Multi-sensor fusion basin-type insulator automatic demolding method

Abstract

The invention discloses a multi-sensor fusion basin-type insulator automatic demoulding method, which is divided into two parts of mould upper half part separation and workpiece and mould separation, a position in contact with a workpiece is taken as a boundary, the upper half part is above the boundary, the lower half part is below the boundary, and the workpiece is wrapped by a mould A and a mould B together. The problems of workpiece damage and unclean demolding are effectively avoided, the production efficiency is improved, and the safety risk is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of demoulding of pot-type insulators, and in particular relates to an automatic demoulding method for pot-type insulators by multi-sensor fusion. Background Art

[0002] Basin insulators are important components in the field of power transmission and transformation. Demolding basin insulators and ensuring the production quality of insulators are crucial to the smooth operation of power transmission and transformation. Basin insulators are mostly demolded by knocking, vibrating the mold, etc., which has great limitations in terms of complete demolding and preventing damage to the workpiece. With the rapid development of industrial automation and intelligent manufacturing, the demand for efficient, precise and reliable automated demolding solutions is growing. The advancement of modern sensor technology and advanced control algorithms has provided a technical basis for the development of new automated demolding equipment, making it possible to integrate multi-sensor data and realize intelligent control. Therefore, this invention aims to create an automated demolding equipment that can simulate manual operation and surpass traditional methods by integrating robotics technology, sensor technology, control algorithms and software systems to meet the needs of modern manufacturing for high-efficiency, high-quality and high-safety production. Summary of the invention

[0003] The purpose of the present invention is to provide a multi-sensor fusion pot-type insulator automatic demoulding method, which can effectively avoid the problems of workpiece damage and unclean demoulding, improve production efficiency and reduce safety risks.

[0004] The technical solution adopted by the present invention is: a multi-sensor fusion basin insulator automatic demoulding method, which is divided into two parts: the upper half of the mold is disengaged and the workpiece is separated from the mold. The contact position with the workpiece is the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half, and the workpiece is wrapped by mold A and mold B.

[0005] The present invention is also characterized in that: The upper part of the contact point between mold A and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

[0006] Step 1 is as follows: Use an overhead crane to lift the cured pot-type insulator mold onto a mobile platform. A gantry structure is set up at the other end of the mobile platform. The slide rail of the mobile platform is located at the bottom middle position of the gantry structure. The cured pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure to wait for demoulding. A pair of flip motors are symmetrically installed in the middle and lower parts of the two side columns of the gantry structure. The flip motor is electrically connected to the control unit. The output shaft of the flip motor is connected to the mold B to control the rotational power required for the mold B to be separated from the pot-type insulator. A mechanical claw is also installed on the inner surface in the middle of the upper part of the gantry structure. A camera is installed next to the mechanical claw. The workpiece demoulding push rod passes through the upper middle of the gantry structure and is connected to the mechanical claw. The mold B is also connected to the hydraulic system and the pneumatic system to fix the cured pot-type insulator mold A on the L-shaped bracket of the mobile platform.

[0007] Step 2 is as follows: install the top screw assembly at the installation center points of the four corners of the mold. The top screw assembly includes pressure sensors and top screws, so that the installation positions of the four top screws and pressure sensors are symmetrically distributed to ensure that the force condition of the mold can be evenly monitored; accurately measure the center position of the mold, install the attitude sensor at the center position of the mold, ensure that the attitude sensor is installed horizontally, and the measurement coordinate axis of the attitude sensor is consistent with the actual coordinate axis of the mold, so as to accurately monitor the inclination angle of the mold in real time; the hydraulic system is connected to the top screw in the top screw assembly, and the hydraulic system is controlled to apply force to the top screw in the top screw assembly during the demolding process to assist in demolding. The pressure at the main oil pipe after the hydraulic pump outlet of the hydraulic system can reflect the overall force applied by the hydraulic system. A force sensor is installed on the hydraulic pipeline here to measure the force applied by the hydraulic system. Connect the signal output cables of the pressure sensors, attitude sensors and force sensors on the hydraulic pipeline in the four top screw assemblies according to the corresponding input interface type of the control unit, mark each sensor channel with a number on the control unit end, and configure the corresponding sensor range, zero point calibration, filtering parameters, sensor working mode, and accuracy setting parameters on the control unit end, so as to accurately convert and analyze the collected data in the future, and realize accurate monitoring and control of the mold demolding process; Step 3 is as follows: The mechanical claw is controlled by using a PID algorithm to simulate the actions of manual operation, such as removing screws, knocking the mold, pulling open the mold, and removing the workpiece.

