An automatic bending unit control system and a control method thereof

Abstract

The application discloses an automatic bending machine group control system and a control method thereof, and relates to the technical field of automatic bending machine group control systems, and aims to improve production efficiency and product quality.

Description

Technical Field

[0001] This invention relates to the field of metal sheet bending technology, and in particular to an automatic bending machine control system and its control method. Background Technology

[0002] In traditional manufacturing, particularly in the metal processing and forming sector, bending machines, as key forming equipment, are widely used in the production of various metal components and parts. For a long time, bending machine production in the industry has primarily relied on a combination of manual labor and individual machine operation. During the bending stage, workers are responsible for feeding the bending machine and unloading the finished product after bending. The entire process almost entirely depends on manual operation and the independent operation of individual machines.

[0003] However, with the continuous expansion of production scale and the increasing market demand, this traditional production method has gradually exposed many drawbacks. First, low production efficiency has become a key factor restricting capacity improvement. Manual operation is not only slow, but also limited by the physical strength, skills, and fatigue level of workers, making it difficult to adapt to large-scale, high-intensity production tasks. Second, the labor intensity of workers is extremely high; prolonged repetitive physical labor can easily lead to health problems, increasing the company's human resource costs and management difficulties. More importantly, during the manual handling and flipping of materials, improper operation or inaccurate force control can easily damage metal parts, such as deformation of condenser fins and defects in fin quality. These problems not only affect the product's aesthetics and performance but also increase scrap rates and quality control costs. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic bending machine control system and its control method, which aims to solve the problems of low production efficiency and low quality in existing bending machine production methods.

[0005] This invention provides an automatic bending machine control system, including: a material receiving line, a feeding robot, a bending machine, a material unloading robot, and a material unloading line;

[0006] The material receiving line is used to feed workpieces;

[0007] The loading robot is positioned next to the incoming material line and on one side of the bending machine to grab the workpieces on the incoming material line and place the grabbed workpieces onto the bending machine.

[0008] The bending machine is used to bend the workpiece;

[0009] The unloading robot is positioned next to the unloading line and on the other side of the bending machine to grab the bent workpiece from the bending machine and place the grabbed workpiece onto the unloading line.

[0010] The unloading line is used to unload workpieces.

[0011] Furthermore, the bending machine includes: a first bending machine and a second bending machine, the first bending machine and the second bending machine are arranged side by side, the loading robot is arranged on the same side of the first bending machine and the second bending machine, and the unloading robot is arranged on the other side of the first bending machine and the second bending machine.

[0012] Furthermore, it also includes: a destacking robot and a destacking area, wherein the destacking robot is positioned next to the incoming material line and the destacking area to destacking workpieces from the destacking area onto the incoming material line.

[0013] Furthermore, the material receiving line includes a transmission line and a positioning line. One end of the transmission line is located next to the depalletizing robot, and the other end of the transmission line is connected to one end of the positioning line, which is located next to the loading robot.

[0014] Furthermore, the destacking area includes: a feeding area, a transplanting area, an empty board placement area, and a destacking area. The feeding area and the empty board placement area are located on one side of the transplanting area, and the destacking area is located on the other side of the transplanting area and next to the destacking robot.

[0015] Furthermore, there are two destacking areas, which are arranged side by side and located between the destacking robot and the transplanting area.

[0016] Furthermore, it also includes a main control cabinet, to which the incoming material line, loading robot, bending machine, unloading robot, and unloading line are all connected.

[0017] Furthermore, it also includes: a line host computer, which is connected to the main control cabinet.

[0018] This invention also provides a control method for an automatic bending machine control system, comprising:

[0019] Obtain the production formula selected by the user;

[0020] Drive the incoming material line to move the workpiece to the loading position;

[0021] The loading robot is controlled to grab the workpiece at the loading position and place the workpiece onto the bending machine;

[0022] The bending machine is controlled to bend the workpiece according to the production formula selected by the user;

[0023] The unloading robot is controlled to grab the bent workpiece from the bending machine and place the bent workpiece onto the unloading line.

[0024] The unloading line is driven to move the workpiece to the unloading position.

[0025] Furthermore, the process of obtaining the user-selected production formula includes:

[0026] Perform a self-test on the automatic bending machine control system and determine whether the self-test of the automatic bending machine control system is successful;

[0027] If the self-test is successful, then the step of obtaining the production formula selected by the user can be performed.

[0028] If the self-test fails, troubleshooting should be performed on the automatic bending unit control system.

