of gravity of the workpiece and other on-site factors. The gantry equipment 100 provides the real-time position of each axis to obtain the shape of the acceleration and deceleration S-curve, and the partition switch of the Z-axis center of gravity height for engineers to record and refer to during on-site debugging, so as to quickly plan an anti-sway strategy for the on-site process.

[0119] The control method of the gantry device 100 can be used for motion control of the gantry mechanical structure, realizing a servo system or a variable frequency system including a closed loop of a position sensor, a synchronous control method and system. The double tracks of the gantry mechanism are jointly driven by two power drive systems. Any servo driver or variable frequency controller in the two power systems adjusts the speed of the servo motor or variable frequency motor it controls by comparing the position relationship between the servo motor or variable frequency motor it controls and the other motor, thereby realizing synchronous deviation correction control of the two motors.

[0120] Combination Fig.15 Absolute multi-turn encoders can also be used to sense and measure flat moving objects: for example, measuring wheels are installed on tracks. Fig.16 In the figure, the absolute value multi-turn encoder measurement installation method of the gear and rack transmission on the truss robot track. The output signal of the absolute value multi-turn encoder is a digital signal with unique absolute value encoding for each position. The signal format for connecting the gantry device 100 is a signal in RS485 active transmission mode, which contains a check code for the data to check for possible errors in transmission and reception. The signal time domain refresh cycle is 2ms or 8ms. Selecting an 8ms signal can transmit a longer distance, for example, in a gantry lifting device, the signal can be transmitted 100 meters away.

[0121] Combination Figure 5 class Fig.18 The on-site mechanical return difference measurement and calibration of the gantry's 4 axes is divided into four segments according to the total stroke, and transmitted to the host controller when output, and the controller performs back and forth motion mechanical return difference compensation calculation. Fig.18 Measurement of the return difference of the linear module.

[0122] Combination Fig.19 , Fig. 20 and Fig.21Each axis of the edge calculator can quickly calculate in the internal CPU, and preset the value input, and plan the logic switch output: each encoder can design a partitioned electronic cam switch according to the on-site process requirements. For Y1, one of the double tracks, you can set the input upper limit position zone switch, lower limit position zone switch, common stop position switch, common loading position switch, and common unloading position switch. The switch output preset interface of the logic calculation is as follows Fig.21 As shown, A is Y1 and B is Y2.

[0123] Combination Fig. 22 , Fig.23 and Fig.24 , the synchronous deviation vector calculation of the gantry double track can be preset on the human-machine interface, the planned correction range is input, and the correction logic electronic switch of the deviation partition is output after calculation: the vector axis (BA) of the difference between the two encoder positions is calculated; the absolute value multi-turn encoder on Y2 is used as B, and the absolute value multi-turn encoder on Y1 is used as A, and the calculation is compared with each other and the setting interface of the synchronous difference switch is set, BA

[0124] Combination Fig.12 , Fig.13 , Fig.25 and Fig.26 In the past, the synchronous control of gantry mechanical motion often used a fixed motion axis Y1 as the main axis and another motion axis Y2 as the slave axis of the follow-up main axis. However, in actual working conditions, a considerable proportion of working conditions are that the load of the working axis is on the slave axis side. During synchronous control, the slave axis that follows the main axis has to move with the heavy load gravity torque and adjust the speed to follow the main axis, which can easily cause speed loop oscillation or difficulty in position synchronization. The motor drive control strategy loses sight of one thing while focusing on another, resulting in the inability to achieve follow-up synchronization. The load-side machine is dragged away, which can easily damage the mechanical structure on the load side, and even cause safety accidents such as jamming and tipping.

[0125] To this end, the gantry device 100 provides a real-time sensing position switch for the beam axis X, and a partitioned electronic switch calculated by the process logic in the edge calculator, so that the host computer can timely adjust the flexible switching of the master and slave axes on the heavy-load and light-load sides. For example: keep the motor drive on the heavy-load side of the load as the main axis drive, use the movement direction of the heavy-load axis as the main drive for the motor output torque target, and the motion control strategy on the light-load side is to correct the balance of the beam X, and position following is the control target to prevent the load Z from being dragged away. This edge computing function of the inventive device provides a reasonable and safe synchronization strategy for the subsequent host computer to choose from.

[0126] The gantry working axis Z is prone to swaying after stopping in place due to the acceleration from the start acceleration to the stop deceleration brake due to the heavy objects in the processing device. There are many reasons for this swaying, mainly unreasonable motor acceleration control and unreasonable in-place deceleration and stop control. In order to prevent the Z axis from swaying when stopping in place, the main controller needs to have an anti-sway control strategy planning.

[0127] The occurrence and prevention of Z-axis sway mainly lies in the following aspects: the acceleration of the motor when it starts and its time and actual position form an S-shaped curve, which is recorded in real time by the Y1 sensor. Fig.13 The positions and travel time of 1, 2, 3, and 4 constitute the S-shaped curve at startup. Because of the absolute position perception, engineers can plan and debug this S-shaped curve at startup based on the perception data.

