Turbine blade intelligent identifying, sorting and sequencing control system based on collaborative robot

Abstract

The invention relates to the field of detection, sorting and sequencing of turbine blades before installation, in particular to a control system for intelligent identification, sorting and sequencing of turbine blades based on a collaborative robot. The robot is installed on the robot stand column, a blade picking clamping jaw is carried at the tail end of the robot, and a camera, a balance and a code spraying machine are sequentially distributed on the inner side equipment. And the robot drives the clamping jaw at the tail end to move so as to complete operations such as detection before installation of all turbine blades. Blade picking of the blade feeding box is completed through the clamping jaw, blade code recognition is achieved through the camera system, automatic weighing of the blades is achieved through the balance, blade weight information jet printing is achieved through the ink-jet printer, and finally the jet-printed blades are placed in the blade discharging box. And the operations of picking up the blades, scanning and identifying the codes, weighing the blades, spraying the codes on the blades and placing the blades are repeatedly executed in sequence until all the operations of the blades in the whole box are completed. According to the invention, the installation efficiency of subsequent assembly is improved, and the risk of information acquisition or input errors caused by manual operation originally is reduced.

Description

Technical Field

[0001] The invention relates to the field of pre-installation detection and sorting of turbine blades, and in particular to a control system for intelligent identification, sorting and sorting of turbine blades based on a collaborative robot. Background Art

[0002] Turbine blades are key components in the engine, responsible for converting airflow energy into rotary power. They are subject to greater working stress and higher operating temperatures, and are components that are frequently operated, repeatedly maintained, and regularly replaced. Each turbine blade is equipped with an independent code for assembly information recording and repair and maintenance traceability. The installation of turbine blades is arranged in a certain weight order, and the weight sorting distribution is a key factor affecting the overall turbine operating efficiency and life.

[0003] The existing maintenance and assembly of turbine blades are all done manually, including coding hand-eye recording, manual weighing of blades, handwritten marking of weight information, and manual sorting of blades in a specific way. The entire process of pre-installation inspection and sorting of blades cannot be effectively supervised and is greatly affected by the subjective factors of the operator. It is difficult to effectively guarantee product quality, which affects the service life of the engine.

[0004] How to automatically realize pre-installation inspection and information collection of blades, and automatic sorting, sorting and marking according to specific methods are very necessary to fully ensure the quality and operating efficiency of the turbine, as well as maintenance and troubleshooting after repair. Summary of the invention

[0005] In order to solve the problem of how to automatically detect and sort turbine blades before installation, the present invention provides a control system for blade coding recognition, automatic weighing, blade coding, sorting and sorting based on a collaborative robot. The technical solution adopted by the present invention to achieve the above purpose is:

[0006] A control system for intelligent identification, sorting and sequencing of turbine blades based on a collaborative robot, comprising: a six-axis collaborative robot, with a loading station and an unloading station on both sides of the robot, and a visual acquisition system, a blade weighing system and a blade printing system arranged in sequence on the movement trajectory of the robot from the loading station to the unloading station.

[0007] A blade loading box and a blade unloading box are respectively placed on the loading station and the unloading station, and are fixed by station blocks fixed on the stations.

[0008] The blade unloading box is an intelligent box, and a plurality of light guide columns and a plurality of blade holes are evenly arranged on the upper surface of the box, and the light guide columns and the blade holes are in a one-to-one correspondence. A lithium battery and a circuit board connected thereto are installed at the bottom of the box, and a plurality of LED patch indicator lights and a plurality of blade sensing sensors are arranged on the circuit board, and each LED patch indicator light is arranged directly below each light guide column, and each blade sensing sensor is arranged directly below each blade hole. A communication interface and a lithium battery charging interface are also arranged on the side of the box.

[0009] The visual acquisition system consists of a strip light source and a surface array camera arranged within the light source range.

[0010] The blade weighing system is composed of an electronic balance and a tray placed on the balance.

[0011] The blade printing system is composed of a fully automatic inkjet printer and an inductive optical fiber connected thereto.

