Whole vehicle assembly line position safety system and control method

Abstract

The invention discloses a whole vehicle assembly line position safety system and a control method, the system comprises an assembly line monitoring module, an AGV group, a line edge button box and a two-dimensional code tape, the assembly line monitoring module communicates with the AGV group through a wireless communication network, the AGV group comprises multiple sets of AGVs, each AGV is equipped with a vehicle-mounted control system, a vehicle-mounted wireless transceiver unit and a two-dimensional code camera, and the vehicle-mounted wireless transceiver unit is connected with the two-dimensional code tape. Each AGV is provided with a distance measuring sensor group in the advancing direction, and the distance measuring sensor group comprises a plurality of distance measuring sensors and is connected to a vehicle-mounted control system of the AGV; the line edge button box is directly connected to the input end of the assembly line monitoring module; and the two-dimensional code belt is continuously laid along the whole path of the assembly process section. According to the whole vehicle assembly line position safety system and the control method, the position safety of the AGVs in a special application scene can be achieved, it is ensured that the distance between the adjacent AGVs in the whole vehicle assembly line process section is not smaller than the safety distance under the normal operation condition, and safe and stable operation of the whole vehicle assembly line is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of mobile equipment motion control, and more specifically, to a vehicle assembly line position safety system and a control method. Background Art

[0002] With the development of electronic information technology and market competition in the manufacturing equipment industry, the market price of intelligent mobile equipment AGV is getting lower and lower, and the application scenarios are also increasing, from the logistics field to the field of automatic workpiece conveying production lines. In the vehicle manufacturing industry, especially the final assembly process, there are several AGVs that constitute the application scenario of the vehicle assembly line. The biggest feature of this form of process conveying assembly line is that the process route can be changed flexibly, which can reduce the one-time investment cost in the planning stage.

[0003] At present, most vehicle-mounted control systems are equipped with a laser obstacle avoidance radar at the front of the AGV to detect whether there is an obstacle in front of the AGV that enters the deceleration zone or parking zone set by the laser obstacle avoidance radar configuration software. Once the laser obstacle avoidance radar scans an obstacle in the set area, it generates a deceleration signal or a parking signal; the vehicle-mounted control system receives the deceleration signal or the parking signal sent by the laser obstacle avoidance radar, and after program processing, the AGV is decelerated or stopped.

[0004] When the AGV group is used as a vehicle assembly line, in the vehicle assembly process section, operators need to work close to the vehicle body in front and behind the AGV that is continuously moving at a low speed. The vehicle control system needs to automatically shield the AGV's laser obstacle avoidance radar signal, otherwise the laser obstacle avoidance radar signal triggers the vehicle control system to stop, affecting production efficiency. After the vehicle control system shields the AGV's laser obstacle avoidance radar signal, the AGV spacing is completely controlled by the AGV scheduling system collecting the position data of each AGV. Position data errors, wireless transmission delays, and equipment abnormalities will cause position interval data errors in the AGV scheduling system data, resulting in safety risks for adjacent AGVs squeezing operators. There are no redundant technical measures for position safety.

[0005] Therefore, there is an urgent need for a vehicle assembly line position safety system and control method. Summary of the invention

[0006] The purpose of the present invention is to provide a complete vehicle assembly line position safety system and control method to solve the above-mentioned problems in the prior art, to achieve the position safety of AGVs in special application scenarios, to ensure that the distance between adjacent AGVs in the process section of the complete vehicle assembly line is not less than the safety distance under normal operation, to solve the safety risk problem of adjacent AGVs squeezing workers, and to ensure the safe and stable operation of the complete vehicle assembly line.

[0007] The present invention provides a vehicle assembly line position safety system and control method, which includes: an assembly line monitoring module, an AGV group, a line side button box OP and a QR code belt, wherein:

[0008] The assembly line monitoring module communicates with the AGV group via a wireless communication network,

[0009] The AGV group includes multiple sets of AGVs, each of which is equipped with an on-board control system, and each of which is equipped with an on-board wireless transceiver unit, the signal of which is connected to the on-board control system of the corresponding AGV, each of which is equipped with a two-dimensional code camera, the signal of which is connected to the on-board control system of the corresponding AGV, each of which is equipped with a distance sensor group in the forward direction, the distance sensor group includes multiple distance sensors, and the signal of each of which is connected to the on-board control system of the corresponding AGV;

[0010] The line side button box OP is directly connected to the input end of the assembly line monitoring module;

[0011] The two-dimensional code tape is laid continuously along the entire path of the assembly process section.

[0012] As described above, in the vehicle assembly line position safety system and control method, preferably, the assembly line monitoring module includes an industrial computer and / or a PLC device.

[0013] As described above, the whole vehicle assembly line position safety system and control method, wherein preferably, the wireless communication network includes a switch, a network cable and multiple sets of antenna modules, wherein the wireless communication network is based on the industrial WIFI technology architecture and / or the industrial 5G technology architecture, and the number of sets of antenna modules is based on the wireless signal being able to stably cover the activity area of ​​all AGVs.

[0014] As described above, in the vehicle assembly line position safety system and control method, preferably, the assembly line monitoring module includes a human-computer interaction unit, and the display information of the human-computer interaction unit includes the position and operation status information of the AGV group.