[0128] The height of the center of gravity of the Z axis is recorded in real time by the sensor on the Z axis and output by the edge computing partition as a logical electronic switch. Due to the pendulum principle, the frequency and time of the Z axis's swing are related to the height of its center of gravity.

[0129] Finally, the deceleration plan of the main controller Fig.13 The deceleration and travel time of 6, 7, 8, 9, 10 in the figure - the calculation and planning of the current real-time position, the previously memorized S curves 1, 2, 3, 4 and the center of gravity height partition switch, and the debugging and exploration of the mechanical characteristics of the deceleration brake of the on-site mechanical equipment, etc., are combined and planned. The gantry device 100 provides real-time perception of the positions of Y1, Y2, and Z, as well as the center of gravity partition calculation of Z and the rapid output of the electronic switch, to help on-site engineers to debug a reasonable anti-sway acceleration and deceleration plan for the main controller more simply and quickly.

[0130] Combination Fig. 27 , in the data address number setting interface in the edge calculator, to provide the host computer with a quick and selective way to find the data group required for control.

[0131] Combination Fig.28 , the logical calculation process of the edge computer Fig.28 As shown, the gantry device 100 performs optimization, logic calculation and control switch output according to ⑧ preset parameters for the data received by each encoder sensor, and ③ CPU processing.

[0132] The setting parameters and equipment operation records of the gantry device 100 can be permanently stored by the data storage device in a non-lost manner when power is off.

[0133] After the logical calculation of CPU ③, the gantry device 100 is connected to the industrial Ethernet line via the industrial Ethernet output interface ⑤, which can be the commonly used RJ45 of Ethernet ⑦. The industrial Ethernet protocols that can be provided include Ether Cat, or profinet, or CC-link IE, and other industrial standard protocol interfaces.

[0134] The gantry device 100 is connected to the host computer controller via industrial Ethernet. According to the instructions of the host computer of industrial Ethernet, the output time domain signal is as follows: Fig.29 shown.

[0135] The state of the gantry device 100 after data self-checking and logic switch calculation can be preset and planned to be displayed via the ⑥ indicator light, which is convenient for debugging and operator identification on site.

[0136] Combination Fig.30 , using the typical gantry double-track synchronous control scheme of this device, the actual application examples of synchronous comparison and synchronous control of two mechanical motion axes: such as gantry machine tool processing, gantry crane and other double-track mechanical movements.

[0137] The example is the movement of two linear modules driven by servo motors in the same direction, which needs to achieve real-time synchronous motion control of the two axes.

[0138] Two absolute value multi-turn encoders are installed at the terminals of the two linear modules respectively. The digital signal output of these two absolute value multi-turn encoders is RS485 signal, which is connected in parallel to the 1# input port of the device of the present application as the main axis A and the 2# input port as the slave axis B. After data optimization, zero point alignment, clock alignment, and logical calculation and comparison and fusion calculation of the two encoder sensors, their position difference is compared in real time and synchronously. According to the preset parameters of the difference between the two, a set of logical electronic cam switches after synchronous comparison and fusion calculation is output and uploaded to the industrial Ethernet. The upper computer host on the industrial Ethernet receives the position values ​​of the two mechanical motion axes (main axis and slave axis) and the difference electronic cam switches between them, and makes a control instruction to the drive motor to adjust the speed so that the positions of the two linear module moving parts are always within a position synchronization range, and the perception values ​​of the two absolute value multi-turn encoders are fed back to the device of the present application again, and the device of the present application compares again to see whether the difference between them is reduced until the two are completely equal.

[0139] It can be seen that the gantry device 100 includes input signal processing, intelligent logic calculation microprocessor CPU, preset parameters and long-term non-loss storage E2ROM, which can save online resources and controller computing capacity resources; especially in the synchronous calculation control of the gantry multi-encoder sensor, it can realize parallel input of sampling time, zero point alignment, clock alignment and real-time synchronous motion control without time difference.

[0140] The gantry device 100 and the gantry device 100 control method are for on-site real-time perception of the specific process of the gantry structure, and are associated with fast local edge process calculations, and optimize the compressed data packet to be an industrial Ethernet output of an address, which can realize the real-time perception and monitoring of the gantry structure machinery, intelligently realize the perception of the gantry full-power machinery, position zero point alignment, and data acquisition clock alignment, realize industrial Ethernet networking, and synchronize the gantry mechanical movement and anti-sway control. The benefits of this technology to the application of the gantry structure in the digital factory are as follows: it can help the gantry structure, which is widely used in the digital factory transformation, realize its intelligent manufacturing part, and use a relatively economical, simple and fast method to help solve the technical problems existing in the mechanical movement of the gantry structure. It can also make the production line efficient and energy-saving. With the planning of all the execution motor movements on the production line, the gantry synchronous linkage coordination is realized, and the rhythm of the front and rear production processes is coordinated, which reduces the waste of redundant mechanical movements, idling waiting, and the mechanical movements of the motors adjusted by shutdown, improves production efficiency, and saves energy consumption of each motor on the production line. It can also reduce the possibility of damage to the gantry device 100 and achieve safe production. Thanks to the perception, planning, and synchronous linkage of the movements of all the actuator motors on the gantry structure, logical calculation provides position limit protection switches and front and rear asynchronous tolerance limit switches, which can greatly reduce the unsafe factors of equipment over-limit positions and uncoordinated processing rhythms of front and rear process equipment. Scientific management of equipment can also be achieved. With real-time perception, monitoring, and recording of all mechanical transmission parts of the gantry equipment 100 moving parts, the big data collection, supervision, and recording of the bottom-level machinery in the factory are convenient for managers to continuously improve the production process efficiency and equipment maintenance management from big data analysis.