[0012] A method for intelligently identifying, sorting and arranging turbine blades based on a collaborative robot comprises the following steps:

[0013] 1) The robot picks up the blades from the loading box in the order of the blades in the box;

[0014] 2) The robot grabs the blade and moves it to the visual acquisition system, which takes a photo of the blade, and the industrial computer recognizes the blade coding information in the picture;

[0015] 3) The robot grabs the blade and moves it to the blade weighing system, which weighs the blade. The industrial computer converts the weight information into inkjet information and sends it to the blade printing system;

[0016] 4) The robot grabs the blade and moves it to the blade printing system, which prints the coding information on the blade surface;

[0017] 5) The robot puts the printed blades into the corresponding position of the unloading box according to the serial number, and accumulates the blade counter, and the industrial computer displays the counter value in real time;

[0018] 6) Determine whether the blade count reaches the total number of blades. If not, return to step 1); if reached, complete the pre-loading inspection and sorting of the entire box of blades.

[0019] The following steps are also included:

[0020] After completing the pre-loading inspection and sorting of the whole box of blades, the input information is confirmed, individual problematic blades are re-entered, and the blades are sorted after the whole box of blades is weighed through the blade unloading box.

[0021] The blade unloading box is used to complete the sorting of the blades after the whole box of blades are weighed, specifically:

[0022] The industrial computer sorts all the blade weight information according to the set sorting order and sends it to the circuit board memory inside the blade unloading box. The LED patch indicator lights on the circuit board will light up in sequence according to the set sorting order. Each time it lights up, it indicates the blade that needs to be picked up and installed. The blades are picked up and installed in sequence according to the indicator light until all the blades in the unloading box are picked up.

[0023] The present invention has the following beneficial effects and advantages:

[0024] 1. Greatly reduce the operator's labor intensity and improve the accuracy of blade code recognition.

[0025] 2. The leaf sorting can be automatically completed according to any specific method, and the leaf sorting is more flexible and accurate.

[0026] 3. The inkjet printer is used for printing, so the blade marking is more standardized and the coding information is clear at a glance.

[0027] 4. The blade coding, weight, and sorting information are effectively linked and recorded in the database, providing a data basis for repair maintenance and quality traceability. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 Provide a layout diagram for the system composition;

[0029] Figure 2 This is a schematic diagram of device communication;

[0030] Figure 3 This is the structural composition diagram of the blade unloading box;

[0031] Figure 4 A schematic diagram of specific implementation steps. DETAILED DESCRIPTION

[0032] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0033] The system of the present invention comprises the following components:

[0034] 1) Six-axis collaborative robot

[0035] 2) Robotic gripper

[0036] 3) Robot column

[0037] 4) Loading station

[0038] 5) Blade loading box

[0039] 6) Unloading station

[0040] 7) Blade unloading box

[0041] 8) Station blocks for upper and lower material boxes

[0042] 9) Visual acquisition system (camera)

[0043] 10) Blade weighing system (balance)

[0044] 11) Blade printing system (inkjet printer)

[0045] 12)PLC control system

[0046] 13) Industrial computers and displays

[0047] like Figure 1 As shown, the six-axis collaborative robot is equipped with a blade gripper at the end, and the left and right sides are respectively the loading station and the unloading station. Blade loading box and blade unloading box are placed on the stations respectively, and the upper and lower boxes are fixed with station blocks.

[0048] The devices on the inner side of the robot are distributed in the order of left and right, including the visual acquisition system (camera), the blade weighing system (balance), and the blade printing system (inkjet printer). The visual acquisition system consists of a strip light source, an array camera, and an intelligent recognition algorithm. It collects various types of blade codes, performs labeling, sample statistics, and training, forms a sample library, and then realizes the code recognition of various types of blades through a deep learning algorithm; the blade weighing system consists of a high-precision electronic balance and a tray. The tray is used to effectively support the blade. When the robot gripper releases the blade, the blade weight is effectively measured and collected; the blade inkjet system consists of a fully automatic inkjet printer and an induction fiber. When the robot grips the blade and moves in a straight line at a fixed speed after passing the induction fiber signal, the inkjet printer receives the fiber sensing signal and prints the weight information on the blade surface after a fixed delay.

[0049] First, the robot picks up the blades from the blade loading box in order. After picking up the blades, the robot drives the blades to identify the blade codes, obtain the blade weight information, print the blade weight information, and place them in the corresponding position of the specific blade unloading box in order. The robot performs the operations of blade picking-scanning identification-blade weighing-blade coding-blade placement in a cycle until all operations are completed for the entire box of blades.