[0015] The present invention also provides a method for position safety control of a vehicle assembly line using the above system, comprising:

[0016] As the main control terminal, the assembly line monitoring module monitors and uniformly manages all AGVs in the AGV group to ensure the safe spacing of all AGVs;

[0017] The on-board control system of each AGV in the AGV group ensures the safe distance between each AGV and adjacent AGVs based on the signals from the on-board wireless transceiver unit, QR code camera and distance sensor.

[0018] As described above, the vehicle assembly line position safety control method, wherein preferably, the assembly line monitoring module acts as a master control end to monitor and uniformly manage all AGVs in the AGV group to ensure the spacing safety of all AGVs, specifically including:

[0019] The assembly line monitoring module adopts object-oriented and multi-threaded computer technology to perform data interaction, data processing and logic processing; the basic program architecture of the assembly line monitoring module includes an initialization part and a main thread part according to its functions.

[0020] In the above-mentioned vehicle assembly line position safety control method, preferably, the initialization process of the assembly line monitoring module includes:

[0021] The main control system function block is initialized, and AGV objects are established for all AGVs in the AGV group; a data sending thread and a data receiving thread of the AGV object are created and started; wherein the data sending thread is used to send data acquisition messages, and the data receiving thread is used to receive data return messages;

[0022] Wherein, the data collection message and the data return message both include a message frame header, a message length, a message body, an error correction code and a frame tail.

[0023] As described above, the vehicle assembly line position safety control method, wherein preferably, the assembly line monitoring module acts as a master control end to monitor and uniformly manage all AGVs in the AGV group to ensure the spacing safety of all AGVs, specifically including:

[0024] In the data sending thread of the AGV object, the assembly line monitoring module periodically sends data acquisition messages to the vehicle-mounted control system of the AGV object; after the AGV object sends the data acquisition message, it must be able to receive the data return message of the vehicle-mounted control system within a set time, otherwise the communication status attribute of the AGV object is assigned a communication abnormality code;

[0025] In the data receiving thread of the AGV object, the assembly line monitoring module receives the data return message of the AGV object and obtains the path coordinate data x after parsing. i ;

[0026] After the assembly line monitoring module is initialized, the main thread is started;

[0027] The assembly line monitoring module performs periodic communication status monitoring on the vehicle-mounted control systems of all AGVs in the AGV group in the main thread to monitor whether the communication link between the assembly line monitoring module and the vehicle-mounted control systems of all AGVs in the AGV group is normal; if the assembly line monitoring module obtains the communication status attribute of the AGV object as a communication abnormality code, the command code attribute of other AGV objects of all AGVs in the AGV group is assigned a value of stop running, and the position security of the main control end based on communication link detection is realized by sending a thread;

[0028] In the main thread of the assembly line monitoring module, the assembly line monitoring module 1 comprehensively processes and determines the AGV objects of all AGVs in the AGV group, sorts them on the path, and generates the path coordinate data x i The corresponding front vehicle coordinate data x i前 ;

[0029] In the main thread of the assembly line monitoring module, according to the path coordinate data x i and safety threshold Δx lim3 After comprehensive judgment, the assembly line monitoring module generates the command code for the AGV object for all AGVs; the assembly line monitoring module transmits the command code to the corresponding AGV object; the AGV object transmits the command code and the preceding vehicle coordinate data x i前 It is encapsulated into the data acquisition message and sent through the command of the data sending thread of the AGV object to realize the position security protection based on coordinate monitoring of the main control end.

[0030] In the above-mentioned method for controlling the position safety of the whole vehicle assembly line, preferably, the vehicle-mounted control system of each AGV of the AGV group ensures the safety of the distance between each AGV and the adjacent AGV according to the signals of the vehicle-mounted wireless transceiver unit, the two-dimensional code camera and the distance sensor, which specifically includes:

[0031] The vehicle control system of all AGVs in the AGV group collects dynamic data of the corresponding QR code camera in real time id , after filtering and range conversion, the path coordinate data x is generated i ;

[0032] The vehicle control systems of all AGVs in the AGV group use computer interrupt technology to exchange data, receive data acquisition messages from the assembly line monitoring module, generate and send data return messages; the data return messages include the path coordinate data x i , wherein the data acquisition message includes a command code and the front vehicle coordinate data x i前 , the command code is one of the codes for start, stop, run, or wait;

[0033] According to the path coordinate data x i , the preceding vehicle coordinate data x i前 and safety threshold Δx lim1 ,After comprehensive judgment, coordinate-based position security protection is realized on the vehicle control system side;

[0034] The vehicle-mounted control system of all AGVs in the AGV group performs periodic communication link detection to detect whether the communication link between the assembly line monitoring module and the vehicle-mounted control system corresponding to all AGVs in the AGV group is normal. If the communication link is abnormal, an alarm is issued. When an alarm is issued, the vehicle-mounted control system controls the corresponding AGV to stop running immediately, so as to realize the position safety protection based on the communication link detection at the vehicle-mounted control system end;

[0035] The vehicle control system of all AGVs in the AGV group collects the signal or data of the distance measurement sensor group, processes the data to generate a distance measurement data group, and processes the data according to the process safety strategy, the distance measurement data group and the safety threshold Δx. lim2 , realizing ranging-based location security protection on the vehicle control system side.