[0029] This invention discloses an automatic bending machine control system and its control method. The system includes: an incoming material line, a loading robot, a bending machine, an unloading robot, and an unloading line. The incoming material line is used to load workpieces. The loading robot is positioned next to the incoming material line and on one side of the bending machine to pick up workpieces from the incoming material line and place them onto the bending machine. The bending machine is used to bend the workpieces. The unloading robot is positioned next to the unloading line and on the other side of the bending machine to pick up the bent workpieces from the bending machine and place them onto the unloading line. The unloading line is used to unload workpieces. By setting up the loading and unloading robots, this invention not only achieves fully automatic loading and unloading of workpieces, significantly improving production efficiency, but also effectively avoids workpiece damage or quality inconsistencies caused by human factors by reducing direct human intervention, thus significantly improving product quality. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the control system of an automatic bending machine unit;

[0032] Figure 2 This is another structural schematic diagram of the automatic bending machine control system;

[0033] Figure 3 This is a schematic diagram of the bending machine.

[0034] Figure 4 This is a schematic diagram of the feeding robot.

[0035] Figure 5 This is a structural diagram of the gripper component;

[0036] Figure 6 This is a system diagram of the automatic bending machine control system;

[0037] Figure 7 This is a schematic diagram of the workpiece's structure;

[0038] Figure 8 This is a flowchart illustrating the control method of the automatic bending machine control system.

[0039] Figure 9 This is a schematic diagram of the sub-flow of the control method for the automatic bending machine control system;

[0040] Explanation of the labels in the diagram:

[0041] 1. Incoming material line; 2. Loading robot; 3. Bending machine; 4. Unloading robot; 5. Unloading line; 6. Workpiece; 7. First bending machine; 8. Second bending machine; 9. Shaft roller; 10. Support assembly; 11. Insertion mechanism; 12. Lifting and feeding mechanism; 13. Robot body; 14. Mounting plate; 15. Drive component; 16. Connecting component; 17. Rotating component; 18. Gripping component; 19. Gripping plate; 20. Through hole; 21. Destacking robot; 22. Destacking area. Detailed Implementation

[0042] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0044] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0045] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0046] Please see Figure 1 and Figure 2 This invention provides an automatic bending machine control system, comprising:

[0047] Material receiving line 1, material loading robot 2, bending machine 3, material unloading robot 4, and material unloading line 5;

[0048] The material receiving line 1 is used to feed workpiece 6;

[0049] The loading robot 2 is set next to the material receiving line 1 and on one side of the bending machine 3 to grab the workpiece 6 on the material receiving line 1 and place the grabbed workpiece 6 on the bending machine 3.

[0050] The bending machine 3 is used to bend the workpiece 6;

[0051] The unloading robot 4 is set next to the unloading line 5 and on the other side of the bending machine 3 to grab the bent workpiece 6 on the bending machine 3 and place the grabbed workpiece 6 onto the unloading line 5.

[0052] The unloading line 5 is used to unload the workpiece 6.

[0053] This embodiment, by setting up loading robot 2 and unloading robot 4, not only achieves fully automated loading and unloading of workpiece 6, significantly improving production efficiency, but also effectively avoids workpiece 6 damage or quality inconsistencies caused by human factors due to reduced direct human intervention, thus significantly improving product quality. Furthermore, the introduction of the automation system also reduces labor costs and improves the overall safety and cleanliness of the production environment.

[0054] In some embodiments, the bending machine 3 includes: a first bending machine 7 and a second bending machine 8, the first bending machine 7 and the second bending machine 8 are arranged side by side, the loading robot 2 is arranged on the same side of the first bending machine 7 and the second bending machine 8, and the unloading robot 4 is arranged on the other side of the first bending machine 7 and the second bending machine 8.

[0055] By setting up the first bending machine 7 and the second bending machine 8 in parallel, simultaneous operation can be achieved, significantly improving production efficiency. The two machines can complete different bending tasks independently or collaboratively, effectively shortening the production cycle. Automated operation reduces the need for workers to directly operate the bending machine 3, reducing workload and also reducing the risk of workers being exposed to potentially hazardous environments, improving the working environment and enhancing operational safety.

[0056] In some embodiments, please refer to Figure 3 The first bending machine 7 includes: shaft roller 9;

[0057] Support assembly 10 is disposed below shaft roller 9. Support assembly 10 and shaft roller 9 are used to bend workpiece 6.

[0058] Insertion mechanism 11 is used to insert into the receiving gap of workpiece 6. When workpiece 6 is bent, insertion mechanism 11 contacts at least one of the two wall surfaces forming the receiving gap to prevent relative displacement between the two wall surfaces.

[0059] The lifting and feeding mechanism 12 is at least partially disposed below the support assembly 10. The lifting and feeding mechanism 12 is used to separate the workpiece 6 from the support assembly 10 and to transport the workpiece 6 to a preset bending position.