[0050] Figure 2 This is a schematic diagram of device communication. The specific description is shown in Table 1:

[0051] Table 1 Description of the device communication diagram

[0052] Serial number illustrate ① The PLC control system and the collaborative robot communicate via Profinet networking, with two-way information transmission ② The PLC control system controls the trigger signal of the camera through the IO interface ③ The PLC control system is connected to the industrial computer through the Ethernet interface and uses the OPC UA protocol for two-way information exchange ④ The industrial computer uses the RS232 interface to connect to the balance to obtain weighing information and send calibration signals ⑤ The industrial computer and the camera are connected via a Gigabit Ethernet port to obtain camera image information ⑥ The industrial computer is connected to the inkjet printer through the Ethernet interface to send inkjet information and obtain inkjet status ⑦ The industrial computer is connected to the unloading box through a dedicated communication interface, sends sorting information, and receives sorting completion signals

[0053] The blade unloading box is an intelligent box, such as Figure 3As shown. A lithium battery and an intelligent circuit board are installed at the bottom of the box. The surface of the circuit board is distributed with blade sensing sensors and LED patch indicators corresponding to the blade positions. The blades are placed vertically in the upper and lower material boxes. When the blades are placed in the lower material box, the intelligent circuit board senses whether there are blades in each hole. The surface of the material box uses a light guide column to guide the bottom LED patch indicator to the surface of the material box for display, which is used to guide the sorted blades to be picked up. The front of the material box contains a start button with light, a communication interface and a lithium battery charging interface. The start button with light can realize the on and off operation of the material box. The communication interface is used to connect to the industrial computer to receive the blade sorting information and store it in the circuit board memory. The lithium battery charging interface can realize the charging of the material box.

[0054] When the robot completes all blade cycles and stops running, all blade weight information has been acquired, calculated according to a specific sorting method, and the sorted information is sent to the circuit board memory inside the blade unloading box. After storage is completed and restarted, the blade indicator lights will light up in a specific sorting order, but only indicate the blades that need to be picked up and installed at the moment. The operator only needs to complete the picking and installation of all blades in sequence according to the indicator lights until all blades in the unloading box are picked up. At this time, the turbine blades are installed according to the different blade weights using a specific sorting method, avoiding manual sorting.

[0055] The operation process and logical interaction signals of using collaborative robots for pre-installation inspection of blades, such as Figure 4 As shown:

[0056] 1. Initialization. Check that the blade is inserted into the corresponding position of the upper material box and the lower material box is empty. Place the upper and lower material boxes to the workstation block position, start the camera, scale, and inkjet printer to initialize the equipment and the material box. At this time, the robot is ready signal obtained by the electrical PLC and sent to the industrial computer. Only when the robot is ready, the material box scanning operation is allowed to continue;

[0057] 2. The operator uses a barcode scanner to scan the upper and lower material boxes to obtain the material box type number. The barcode scanner is connected to the industrial computer, and after obtaining the scanned information, the material box type is sent to the electrical PLC, and the PLC obtains the type and the corresponding total number of blades;

[0058] 3. Press the start button on the industrial computer interface, and the PLC will control and light up the bar light source for blade code reading;

[0059] 4. The robot starts running and picks up the leaves in the loading box in the order of the leaves in the loading box;

[0060] 5. The robot grabs the blade and moves to the camera position. The PLC controls the camera to automatically take pictures and sends the completion signal to the industrial computer. The industrial computer stores the pictures and automatically calls the deep learning algorithm to realize code recognition.

[0061] 6. After the blade code recognition is completed, the industrial computer sends the blade code reading completion signal to the PLC, the robot clamps the blade and runs to the weighing position, and slowly places the blade on the corresponding position of the customized tray and releases the clamping claw. The PLC sends the weighing arrival signal to the industrial computer;

[0062] 7. The industrial computer is connected to the electronic balance through the communication interface, and the signal is placed through the PLC to obtain the weighing information. After the weighing is completed, the blade weight is converted into printing information and sent to the inkjet printer. The weighing completion signal is sent to the PLC. The robot re-grips the blade and moves it to the optical fiber sensing position of the inkjet printer. The blade is moved in a straight line at a fixed speed to automatically print the inkjet information on the blade surface;

[0063] 8. The robot puts the printed blades into the corresponding position of the unloading box according to the serial number, and accumulates the blade counter. The industrial computer displays the counter value in real time;

[0064] 9. Determine the leaf count and the total number of leaves. If the total number of leaves is not reached, continue the cycle according to steps 4-8;

[0065] 10. When the blade count is greater than the total number of blades, the cycle ends, and the pre-loading inspection and sorting of the entire box of blades is completed;

[0066] 11. The operator confirms the input information and performs operations such as re-entering for individual problematic blades, and clicks the sorting button to complete the sorting of the blades after weighing the entire box of blades;

[0067] 12. Connect the communication cable of the industrial computer to the communication interface of the material box, send the sorting information to the memory of the material box circuit board, and then shut down and restart the computer to check whether the corresponding indicator light is on.