[0036] The present invention provides a whole vehicle assembly line position safety system and control method. The vehicle-mounted control system of each AGV of the AGV group realizes the position safety of the vehicle body of the whole vehicle assembly line according to the communication link of the vehicle-mounted wireless transceiver unit, the path coordinates of the two-dimensional code camera and the combined distance measurement of each distance measurement sensor; the detection data of the distance measurement sensor group is used to realize intelligent detection through logical processing, and it can identify whether the natural object too close in front is an AGV, thereby avoiding the influence of the AGV surrounding workers on the AGV operation when the AGV spacing is normal, and combining the position safety technical route based on coordinate and communication link detection to ensure the economy, reliability and safety of the whole vehicle assembly line position safety system; improve the vehicle body position interval safety of the whole vehicle assembly line based on AGV alignment, ensure that there is no collision between vehicle bodies, and protect product quality; ensure the personal safety of workers around the AGV, and ensure safe production. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be further described below with reference to the accompanying drawings, in which:

[0038] Figure 1 This is a schematic diagram of an embodiment of a vehicle assembly line position safety system provided by the present invention;

[0039] Figure 2 This is a schematic diagram of the installation of a distance measuring sensor for a vehicle control system according to an embodiment of the present invention;

[0040] Figure 3It is a flow chart of a method for position safety control of a vehicle assembly line according to an embodiment of the present invention;

[0041] Figure 4 It is a flow chart of a vehicle assembly line position safety control method at the vehicle-mounted control system end according to an embodiment of the present invention;

[0042] Figure 5 The present invention is a flowchart of a method for controlling the position safety of a vehicle assembly line at a master control end according to an embodiment of the present invention.

[0043] Explanation of the reference numerals: 1-assembly line monitoring module, 2-wireless communication network, 3-AGV group, 4-line side button box OP, 5-QR code tape. DETAILED DESCRIPTION

[0044] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The description of the exemplary embodiments is merely illustrative and is in no way intended to limit the present disclosure and its application or use. The present disclosure can be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided to make the present disclosure thorough and complete and to fully express the scope of the present disclosure to those skilled in the art. It should be noted that unless otherwise specifically stated, the relative arrangement of the components and steps, the composition of the materials, the numerical expressions and the numerical values ​​set forth in these embodiments should be interpreted as being merely exemplary and not as limiting.

[0045] The words "first", "second" and similar words used in this disclosure do not indicate any order, quantity or importance, but are only used to distinguish different parts. The words "include" or "comprises" and similar words mean that the elements before the word include the elements listed after the word, and do not exclude the possibility of including other elements. "Up", "down" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0046] In the present disclosure, when a specific component is described as being located between a first component and a second component, there may or may not be an intermediate component between the specific component and the first component or the second component. When a specific component is described as being connected to other components, the specific component may be directly connected to the other components without an intermediate component, or may not be directly connected to the other components but have an intermediate component.

[0047] All terms (including technical terms or scientific terms) used in the present disclosure have the same meanings as those understood by ordinary technicians in the field to which the present disclosure belongs, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries, such as general dictionaries, should be interpreted as having meanings consistent with their meanings in the context of the relevant technology, and should not be interpreted in an idealized or extremely formal sense, unless explicitly defined herein.

[0048] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0049] like Figure 1 As shown, the vehicle assembly line position safety system provided in this embodiment includes: an assembly line monitoring module 1, an AGV group 3, a line side button box OP 4 and a QR code tape 5, wherein:

[0050] The assembly line monitoring module 1 communicates with the AGV group 3 via the wireless communication network 2.

[0051] The AGV group 3 includes multiple sets of AGVs, each of which is equipped with a vehicle-mounted control system, and each of which is equipped with a vehicle-mounted wireless transceiver unit, the signal of which is connected to the vehicle-mounted control system of the corresponding AGV, each of which is equipped with a two-dimensional code camera, the signal of which is connected to the vehicle-mounted control system of the corresponding AGV, each of which is equipped with a distance sensor group in the forward direction, the distance sensor group includes multiple distance sensors, and the signal of each of which is connected to the vehicle-mounted control system of the corresponding AGV;

[0052] The line side button box OP 4 is directly connected to the input end of the assembly line monitoring module 1;

[0053] The two-dimensional code tape 5 is laid continuously along the entire path of the assembly process section.

[0054] The assembly line monitoring module 1 includes an industrial computer and / or a PLC device. Through the wireless communication network 2, the assembly line monitoring module 1 can communicate with the on-board control systems of all AGVs in the AGV group.

[0055] Furthermore, the wireless communication network 2 includes a switch, a network cable and multiple sets of antenna modules, wherein the wireless communication network 2 is based on the industrial WIFI technology architecture and / or the industrial 5G technology architecture, and the number of sets (m) of the antenna modules is based on whether the wireless signal can stably cover the activity area of ​​all AGVs.

[0056] Furthermore, the assembly line monitoring module 1 includes a human-machine interaction unit, and the display information of the human-machine interaction unit includes the position and operation status information of the AGV group 3. It should be noted that the present invention does not specifically limit the display information of the human-machine interaction unit. The number (n) of AGVs constituting the AGV group 3 is determined by the process design. It should be noted that the present invention does not specifically limit the number of antenna modules and AGVs.