[0060] The bending machine 3 of this embodiment can bend the workpiece 6 through the shaft roller 9, the support assembly 10, the insertion mechanism 11, and the lifting and feeding mechanism 12. The support assembly 10 is disposed below the shaft roller 9. The insertion mechanism 11 is inserted into the receiving gap of the workpiece 6. When the workpiece 6 is bent, the insertion mechanism 11 contacts at least one of the two walls forming the receiving gap to prevent relative displacement between the two walls. At least a portion of the lifting and feeding mechanism 12 is disposed below the support assembly 10. The lifting and feeding mechanism 12 is used to separate the workpiece 6 from the support assembly 10 and transport the workpiece 6 to a preset bending position. In the specific bending process, the insertion mechanism 11 is inserted into the receiving gap of the workpiece 6, the support assembly 10 and the shaft roller 9 interact to perform a first bend on the workpiece 6, and then the lifting and feeding mechanism 12 separates the workpiece 6 from the support assembly 10 and transports the workpiece 6 to the preset bending position, where the workpiece 6 is bent a second time under the action of the support assembly 10 and the shaft roller 9.

[0061] It should be noted that the first bending machine 7 and the second bending machine 8 have the same structural design, which will not be elaborated further.

[0062] In some embodiments, please refer to Figure 4 and Figure 5The loading robot 2 includes: a robot body 13, a mounting plate 14, and a gripper. The mounting plate 14 is connected to the robot body 13 and is movably connected to the gripper. The gripper includes: a drive component 15, a connector 16, two rotating components 17, two gripping components 18, and two gripping plates 19. The drive component 15 is mounted on the mounting plate 14, and the mounting plate 14 has a through hole 20 corresponding to the drive end of the drive component 15. One end of the connector 16 is connected to the drive end of the drive component 15. The other end of the connector 16 passes through the through hole 20 and is rotatably connected to one end of the two rotating components 17. The other ends of the two rotating components 17 are rotatably connected to one end of the two gripping components 18, respectively. The other ends of the two gripping components 18 are arranged crosswise to form an X shape so that when one end of the two gripping components 18 closes inward, the other end of the two gripping components 18 also closes inward. The other ends of the two gripping components 18 are connected to the two gripping plates 19, respectively.

[0063] When it is necessary to grip the workpiece 6, the driving component 15 drives the connecting component 16 to retract. The retraction of the connecting component 16 causes one end of the two rotating components 17 to retract, thereby shortening the distance between the other ends of the two rotating components 17 and closing them inward. The closing of the other ends of the two rotating components 17 inward causes one end of the two gripping components 18 to close inward. The other ends of the two gripping components 18 close inward at the same time, thereby reducing the distance between the two gripping plates 19 and completing the gripping of the workpiece 6.

[0064] The drive unit 15 drives two rotating parts 17 via the connector 16, thereby controlling the two gripping parts 18 to form an X-shaped structure. This design makes the gripping action both precise and stable, firmly holding materials of different shapes and sizes, effectively reducing material slippage or damage during the gripping process. Simultaneously, the various components of the gripping parts are precisely connected by rotation and transmission, resulting in a compact and stable overall structure. This design not only reduces the robot's size and weight but also lowers the requirements for production space, improving the space utilization of the production line.

[0065] In some embodiments, two grippers are provided, and the two grippers are respectively installed at both ends of the mounting plate 14.

[0066] Installing the two grippers at both ends of the mounting plate 14 helps to balance the load of the entire system, reduce vibration or deviation caused by uneven weight distribution, and thus improve the stability and reliability of the equipment.

[0067] It should be noted that the structural designs of the loading robot 2 and the unloading robot 4 are similar, so we will not go into further detail.

[0068] In some embodiments, please refer to Figure 2It also includes: a destacking robot 21 and a destacking area 22. The destacking robot 21 is set next to the material receiving line 1 and the destacking area 22 to destacking the workpieces 6 on the destacking area 22 onto the material receiving line 1.

[0069] When destacking is required, the workpieces 6 to be processed are neatly stacked in the destacking area 22. The destacking robot 21 identifies the position and orientation of the workpieces 6 through its built-in vision system. Based on the data from the vision system, the destacking robot 21 uses a gripping device to remove the workpieces 6 one by one from the stack. The removed workpieces 6 are placed on the incoming material line 1, ready to be transported to the next processing stage.