[0141] Combination Fig.31 The networking of gantry machinery and digital cloud, due to the real-time perception and data optimization of the underlying gantry machinery and other equipment, the on-site edge computing data compression and packaging saves communication upload resources, and can realize the digital cloud management of real-time monitoring data of more factory underlying mechanical equipment.

[0142] Although the specific embodiments of the present invention are described above, it should be understood by those skilled in the art that this is only for illustration and the protection scope of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, but these changes and modifications all fall within the protection scope of the present invention.

Claims

1. A gantry device, characterized in that: The gantry device includes a first track device, a second track device, a beam device, and a working axis device. The first track device and the second track device are arranged in parallel and at intervals. The beam device is erected between the first track device and the second track device. The working axis is arranged on the beam device. The working axis is used to connect the processing equipment, and the working axis is also used to adjust the height of the processing equipment. The gantry device also includes two sets of beam driving devices. The two sets of beam driving devices are respectively arranged at the two ends of the beam device, and the beam driving devices are used to drive the beam device to move along the first track device and the second track device. Beam position sensors are provided on the moving axes of the two sets of beam driving devices, and the beam position sensors are used to sense the positions of the two ends of the beam device relative to the first track device and the second track device in real time.

2. The gantry device according to claim 1, characterized in that: The two sets of beam driving devices can realize feedback closed-loop control with respect to the positions of the first track device and the second track device.

3. The gantry device according to claim 2, characterized in that: The crossbeam position sensor also includes a crossbeam absolute value multi-turn encoder device, which is used to real-timely detect the positions of the two ends of the crossbeam device relative to the first track device and the second track device, and realize feedback closed-loop control.

4. The gantry device according to claim 1, characterized in that: The gantry device also includes a beam edge calculator, which is communicatively connected to the beam position sensor. The beam edge calculator is used to process the position signal of the beam position sensor in real time and send a drive signal to the beam drive device.

5. The gantry device according to claim 4, characterized in that: The beam edge calculator is also used to complete one or more of the self-check, direction, zero point, and resolution re-adjustment of the beam position sensor.

6. The gantry device according to claim 4, characterized in that: The signals of the two sets of beam position sensors are transmitted in parallel to the host computer.

7. The gantry device according to any one of claims 1 to 6, characterized in that: The gantry equipment also includes a working shaft driving device and a working shaft position sensor. The working shaft driving device acts on the working shaft to move the working shaft relative to the crossbeam device; the working shaft position sensor is used to sense the position of the working shaft device relative to the crossbeam device in real time.

8. The gantry device according to claim 5, characterized in that: The gantry device also includes a working axis edge calculator, which is communicatively connected to the working axis position sensor. The working axis edge calculator is used to process the position signal of the working axis position sensor in real time and send a driving signal to the working axis driving device.

9. The gantry device according to claim 8, characterized in that: The working axis edge processor is also used to calculate the load distribution on the left and right sides of the beam device and generate a load distribution signal. The working axis edge processor is also used to send the distribution signal to the host computer, and the host computer controls the beam drive device according to the distribution signal.

10. The gantry device according to claim 7, characterized in that: The gantry equipment also includes a vertical axis driving device and a vertical axis position sensor. The working axis driving device acts on the working axis to move the processing equipment away from or close to the working axis. The working axis position sensor is used to sense the position of the processing equipment relative to the working axis in real time.

11. The gantry device according to claim 10, characterized in that: The gantry device also provides a vertical axis edge calculator, which is in communication with the vertical axis position sensor. The vertical axis edge calculator is used to process the position signal of the vertical axis position sensor in real time and send a drive signal to the vertical axis drive device.

12. The gantry device according to claim 11, characterized in that: The vertical axis edge processor is also used to calculate the height and center of gravity position of the workpiece processed by the processing equipment and generate a swing signal. The vertical axis edge processor is also used to send the swing signal to the host computer, and the host computer controls the beam drive device according to the swing signal.

13. A gantry equipment control method, characterized in that: The gantry device control method is used to control the gantry device as described in any one of claims 1-12.

14. The gantry equipment control method according to claim 1, characterized in that: The gantry equipment control method comprises: Using a beam position sensor of the gantry device to sense in real time the positions of the two ends of the beam device relative to the first track device and the second track device, respectively, and using a beam edge calculator of the gantry device to control a beam driving device in real time; Using a working axis position sensor to sense the position of the working axis device relative to the crossbeam device in real time, and using a working axis edge calculator to control the working axis driving device in real time; A vertical axis position sensor is used to sense the position of the processing equipment relative to the working axis in real time, and a vertical axis edge calculator is used to control a vertical axis driving device.

Images