[0057] Furthermore, the button signal of the line side button box OP 4 is directly connected to the input module of the assembly line monitoring module. Specifically, the line side button box OP 4 is a workstation button box, which is distributed in the assembly process section, and each workstation is equipped with a set of line side button boxes OP 4. During operation, the buttons of the line side button box OP 4 can provide start, stop and emergency stop signals to the assembly line monitoring module 1, and after being processed by the assembly line monitoring module 1, perform corresponding actions on each of the AGVs in the assembly process section.

[0058] Furthermore, the data interfaces of the two-dimensional code cameras configured for all AGVs of the AGV group 3 are connected to the vehicle-mounted control system of the corresponding AGV. Specifically, the data interface of the two-dimensional code camera can be, for example, Profinet, EtherNet / IP, EtherCAT or CAN. In a specific implementation, the two-dimensional code camera can directly generate position data, and the two-dimensional code position value detection accuracy is not less than 1mm.

[0059] Furthermore, in one embodiment of the present invention, the distance measuring sensor group configured for all AGVs in the AGV group 3 is composed of 5 distance measuring sensors, and the channel numbers are A, B, C, D and E. Exemplarily, the distance measuring sensor is a photoelectric sensor, and the diameter of the measuring light spot at a distance of 3 meters from the target is not greater than 10mm, and the position repeatability value is not greater than 2mm. The target object supported by the distance measuring sensor is a natural object. Figure 2 As shown, at the front part of the AGV, the distance measuring sensors are evenly and parallelly installed in the top projection plane. Specifically, the measuring light beams of the distance measuring sensor group are all emitted in the forward direction of the AGV, and the measuring light beams are parallel to the longitudinal center axis of the vehicle body.

[0060] Furthermore, each two-dimensional code position information of the two-dimensional code tape 5 of the assembly process section is unique, and the two-dimensional code position data is continuous.

[0061] It should be noted that the whole vehicle assembly line of the present invention is composed of n sets of AGVs, which is a circular assembly line consisting of a process section and a conveying section; each AGV in the AGV group 3 carries a vehicle body on its tray and runs continuously at a low speed in the conveying section; in the process section, operators stand on the ground to work around the vehicle body carried by the AGV.

[0062] Accordingly, the present invention also provides a method for position safety control of a vehicle assembly line using the above system, such as Figure 3 As shown, the vehicle assembly line position safety control method provided in this embodiment includes the following steps in actual execution:

[0063] Step S1 : The assembly line monitoring module 1 acts as a master control terminal to monitor and uniformly manage all AGVs of the AGV group 3 to ensure the safe spacing of all AGVs.

[0064] The assembly line monitoring module 1, as the main control terminal, is responsible for monitoring and unified management of all AGVs in the AGV group 3, and is responsible for the safety of all AGV spacing in the AGV group from the main control level. Specifically, the assembly line monitoring module uses object-oriented and multi-threaded computer technology for data interaction, data processing and logic processing; the basic architecture of the assembly line monitoring module program is divided into an initialization part and a main thread part according to function.

[0065] The initialization process of the assembly line monitoring module includes:

[0066] The main control system function block is initialized, and AGV objects are established for all AGVs in the AGV group 3; the data sending thread and the data receiving thread of the AGV object are created and started; wherein the data sending thread is used to send data acquisition messages, and the data receiving thread is used to receive data return messages. The data acquisition messages and the data return messages both include a message frame header, a message length, a message body, an error correction code, and a frame tail.

[0067] In one embodiment of the vehicle assembly line position safety control method of the present invention, step S1 may specifically include:

[0068] Step S11, in the data sending thread of the AGV object, the assembly line monitoring module 1 periodically sends data acquisition messages to the vehicle-mounted control system of the AGV object; after the AGV object sends the data acquisition message, it must be able to receive the data return message from the vehicle-mounted control system within a set time, otherwise the communication status attribute of the AGV object is assigned a communication abnormality code.

[0069] Step S12: In the data receiving thread of the AGV object, the assembly line monitoring module 1 receives the data return message of the AGV object and obtains the path coordinate data x after parsing. i .

[0070] Step S13: After the assembly line monitoring module 1 is initialized, the main thread is started.

[0071] Step S14, the assembly line monitoring module 1 performs periodic communication status monitoring on the on-board control systems of all AGVs in the AGV group 3 in the main thread to monitor whether the communication link between the assembly line monitoring module 1 and the on-board control systems of all AGVs in the AGV group 3 is normal; if the assembly line monitoring module 1 obtains the communication status attribute of the AGV object as a communication abnormality code, the command code attribute of other AGV objects of all AGVs in the AGV group 3 is assigned to stop running, and the position security of the main control end based on communication link detection is realized by sending the thread.

[0072] Step S15: In the main thread of the assembly line monitoring module 1, the assembly line monitoring module 1 comprehensively processes and determines the AGV objects of all AGVs in the AGV group, sorts them on the path, and generates the path coordinate data x i The corresponding front vehicle coordinate data x i前 .