[0070] By introducing the depalletizing robot 21, the rapid and continuous supply of workpieces 6 can be achieved, reducing the time and labor intensity of manual depalletizing and thus improving the efficiency of the entire production line. At the same time, the depalletizing robot 21 can replace manual labor in repetitive depalletizing tasks, reducing the need for human resources and lowering labor costs. The depalletizing robot 21 can also operate in hazardous or unsuitable working environments, reducing workplace accidents and improving the working environment.

[0071] In some embodiments, the material receiving line 1 includes a drive line and a positioning line. One end of the drive line is located next to the depalletizing robot 21, and the other end of the drive line is connected to one end of the positioning line. The other end of the positioning line is located next to the loading robot 2.

[0072] The depalletizing robot 21 removes workpiece 6 from the depalletizing area 22 and places it on the conveyor line. The conveyor line transports workpiece 6 from beside the depalletizing robot 21 to the positioning line. The positioning device on the positioning line precisely positions workpiece 6, ensuring that workpiece 6 is in the correct position before entering the processing equipment. The loading robot 2 picks up workpiece 6 from the other end of the positioning line and places it into the processing equipment for processing.

[0073] By placing one end of the drive line next to the depalletizing robot 21, a seamless connection from depalletizing to transfer is achieved. This design reduces waiting time and processing steps during material transfer, improving the overall efficiency of the production line. Simultaneously, the connection between the drive line and the positioning line, and the placement of the other end of the positioning line close to the loading robot 2, ensure that materials are smoothly and accurately guided to the next processing stage. The positioning line design ensures accurate positioning of the workpiece 6 before entering the processing equipment, thereby improving processing precision and quality. The arrangement of the drive line and positioning line makes full use of workshop space, reduces unnecessary equipment footprint, and optimizes the production line layout.

[0074] In some embodiments, the destacking area 22 includes a feeding area, a transplanting area, an empty board placement area, and a destacking area. The feeding area and the empty board placement area are located on one side of the transplanting area, and the destacking area is located on the other side of the transplanting area and next to the destacking robot 21.

[0075] When the AGV (Automated Guided Vehicle) places the stack of workpieces 6 in the loading area, the conveyor chain moves the stack of workpieces 6 from the loading area to the transfer area. The transfer equipment then moves the stack of workpieces 6 from the transfer area to the destacking area. The destacking robot 21 performs the destacking operation in the destacking area, using a vision recognition system and a gripping device to remove workpieces 6 one by one from the stack. The destacking robot 21 places the removed workpieces 6 onto the incoming material line 1, ready to be transported to the next processing stage. After destacking is completed, the transfer equipment places empty pallets or empty plates in the empty plate placement area, which are then pulled away by the AGV.

[0076] By rationally dividing the space and automating operations, the preparation and destacking times for workpiece 6 were significantly reduced, improving production efficiency. Clear functional zoning and automated operation reduced conflicts between operators and equipment, enhancing the safety of the working environment. Simultaneously, the design of each area ensured high stability and reliability, minimizing downtime due to equipment failure and improving production continuity.

[0077] In some embodiments, there are two destacking areas, which are arranged side by side and located between the destacking robot 21 and the transplanting area.

[0078] When the AGV places stack 6 workpieces in the loading area, the conveyor chain moves the stack from the loading area to the transfer area. The transfer equipment then moves the stack from the transfer area to one of the two destacking areas. The destacking robot 21 performs the destacking operation in the first destacking area, using a vision recognition system and a gripping device to remove the workpieces 6 one by one from the stack. The destacking robot 21 places the removed workpieces 6 onto the incoming material line 1, ready to be transported to the next processing stage. After the stack of workpieces 6 in the first destacking area is destacking, the destacking robot 21 quickly switches to the second destacking area to continue the destacking operation. After destacking is completed, the transfer equipment places the empty pallets or empty plates in the empty plate placement area, which is then pulled away by the AGV.

[0079] By setting up two depalletizing zones, parallel depalletizing of workpiece 6 can be achieved, significantly improving depalletizing speed and production efficiency. Simultaneously, the two depalletizing zones can operate independently or collaboratively, increasing system flexibility and adapting to different production needs. One depalletizing robot 21 can serve both depalletizing zones simultaneously, improving equipment utilization and reducing equipment investment costs.

[0080] In some embodiments, please refer to Figure 6It also includes: the main control cabinet, the material receiving line, the loading robot, the bending machine, the unloading robot, and the unloading line, all of which are connected to the main control cabinet.

[0081] Specifically, the material receiving line, the loading robot, the unloading robot, and the unloading line are all connected to the main control cabinet via I / O interaction. The bending machine and the main control cabinet collect and send data to the two bending machines via Ethernet / IP.