[0068] The intelligent identification, sorting and sorting system for turbine blades based on collaborative robots of the present invention can greatly reduce the labor intensity of operators, improve the accuracy of blade code identification, and preserve blade code images. Blade sorting can be automatically completed according to any specific method, and blade sorting is more flexible and accurate. The use of inkjet printers for printing makes blade identification more standardized and the coding information clear at a glance. The blade code, weight, and sorting information are effectively associated and recorded in a database, providing a data basis for repair maintenance and quality tracing.

Claims

1. A control system for intelligent identification, sorting and sorting of turbine blades based on collaborative robots, characterized in that: include: The six-axis collaborative robot has loading and unloading stations on both sides of the robot. On the movement trajectory of the robot from the loading station to the unloading station, a visual acquisition system, a blade weighing system and a blade printing system are installed in sequence.

2. According to claim 1, a control system for intelligent identification, sorting and sorting of turbine blades based on collaborative robots is characterized in that: A blade loading box and a blade unloading box are respectively placed on the loading station and the unloading station, and are fixed by station blocks fixed on the stations.

3. According to claim 2, a control system for intelligent identification, sorting and sorting of turbine blades based on collaborative robots is characterized in that: The blade unloading box is an intelligent box, and a plurality of light guide columns and a plurality of blade holes are evenly arranged on the upper surface of the box, and the light guide columns and the blade holes are in a one-to-one correspondence. A lithium battery and a circuit board connected thereto are installed at the bottom of the box, and a plurality of LED patch indicator lights and a plurality of blade sensing sensors are arranged on the circuit board, and each LED patch indicator light is arranged directly below each light guide column, and each blade sensing sensor is arranged directly below each blade hole. A communication interface and a lithium battery charging interface are also arranged on the side of the box.

4. According to the control system of the collaborative robot-based turbine blade intelligent identification, sorting and sorting according to claim 1, it is characterized in that: The visual acquisition system consists of a strip light source and a surface array camera arranged within the light source range.

5. The control system for intelligent identification, sorting and sorting of turbine blades based on collaborative robots according to claim 1, characterized in that: The blade weighing system is composed of an electronic balance and a tray placed on the balance.

6. The control system for intelligent identification, sorting and sequencing of turbine blades based on collaborative robots according to claim 1, characterized in that: The blade printing system is composed of a fully automatic inkjet printer and an inductive optical fiber connected thereto.

7. The method for intelligent identification, sorting and sorting of turbine blades based on collaborative robots according to claim 1, characterized in that: The following steps are involved: 1) The robot picks up the blades from the loading box in the order of the blades in the box; 2) The robot grabs the blade and moves it to the visual acquisition system, which takes a photo of the blade, and the industrial computer recognizes the blade coding information in the picture; 3) The robot grabs the blade and moves it to the blade weighing system, which weighs the blade. The industrial computer converts the weight information into inkjet information and sends it to the blade printing system; 4) The robot grabs the blade and moves it to the blade printing system, which prints the coding information on the blade surface; 5) The robot puts the printed blades into the corresponding position of the unloading box according to the serial number, and accumulates the blade counter, and the industrial computer displays the counter value in real time; 6) Determine whether the blade count reaches the total number of blades. If not, return to step 1); if reached, complete the pre-loading inspection and sorting of the entire box of blades.

8. The method for intelligent identification, sorting and sorting of turbine blades based on collaborative robots according to claim 7, characterized in that: The following steps are also included: After completing the pre-loading inspection and sorting of the whole box of blades, the input information is confirmed, individual problematic blades are re-entered, and the blades are sorted after the whole box of blades is weighed through the blade unloading box.

9. The method for intelligent identification, sorting and sorting of turbine blades based on collaborative robots according to claim 8, characterized in that: The blade unloading box is used to complete the sorting of the blades after the whole box of blades are weighed, specifically: The industrial computer sorts all the blade weight information according to the set sorting order and sends it to the circuit board memory inside the blade unloading box. The LED patch indicator lights on the circuit board will light up in sequence according to the set sorting order. Each time it lights up, it indicates the blade that needs to be picked up and installed. The blades are picked up and installed in sequence according to the indicator light until all the blades in the unloading box are picked up.

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