[0073] Step S16: In the main thread of the assembly line monitoring module 1, according to the path coordinate data x i and safety threshold Δx lim3 After comprehensive judgment, the assembly line monitoring module 1 generates the command code for the AGV object for all AGVs; the assembly line monitoring module transmits the command code to the corresponding AGV object; the AGV object transmits the command code and the preceding vehicle coordinate data x i前 It is encapsulated into the data acquisition message and sent through the command of the data sending thread of the AGV object to realize the position security protection based on coordinate monitoring of the main control end.

[0074] Step S2: The vehicle-mounted control system of each AGV of the AGV group 3 ensures the safety of the distance between each AGV and the adjacent AGV according to the signals of the vehicle-mounted wireless transceiver unit, the two-dimensional code camera and the distance measuring sensor.

[0075] All AGVs in AGV group 3 are responsible for the spacing safety of AGVs from the self-protection level, and comprehensively realize the body position safety of the whole vehicle assembly line from three aspects: path coordinates, communication links and combined distance measurement. In one embodiment of the whole vehicle assembly line position safety control method of the present invention, step S2 may specifically include:

[0076] Step S21: The vehicle control systems of all AGVs in AGV group 3 collect dynamic data x corresponding to the QR code cameras in real time. id , after filtering and range conversion, the path coordinate data x is generated i .

[0077] Step S22: The vehicle control systems of all AGVs in AGV group 3 use computer interrupt technology to exchange data, receive data acquisition messages from the assembly line monitoring module, generate and send data return messages; the data return messages include the path coordinate data x i .

[0078] The data acquisition message includes a command code and the coordinate data x of the preceding vehicle. i前 , the command code is one of the codes for start, stop, run or wait.

[0079] Step S23: according to the path coordinate data x i , the preceding vehicle coordinate data x i前 and safety threshold Δx lim1 ,After comprehensive judgment, coordinate-based position security protection is realized on the vehicle control system side.

[0080] Specifically, if the front vehicle coordinate data x i前 -Path coordinate data x i Less than the safety threshold Δx lim1 , it is judged as unsafe; if the front vehicle coordinate data x i前 -Path coordinate data x i Greater than or equal to the safety threshold Δx lim1 Therefore, through step S23, the vehicle-mounted control systems of all AGVs in the AGV group 3 can achieve position safety based on the path coordinates at the vehicle-mounted control system end according to the adjacent path coordinate values.

[0081] Step S24, the on-board control system of all AGVs in AGV group 3 performs periodic communication link detection to detect whether the communication link between the assembly line monitoring module and the on-board control system corresponding to all AGVs in AGV group 3 is normal. If the communication link is abnormal, an alarm is issued. When an alarm occurs, the on-board control system controls the corresponding AGV to stop running immediately, so as to realize position safety protection based on communication link detection on the on-board control system end.

[0082] Through step S24, the location security based on communication link detection at the vehicle control system end can be achieved.

[0083] Step S25: The vehicle control systems of all AGVs in AGV group 3 collect signals or data from the distance measurement sensor group, process the data to generate a distance measurement data group, and calculate the distance measurement data group based on the process safety strategy, the distance measurement data group and the safety threshold Δx. lim2 , realizing ranging-based location security protection on the vehicle control system side.

[0084] According to step S25, the position security based on ranging can be achieved at the vehicle control system end.

[0085] Furthermore, in order to better explain the vehicle assembly line position safety control process at the vehicle control system end, Figure 4 An example functional flow chart of vehicle assembly line position safety at the vehicle control system end is shown, and the implementation steps are as follows:

[0086] Step 100: Start;

[0087] Step 101: Detect the communication link of the vehicle control system, detect communication anomalies, and protect the location security;

[0088] Specifically, the on-board control system of all AGVs in the AGV group 3 performs periodic communication link detection to detect whether the communication link between the assembly line monitoring module 1 and the on-board control system is normal. If the communication link is abnormal, an alarm is triggered. When an alarm is triggered, the on-board control system controls the corresponding AGV to stop running immediately, so as to achieve position safety protection based on communication link detection on the on-board control system side.

[0089] Step 102: The vehicle control system collects dynamic data x from the QR code camera id .

[0090] Step 103: Dynamic data x id Perform filtering.

[0091] Specifically, the dynamic data x acquired by the two-dimensional code camera id It is fluctuating, which is not conducive to data processing. The vehicle-mounted control system adopts a mean filtering algorithm to generate stable two-dimensional code absolute position data.

[0092] Step 104: Filter data coordinate conversion to generate path coordinate data x i ;

[0093] Specifically, the two-dimensional code camera data directly obtained is the absolute position data of the two-dimensional code. After filtering, it is still the absolute position data of the two-dimensional code, not the coordinate data set by the electronic map of the assembly line monitoring module 1 as the main control end, which is not conducive to subsequent processing and logical judgment. Therefore, the coordinate conversion of the filtered data is required to convert the absolute position data of the two-dimensional code into the electronic map coordinate data, that is, the path coordinate data x i .

[0094] Step 105: Path coordinate data x i Store in the send buffer and lock the returned data for sending.

[0095] Specifically, the returned data is not limited to the path coordinate data x i, also includes real-time operating status information of the AGV; after the vehicle-mounted control system stores the return data in the sending buffer, the return data lock flag is set.