[0082] By integrating key equipment such as the incoming material line, loading robot, bending machine, and unloading robot into the main control cabinet, a high degree of automated production is achieved. This integrated design greatly simplifies the production process, reduces manual intervention, and improves production efficiency. The incoming material line, loading robot, and unloading robot are connected to the main control cabinet via I / O interaction, a simple, direct, and fast connection method. The bending machine communicates with the main control cabinet via Ethernet / IP, a communication method that is not only fast but also allows for large data transmission volumes.

[0083] In some embodiments, it further includes: a line host computer, which is connected to the main control cabinet.

[0084] Specifically, the host computer on the production line is connected to the main control cabinet via an Advantech Ethernet / IP gateway.

[0085] The production line's host computer serves as the monitoring center for the entire production line, displaying the real-time operating status, production progress, alarm information, and other data for each piece of equipment. This allows managers to have a comprehensive understanding of the production line's operation. The host computer also enables convenient remote monitoring and management of the production line, allowing for equipment debugging, parameter setting, and fault diagnosis without requiring on-site presence, thus improving management efficiency.

[0086] The control method of the whole machine is as follows: the main control cabinet collects all the interactive signals from the outside (material receiving line, material feeding line, loading robot, unloading robot), and then collects and sends them to the two bending machines via Ethernet / IP. The production status of the whole machine is then collected by Advantech gateway and sent to the line host computer for real-time monitoring. This solves the problems of rapid fault reporting and equipment status management of bending machine unit, thereby minimizing the impact on production.

[0087] Production switching is achieved by the production line's host computer issuing order tasks and product models. After the bending machine identifies the information, it automatically switches to the formula that has already been produced, which improves the speed of product switching and greatly reduces losses caused by operator errors.

[0088] In some embodiments, the dimensions of the two devices are determined according to the drawings. Figure 7The parameters are set, such as the thickness H of the two parts (i.e., the workpiece), bending angle θ1, radius R, L1, L2, first bending angle C, feeding length C, robot recipe number, workpiece height C, first bending angle correction C, push position C, feeding length correction C, bending radius correction C, drag U level C, drag U height C, and drag U lifting height C. Among them, the thickness H of the two parts is related to the lifting height of the bending platform; the bending angle θ1 is related to the bending degree of the bending axis and also determines the angle of the two parts after bending; the radius R determines the size of the mold to be used for bending; L1 and L2 determine the positioning position of the bending machine's feeding axis; the correction is to make fine adjustments based on the actual situation after the parameter settings are completed.

[0089] In one specific embodiment, after obtaining the formula, the corresponding values ​​are obtained in the following manner: L1 = Download parameter [0]; First bending angle C = Download parameter [1]; Feeding length C = Download parameter [2]; Width of two parts C = Download parameter [3]; Robot formula number = REAL_TO_INT(Download parameter [4]); Bending radius = Download parameter [5]; Workpiece height C = Download parameter [6]; First bending angle correction C = Download parameter [7]; Pushing position C = Download parameter [8]; Feeding length correction C = Download parameter [9]; Bending radius correction C = Download parameter

[10] ; Drag U horizontal C = Download parameter

[11] ]; Drag U height C = Download parameter

[12] ; Drag U lifting height C = Download parameter

[13] ; After obtaining the corresponding value, convert it in the following way: Rear positioning fast advance distance = Equipment positioning length C - L1 - Rear positioning slow advance distance + Feeding length correction C; First bending angle = Equipment angle C - REAL_TO_LREAL (First bending angle C + First bending angle correction C); Platform lifting height = Equipment height C - Two-piece thickness - Two-piece thickness correction C; Bending angle = LREAL_TO_REAL (First bending angle); Positioning length = LREAL_TO_REAL (Rear positioning fast advance distance).

[0090] Once the parameters are set, they are saved in the recipe list. For subsequent production runs, the recipe can be directly retrieved from the list, enabling saving and quick switching. During automatic parameter conversion, all parameters can be retrieved by selecting the recipe number from the production order. These parameters are then distributed to the first or second bending machine to automatically switch products. This approach aims to make the equipment easy to operate even without specialized operators, ensuring its simplicity and ease of use.

[0091] In one specific embodiment, during automatic parameter conversion, the recipe number is selected based on the production order. The currently displayed recipe parameters are: Recipe Number: 1; Product Number: 214*19.05; Bending Angle: 90.00 degrees; Bending Radius: 85.00 mm; L1 Length: 110.00 mm; Workpiece Height: 19.05 mm; Drag U Lifting Height: 5.00 mm; Drag U Vertical Position: 12.00 mm. These parameters are then sent to the first or second bending machine respectively, enabling automatic product switching and facilitating easy operation even without specialized operators, thus making the equipment simple and easy to understand.