[0096] Step 106: Whether the data collection message is received.

[0097] Specifically, if the vehicle-mounted control system receives a data collection message triggered by an event, it enters a preliminary analysis process.

[0098] Specifically, after preliminary analysis by the vehicle-mounted control system, if it is determined that the data collection message is valid, step 107 is executed, otherwise, the process jumps to step 108 .

[0099] Step 107: parse the data collection message, generate a return message, and return the data.

[0100] Specifically, after preliminary analysis in step 106, under the condition that the data acquisition message is valid and the feedback data lock flag is true, the vehicle control system encapsulates the feedback data generated in step 105, generates a feedback data message, and sends the feedback data message to the assembly line monitoring module 1 as the main control end. After the sending is completed, the feedback data lock flag is reset.

[0101] Step 108: If the difference between the path coordinate data of the adjacent front and rear AGVs is less than the safety threshold, motion protection is performed.

[0102] Specifically, in step 104, the vehicle control system obtains the path coordinate data x i Based on step 106 and step 107, the vehicle control system obtains the preceding vehicle coordinate data x from the data acquisition message. i前 , the preceding vehicle coordinate data x i前 With the path coordinate data x i The difference is Δx, and the safety threshold is Δx lim1 .

[0103] The calculation formula is as follows: Δx=x i前 -x i Specifically, if Δx<Δx lim1 , indicating that the distance between the front and rear vehicles is too small and there is a safety risk. The vehicle control system then issues an alarm and stops running, actively implementing motion protection, thereby achieving position safety based on path coordinates on the vehicle control system end.

[0104] Specifically, through the touch screen of the vehicle control system, maintenance personnel can adjust the safety threshold Δx according to the on-site process status. lim1 Make reasonable settings.

[0105] Step 109: The batch data of the ranging data group is less than the safety threshold, and motion protection is performed;

[0106] Specifically, the vehicle control system collects the distance data A of the distance measuring sensor group according to the channel. j , B j , C j , D j and E j , wherein j is the array number, the maximum value of j is the data sampling frequency, and in one embodiment of the present invention, the maximum value of j is 10, that is, each channel samples data 10 times per second.

[0107] Specifically, after sampling is completed, the 10 data of each channel are filtered to eliminate interference data, remove the maximum value, remove the minimum value, and calculate the average of the remaining 8 data of each channel. The averages are A 平均 , B 平均 , C 平均 , D 平均 and E 平均 .

[0108] In the specific implementation, in order to facilitate the determination, the A 平均 , B 平均 , C 平均 , D 平均 and E 平均 The value is assigned to the array L[k], and Counter(array) is cleared; specifically, L[k] is looped to determine whether it is less than Δx lim2 , if L[k] is less than Δx lim2 Then the channel counter Counter is incremented by 1. Further, after the L[k] cycle is completed, if the channel counter Counter is equal to 5, it means that the distances measured by the distance measuring sensor group are all less than the safety threshold Δx lim2 , it can be determined that the current AGV is too close to the AGV in front and there is a safety risk, and the vehicle-mounted control system should stop running; if the operator works normally between the AGVs and blocks some ranging sensors of the ranging sensor group, resulting in the channel counter Counter value being less than 5, the vehicle-mounted control system does not determine that the AGV has a safety risk; through the above determination and processing, the vehicle-mounted control system end can achieve position safety based on ranging.

[0109] Step 110: The program ends and automatically jumps to step 100 to start the next program cycle.

[0110] Furthermore, in order to better explain the vehicle assembly line position safety control method at the vehicle control system end, Figure 5An example functional flow chart of the vehicle assembly line position safety of the assembly line monitoring module as the main control end is shown, and the implementation steps are as follows:

[0111] Step 120: Start.

[0112] Step 121: Initialize and create AGV i Object, create data sending thread and receiving thread.

[0113] Step 122: Start Each AGV i The object's data sending thread and receiving thread.

[0114] Step 123: Each AGV i The sending thread of the object periodically sends data collection messages.

[0115] Specifically, each AGV i Before the periodic sending process begins, the object sends the command code and the preceding vehicle coordinate data x i前 Encapsulate it into the data collection message, and then send the data collection message. i The object sets the sent property of the collected data and resets the received property of the returned data.

[0116] Step 124: Each AGV i Receive data return message triggered by object event to obtain path coordinate data x i ;

[0117] Specifically, in each of the AGVs i The data receiving thread of the object, the AGV i The object receives the data return message and initially analyzes whether the data return message is valid. i The object further parses the data return message to obtain the path coordinate data x i ; Further, the AGV i The object sets the received attribute of the returned data and resets the sent attribute of the collected data.

[0118] Step 125: Each AGV i The object's send thread periodically performs communication link monitoring.

[0119] Specifically, after the AGV object sends the data collection message, it must be able to receive the data return message from the vehicle control system within a set time, otherwise a communication abnormality code is generated.

[0120] In one embodiment of the present invention, in each AGV iThe sending thread of the object, based on step 123 and step 124, according to the attribute value sent by the collected data and the attribute value received by the returned data, each AGV i The object performs logical judgment on the communication link it is responsible for and sets or resets its communication status attributes.

[0121] Step 126: Main thread for all AGVs i The object communication link is monitored, and if the result is abnormal, the system will perform motion protection.

[0122] Specifically, the assembly line monitoring module 1 periodically monitors the communication status of all AGV vehicle-mounted control systems of the AGV group 3 to monitor whether the communication link between the assembly line monitoring module 1 and the vehicle-mounted control systems of all AGVs in the AGV group 3 is normal. i If the communication status attribute of the object is true, it means that the communication of the vehicle assembly line position safety system is abnormal. After the assembly line monitoring module 1 obtains the code that the communication status attribute is true (i.e. abnormal), it assigns the command code attribute of other AGV objects with the value of stop running. Through the sending thread of step 123, the position safety of the main control end based on communication link detection is realized.

[0123] Step 127: For all AGVs i The path coordinate data x of the object i Perform analysis and judgment. If the data and interval are abnormal, motion protection will be activated.

[0124] Specifically, in the main thread of the assembly line monitoring module 1, the assembly line monitoring module 1 processes the path coordinate data x of all AGV objects in the AGV group 3. i Analyze and process, sort by path coordinates, and generate the path coordinate data x i The corresponding front vehicle coordinate data x i前 In the main thread of the assembly line monitoring module 1, according to the path coordinate data x i and safety threshold Δx lim3 After analysis and processing, the assembly line monitoring module 1 assigns a value to the command code attribute of the AGV object.

[0125] The basic calculation formula is as follows: Δy=x i前 -x i Specifically, if Δy<Δx lim3 , indicating that the distance between the front and rear vehicles is too small, which poses a safety risk. The assembly line monitoring module 1 then monitors the AGV i The command code attribute of the object is assigned a stop code, and the position safety based on coordinate monitoring of the master control end is realized through the sending thread of step 123.

[0126] Step 128: Update Each AGV i The object's preceding vehicle coordinate data x i前 The attribute value of .

[0127] Specifically, the assembly line monitoring module 1 converts the preceding vehicle coordinate data x generated in step 127 into i前 The value is passed to the corresponding AGV object's preceding vehicle coordinate data x i前 property;

[0128] Step 129: End.

[0129] It should be noted that Figure 4 and Figure 5 The functional flow chart is only for better understanding of the embodiments of the invention. It is only a basic functional flow chart and cannot represent a strict program logic flow.

[0130] The embodiment of the present invention provides a whole vehicle assembly line position safety system and control method. The vehicle-mounted control system of each AGV in the AGV group realizes the position safety of the vehicle body of the whole vehicle assembly line according to the communication link of the vehicle-mounted wireless transceiver unit, the path coordinates of the two-dimensional code camera and the combined distance measurement of each distance measuring sensor; the detection data of the distance measuring sensor group is used to realize intelligent detection through logical processing, and it can identify whether the natural object too close in front is an AGV, thereby avoiding the influence of the workers around the AGV on the operation of the AGV when the AGV spacing is normal. Combined with the position safety technical route based on coordinates and communication link detection, the economy, reliability and safety of the whole vehicle assembly line position safety system are ensured; the vehicle body position interval safety of the whole vehicle assembly line based on AGV alignment is improved to ensure that there is no collision between vehicle bodies and protect product quality; the personal safety of workers around the AGV is ensured to ensure safe production.

[0131] So far, various embodiments of the present disclosure have been described in detail. In order to avoid obscuring the concept of the present disclosure, some details known in the art are not described. Based on the above description, those skilled in the art can fully understand how to implement the technical solution disclosed here.

[0132] Although some specific embodiments of the present disclosure have been described in detail by way of examples, it should be understood by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present disclosure. It should be understood by those skilled in the art that the above embodiments may be modified or some technical features may be replaced by equivalents without departing from the scope and spirit of the present disclosure. The scope of the present disclosure is defined by the appended claims.

Claims

1. A vehicle assembly line position safety system, characterized in that: include: Assembly line monitoring module, AGV group, line side button box OP and QR code tape, including: The assembly line monitoring module communicates with the AGV group via a wireless communication network, The AGV group includes multiple sets of AGVs, each of which is equipped with an on-board control system, and each of which is equipped with an on-board wireless transceiver unit, the signal of which is connected to the on-board control system of the corresponding AGV, each of which is equipped with a two-dimensional code camera, the signal of which is connected to the on-board control system of the corresponding AGV, each of which is equipped with a distance sensor group in the forward direction, the distance sensor group includes multiple distance sensors, and the signal of each of which is connected to the on-board control system of the corresponding AGV; The line side button box OP is directly connected to the input end of the assembly line monitoring module; The two-dimensional code tape is laid continuously along the entire path of the assembly process section.

2. The vehicle assembly line position safety system according to claim 1, characterized in that: The assembly line monitoring module includes an industrial computer and / or a PLC device.

3. The vehicle assembly line position safety system according to claim 1, characterized in that: The wireless communication network includes a switch, a network cable and multiple sets of antenna modules, wherein the wireless communication network is based on an industrial WIFI technology architecture and / or an industrial 5G technology architecture, and the number of antenna modules is based on whether the wireless signal can stably cover the activity area of ​​all AGVs.