[0092] This embodiment enables rapid production through direct parameter setting; it overturns the cumbersome process of requiring separate input and conversion, and realizes automatic parameter conversion; it also enables rapid order switching through a unified host computer, making it more convenient and reducing operational errors caused by personnel.

[0093] Please see Figure 8 and Figure 9 The present invention also provides a control method for an automatic bending machine control system, comprising:

[0094] S101: Obtain the production formula selected by the user;

[0095] S102: Drive the incoming material line to move the workpiece to the loading position;

[0096] S103: Control the loading robot to grab the workpiece on the loading position and place the workpiece on the bending machine;

[0097] S104: Control the bending machine to bend the workpiece according to the production formula selected by the user;

[0098] S105: Control the unloading robot to grab the bent workpiece from the bending machine and place the bent workpiece onto the unloading line;

[0099] S106: Drive the unloading line to move the workpiece to the unloading position.

[0100] By using user-selected production formulas, different production needs can be flexibly adapted, improving production flexibility. Precise control of each step ensures the processing quality and consistency of the workpieces.

[0101] In some embodiments, prior to obtaining the user-selected production formula, the following steps are included:

[0102] Perform a self-test on the automatic bending machine control system and determine whether the self-test was successful. If the self-test is successful, confirm that the step of obtaining the production formula selected by the user can be executed. If the self-test fails, troubleshoot the automatic bending machine control system.

[0103] Self-inspection allows for the timely detection of potential problems or faults in the automatic bending machine's control system, thus preventing downtime or product quality issues caused by system malfunctions during production. The self-inspection process also ensures that all system components operate in optimal condition, improving the overall system's stability and reliability. Furthermore, by ensuring that the production formula is selected and executed only after a successful self-inspection, production interruptions and repeated debugging due to system instability are avoided, thereby improving production efficiency.

[0104] The self-test of the automatic bending machine control system includes: self-testing the communication status of the control system, the connection status of the servo motor, and the air pressure supply status of the system.

[0105] Specifically, the communication status self-test of the control system includes: the main control cabinet sending test signals to each module; the main control cabinet receiving response signals from each module and checking whether the communication link is unobstructed; if all modules respond normally, the communication status self-test is successful; otherwise, the communication status self-test fails.

[0106] The servo motor connection status self-test includes: the main control cabinet sending control signals to the servo motors; the main control cabinet detecting the servo motor response to ensure normal start-up and operation; and the servo motor connection status self-test succeeding if all servo motors respond normally, otherwise failing.

[0107] The system air pressure supply status self-check includes: the main control cabinet detects the system air pressure through a pressure sensor. If the system air pressure is within the predetermined range, the air pressure supply status self-check is successful; otherwise, the air pressure supply status self-check fails.

[0108] If the communication status, servo motor connection status, and system air pressure supply status all pass self-tests, the main control cabinet will display "Self-test successful," and the system will confirm that it can proceed with the step of obtaining the user-selected production formula. If any of the check items fails, the main control cabinet will display "Self-test unsuccessful," and the system will enter the fault handling process.

[0109] By performing self-checks on communication status, servo motor connection status, and system air pressure supply status, the system ensures it is in normal working condition before startup, avoiding production interruptions or quality problems caused by system failures. Self-checks can also detect potential faults early, reducing safety risks to operators and equipment. The self-check process also helps to promptly identify and address faults, thereby extending equipment lifespan and reducing maintenance costs. Through self-checks, the system can operate in optimal condition, improving production efficiency and product quality.

[0110] In some embodiments, after the unloading line moves the workpiece to the unloading position, the process includes: signal acquisition and processing, followed by displaying the acquired signal on a human-machine interface (HMI), and then determining whether the acquired signal is normal. If the acquired signal is normal, the process then determines whether to terminate the operation. If the operation is terminated, the system exits. If the operation is not terminated, the user-selected production formula is reacquired. If the acquired signal is abnormal, an audible and visual alarm is triggered, followed by fault display, fault handling, and finally, the acquired signal is displayed on the HMI.

[0111] By acquiring and processing signals, the system ensures normal operation after each production step, promptly detecting and addressing potential faults to prevent production interruptions. Audible and visual alarms, along with fault displays, alert operators to address malfunctions promptly, reducing safety risks.

[0112] In some embodiments, the loading robot checks the allowable loading signals from the first and second bending machines each time it loads material. Specifically, after the loading robot has picked up the material, it checks at the loading waiting point whether the received loading signal is from the first or second bending machine. If the received signal is from the first bending machine, the workpiece is placed on the first bending machine. If the received signal is from the second bending machine, the workpiece is placed on the second bending machine.