4. The vehicle assembly line position safety system according to claim 1, characterized in that: The assembly line monitoring module includes a human-machine interaction unit, and the display information of the human-machine interaction unit includes the position and operation status information of the AGV group.

5. A method for position safety control of a vehicle assembly line using the system according to any one of claims 1 to 4, characterized in that: include: As the main control terminal, the assembly line monitoring module monitors and uniformly manages all AGVs in the AGV group to ensure the safe spacing of all AGVs; The on-board control system of each AGV in the AGV group ensures the safe distance between each AGV and adjacent AGVs based on the signals from the on-board wireless transceiver unit, QR code camera and distance sensor.

6. The vehicle assembly line position safety control method according to claim 5, characterized in that: The assembly line monitoring module acts as the main control terminal to monitor and uniformly manage all AGVs in the AGV group to ensure the safe spacing of all AGVs, specifically including: The assembly line monitoring module adopts object-oriented and multi-threaded computer technology to perform data interaction, data processing and logic processing; the basic program architecture of the assembly line monitoring module includes an initialization part and a main thread part according to its functions.

7. The vehicle assembly line position safety control method according to claim 6, characterized in that: The initialization process of the assembly line monitoring module includes: The main control system function block is initialized, and AGV objects are established for all AGVs in the AGV group; a data sending thread and a data receiving thread of the AGV object are created and started; wherein the data sending thread is used to send data acquisition messages, and the data receiving thread is used to receive data return messages; Wherein, the data collection message and the data return message both include a message frame header, a message length, a message body, an error correction code and a frame tail.

8. The vehicle assembly line position safety control method according to claim 7, characterized in that: The assembly line monitoring module acts as the main control terminal to monitor and uniformly manage all AGVs in the AGV group to ensure the safe spacing of all AGVs, specifically including: In the data sending thread of the AGV object, the assembly line monitoring module periodically sends data acquisition messages to the vehicle-mounted control system of the AGV object; after the AGV object sends the data acquisition message, it must be able to receive the data return message of the vehicle-mounted control system within a set time, otherwise the communication status attribute of the AGV object is assigned a communication abnormality code; In the data receiving thread of the AGV object, the assembly line monitoring module receives the data return message of the AGV object and obtains the path coordinate data x after parsing. i ; After the assembly line monitoring module is initialized, the main thread is started; The assembly line monitoring module performs periodic communication status monitoring on the vehicle-mounted control systems of all AGVs in the AGV group in the main thread to monitor whether the communication link between the assembly line monitoring module and the vehicle-mounted control systems of all AGVs in the AGV group is normal; if the assembly line monitoring module obtains the communication status attribute of the AGV object as a communication abnormality code, the command code attribute of other AGV objects of all AGVs in the AGV group is assigned a value of stop running, and the position security of the main control end based on communication link detection is realized by sending a thread; In the main thread of the assembly line monitoring module, the assembly line monitoring module 1 comprehensively processes and determines the AGV objects of all AGVs in the AGV group, sorts them on the path, and generates the path coordinate data x i The corresponding front vehicle coordinate data x i前 ; In the main thread of the assembly line monitoring module, according to the path coordinate data x i and safety threshold Δx lim3 After comprehensive judgment, the assembly line monitoring module generates the command code for the AGV object for all AGVs; the assembly line monitoring module transmits the command code to the corresponding AGV object; the AGV object transmits the command code and the preceding vehicle coordinate data x i前 It is encapsulated into the data acquisition message and sent through the command of the data sending thread of the AGV object to realize the position security protection based on coordinate monitoring of the main control end.

9. The vehicle assembly line position safety control method according to claim 5, characterized in that: The vehicle-mounted control system of each AGV in the AGV group ensures the safety of the distance between each AGV and the adjacent AGV according to the signals of the vehicle-mounted wireless transceiver unit, the QR code camera and the distance measuring sensor, specifically including: The vehicle control system of all AGVs in the AGV group collects dynamic data of the corresponding QR code camera in real time id , after filtering and range conversion, the path coordinate data x is generated i ; The vehicle control systems of all AGVs in the AGV group use computer interrupt technology to exchange data, receive data acquisition messages from the assembly line monitoring module, generate and send data return messages; the data return messages include the path coordinate data x i , wherein the data acquisition message includes a command code and the front vehicle coordinate data x i前 , the command code is one of the codes for start, stop, run, or wait; According to the path coordinate data x i , the preceding vehicle coordinate data x i前 and safety threshold Δx lim1 ,After comprehensive judgment, coordinate-based position security protection is realized on the vehicle control system side; The vehicle-mounted control system of all AGVs in the AGV group performs periodic communication link detection to detect whether the communication link between the assembly line monitoring module and the vehicle-mounted control system corresponding to all AGVs in the AGV group is normal. If the communication link is abnormal, an alarm is issued. When an alarm is issued, the vehicle-mounted control system controls the corresponding AGV to stop running immediately, so as to realize the position safety protection based on the communication link detection at the vehicle-mounted control system end; The vehicle control system of all AGVs in the AGV group collects the signal or data of the distance measurement sensor group, processes the data to generate a distance measurement data group, and processes the data according to the process safety strategy, the distance measurement data group and the safety threshold Δx. lim2 , realizing ranging-based location security protection on the vehicle control system side.

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