[0113] By automatically judging and responding to the unloading signals of different bending machines, the loading robot can ensure that workpieces are placed on the bending machines that need processing in a timely and accurate manner. This reduces the need for manual intervention and improves the automation level and efficiency of the entire production line. At the same time, this process allows the loading robot to be flexibly scheduled according to the needs of the bending machines. If a bending machine is currently idle or has a higher priority, the robot will prioritize placing the workpiece on that machine, thereby optimizing the allocation of production resources and improving overall production efficiency. Furthermore, by judging the unloading signals in real time, the loading robot can avoid placing workpieces on busy bending machines or machines that cannot be processed immediately, thus reducing production delays and waiting time.

[0114] In some embodiments, the bending speed of the first bending machine is greater than that of the second bending machine. When the first bending machine and the second bending machine simultaneously give the allow feeding signal, the workpiece is placed on the first bending machine.

[0115] Prioritizing faster equipment allows for more efficient use of production resources, reducing waiting time and bottlenecks. This helps optimize the production process, making the production line smoother and more efficient. Furthermore, when two bending machines request feed simultaneously, selecting the faster machine ensures the workpiece moves to the next process as quickly as possible, minimizing production delays caused by waiting.

[0116] In some embodiments, an environmental map of the transplanting area is acquired, including the locations of fixed and dynamic obstacles (such as other robots). The robot's starting and target positions are defined. Then, the RRT algorithm is used to generate an initial path, ensuring its feasibility and safety. Next, the A algorithm or D Lite algorithm is used to optimize the path, considering factors such as shortest path and minimum energy consumption. Environmental changes, such as changes in the positions of other robots, are monitored in real time. Based on the new environmental data, the path is dynamically updated to ensure its safety and optimality.

[0117] Specifically, an environmental map of the depalletizing area is acquired, including the locations of fixed and dynamic obstacles (such as other robots). The starting and target positions of each depalletizing robot are determined. Next, a sample point is randomly generated within the environment. The node closest to the random sample point is found in the existing tree. Then, a new node is generated from the nearest node towards the random sample point, ensuring that the new node is feasible within the environment (i.e., does not collide with obstacles). The new node is then added to the tree, connecting the nearest node and the new node. If the new node is close enough to the target position, or if the new node can be directly connected to the target position, the generated path is successful. The path is then backtracked from the target node to the starting node to generate a complete path. The generated path is then smoothed to reduce its detours and improve its smoothness and feasibility. The path is dynamically updated as the environment changes to ensure its safety and optimality.

[0118] The initial path generated by the RRT algorithm ensures efficient robot operation within the depalletizing area, reducing unnecessary movement time. Dynamic task allocation and load balancing ensure a balanced workload for each depalletizing area and the robot, preventing overload and idleness.

[0119] In some embodiments, LiDAR, ultrasonic sensors, and infrared sensors are installed on each transplanting device, covering a 360-degree sensing range. Visual sensors are installed at key locations in the transplanting area to provide global environmental information. Multi-sensor fusion technology is then used to combine data from LiDAR, ultrasonic sensors, infrared sensors, and visual sensors to improve the accuracy and reliability of obstacle avoidance. Sensor data is then processed in real time to generate an environmental model. A real-time obstacle avoidance algorithm is implemented to dynamically adjust the movement trajectory of the transplanting device based on sensor data. Simultaneously, a local obstacle avoidance algorithm (such as the potential field method) is used to handle emergency obstacle avoidance situations, ensuring that the transplanting device can react quickly when encountering obstacles.

[0120] Multi-sensor fusion technology integrates data from different sensors to form a more comprehensive and accurate environmental model. This fusion not only improves obstacle avoidance accuracy but also provides richer information for the path planning of transplanting equipment. Simultaneously, using local obstacle avoidance algorithms (such as the potential field method) to handle emergency obstacle avoidance situations ensures that the transplanting equipment can react quickly when encountering obstacles. This algorithm guides the transplanting equipment to avoid obstacles by simulating a virtual force field and takes emergency braking measures when necessary.

[0121] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make various improvements and modifications to this invention without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this invention.

[0122] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusivity.

[0123] The term "comprises" implies that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprises a..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. An automatic bending machine control system, characterized in that, include: Material receiving line, loading robot, bending machine, unloading robot and unloading line; The material feeding line is used to feed workpieces; The loading robot is positioned next to the incoming material line and on one side of the bending machine to grab the workpieces on the incoming material line and place the grabbed workpieces onto the bending machine. The bending machine is used to bend the workpiece; The unloading robot is positioned next to the unloading line and on the other side of the bending machine to grab the bent workpiece from the bending machine and place the grabbed workpiece onto the unloading line. The unloading line is used to unload workpieces; The bending machine includes: a first bending machine and a second bending machine, the first bending machine and the second bending machine are arranged side by side, the loading robot is arranged on the same side of the first bending machine and the second bending machine, and the unloading robot is arranged on the other side of the first bending machine and the second bending machine; The first bending machine includes: a shaft roller; a support assembly disposed below the shaft roller, the support assembly and the shaft roller being used for bending workpieces; an insertion mechanism for insertion into a receiving gap of the workpiece, wherein when the workpiece is bent, the insertion mechanism contacts at least one of the two wall surfaces forming the receiving gap to prevent relative displacement between the two wall surfaces; and a lifting and feeding mechanism, at least a portion of which is disposed below the support assembly, the lifting and feeding mechanism being used to separate the workpiece from the support assembly and to transport the workpiece to a preset bending position. It also includes: a depalletizing robot and a depalletizing area, wherein the depalletizing robot is positioned next to the incoming material line and the depalletizing area to depalletize the workpieces on the depalletizing area onto the incoming material line; The material receiving line includes a transmission line and a positioning line. One end of the transmission line is located next to the depalletizing robot, and the other end of the transmission line is connected to one end of the positioning line. The other end of the positioning line is located next to the loading robot. It also includes: a main control cabinet, to which the incoming material line, loading robot, bending machine, unloading robot and unloading line are all connected; The loading robot includes: a robot body, a mounting plate, and a gripper. The mounting plate is connected to the robot body and is movably connected to the gripper. The gripper includes: a drive component, a connector, two rotating components, two clamping components, and two gripping plates. The drive component is mounted on the mounting plate, and the mounting plate has a through hole corresponding to the drive end of the drive component. One end of the connector is connected to the drive end of the drive component. The other end of the connector passes through the through hole and is rotatably connected to one end of the two rotating components. The other ends of the two rotating components are rotatably connected to one end of the two clamping components. The other ends of the two clamping components are arranged crosswise to form an X shape so that when one end of the two clamping components closes inward, the other ends of the two clamping components also close inward. The other ends of the two clamping components are connected to the two gripping plates. After the loading robot finishes picking up the material, it determines at the loading waiting point whether the received feeding signal is a feeding permission signal from the first bending machine or the second bending machine. If the received feeding signal is a feeding permission signal from the first bending machine, the workpiece is placed on the first bending machine; if the received feeding signal is a feeding permission signal from the second bending machine, the workpiece is placed on the second bending machine. The bending speed of the first bending machine is greater than that of the second bending machine. When the first bending machine and the second bending machine simultaneously give the allow feeding signal, the workpiece is placed on the first bending machine. Obtain an environmental map of the depalletizing area, including the locations of fixed and dynamic obstacles; determine the starting and target positions of each depalletizing robot; randomly generate a sample point within the environment; find the node closest to the random sample point in the existing tree; generate a new node from the nearest node towards the random sample point; add the new node to the tree and connect the nearest node and the new node; if the new node is directly connected to the target position, the path is successfully generated; backtrack from the target node to the starting node to generate the complete path.

2. The automatic bending machine control system according to claim 1, characterized in that, The destacking area includes a feeding area, a transplanting area, an empty board placement area, and a destacking area. The feeding area and the empty board placement area are located on one side of the transplanting area, and the destacking area is located on the other side of the transplanting area and next to the destacking robot.

3. The automatic bending machine control system according to claim 2, characterized in that, There are two destacking areas, which are arranged side by side and located between the destacking robot and the transplanting area.

4. The automatic bending machine control system according to claim 1, characterized in that, Also includes: The production line host computer is connected to the main control cabinet.

5. A control method for an automatic bending machine control system as described in any one of claims 1-4, characterized in that, include: Obtain the production formula selected by the user; Drive the incoming material line to move the workpiece to the loading position; The loading robot is controlled to grab the workpiece at the loading position and place the workpiece onto the bending machine; The bending machine is controlled to bend the workpiece according to the production formula selected by the user; The unloading robot is controlled to grab the bent workpiece from the bending machine and place the bent workpiece onto the unloading line. The unloading line is driven to move the workpiece to the unloading position.

6. The control method of the automatic bending machine control system according to claim 5, characterized in that, Before obtaining the production formula selected by the user, the following steps are included: Perform a self-test on the automatic bending machine control system and determine whether the self-test of the automatic bending machine control system is successful; If the self-test is successful, then the step of obtaining the production formula selected by the user can be performed. If the self-test fails, troubleshooting should be performed on the automatic bending unit control system.

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