[0008] Step 3 is implemented as follows: Step 3.1, remove the screws; Step 3.2, tap the mold: Step 3.3, demoulding operation.

[0009] Step 3.1 is implemented as follows: First, initialize the PID controller and set the initial proportional Kp, integral Ki, and differential Kd parameters; then use the camera set on the top inner surface of the gantry structure to collect the position of the connecting screws of mold A and mold B, and transmit the position signal detected by the camera to the control unit, so as to control the mechanical claw to move to the top of each corresponding connecting screw in turn; then start the pressure sensor in the top screw assembly at the four corners of the mold, activate the pressure sensor in the top screw assembly to detect the contact force between the mold and the top screw in the top screw assembly; according to the feedback from the pressure sensor in the top screw assembly, use the PID algorithm to adjust the torque of the mechanical claw to achieve accurate loosening of the screws; Step 3.2 is implemented as follows: The camera is used to determine the specific position on the mold that needs to be knocked, including the mold gap and mold edge that the mechanical claw can penetrate, but it is necessary to avoid directly knocking on the surface where the workpiece and the mold are in contact; then the mechanical claw is controlled to move above the knocking point, and by analyzing the force changes of the pressure sensor in the top screw assembly, the force that has changed in size and position due to external interference is adjusted to the appropriate size and direction to ensure the accuracy and strength of the knocking, and the knocking strength and frequency of the mechanical claw are adjusted at all times to ensure the stability and performance of the system; the posture and force of the mold are detected in real time by real-time monitoring of the data of the pressure sensor and posture sensor in the top screw assembly. The change in sensor data indicates the separation state of the mold and the workpiece. When it is confirmed that the mold and the workpiece are properly separated, that is, when the pressure sensor in the top screw assembly shows that the pressure between the mold and the workpiece has changed significantly and the posture sensor shows that the workpiece has slightly moved, prepare for the next step of disengaging the mold.

[0010] Step 3.3 is implemented according to the following steps: The camera is used for visual recognition to accurately locate the mold, especially to identify the key positions on the edge of the upper half of the mold, that is, the mold gap and mold edge where the mechanical claw can penetrate. The mechanical claw moves to the initial demoulding position based on these feedback information; at this moment, the hydraulic system is activated to provide power for the ejector screw. In the process of ejecting the mold, multiple sensors on the mold play a role. The pressure sensor in the ejector screw assembly monitors the strength of the contact point between the ejector screw and the mold in real time to ensure that the applied force is within a safe range. The posture sensor monitors the tilt angle and direction of the mold to prevent any mold tilt that may cause the workpiece to get stuck. The camera provides real-time images to help analyze the relative position of the mold and the workpiece and the movement of the mold; by integrating these sensor data, the control unit applies PID control The control algorithm dynamically adjusts the action of the hydraulic system and the push screw in the push screw assembly to achieve precise control. When pushing open the upper part of the mold, the control unit calculates the required force and speed in real time to ensure that the mold is evenly stressed and avoid damage to the workpiece or mold due to sudden or uneven force. In order to prevent the mold from tilting, once the posture sensor detects any tilting trend, the control unit will respond quickly and adjust the force point and force of the push screw in the push screw assembly to correct the mold posture and maintain the stability and synchronization of the demolding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and workpiece throughout the demolding process. When the upper part of the mold is completely separated and the various sensors confirm that the workpiece is not stuck or damaged, the mechanical claw will stop the demolding action and move to a safe position to wait for the next instruction.

[0011] The separation of the workpiece and the mold is carried out according to the following steps: Step a, install the lifting ring: install a special lifting ring at the center of the pot-type insulator, ensure that the lifting ring is firmly connected to the pot-type insulator and can bear the weight of the insulator; Step b, hang the workpiece: operate the overhead crane, slowly lift the lifting ring, so that the basin insulator is completely suspended and kept stable; Step c, applying force with a top screw: inserting a top screw in the top screw assembly into the top screw hole below the mold, and applying a uniform upward force to the bottom of the insulator using the top screw in the top screw assembly to assist in separating the pot-type insulator from the mold B; Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the molecular attraction between the two surfaces is destroyed, the demoulding resistance is reduced, so as to ensure the complete demoulding of the insulator and prevent residues and defects on the mold.

[0012] Step e, monitoring the force of the top screw in the top screw assembly: obtaining the force condition of the top screw in the top screw assembly by real-time monitoring the force data of the pressure sensor in the top screw assembly, judging the separation state of the insulator and the mold, and ensuring the complete demolding of the insulator; Step f, removing the workpiece: when the control unit displays that the force on the top screw in the top screw assembly suddenly decreases, indicating that the insulator has completely separated from the mold, the operator smoothly and quickly moves the insulator to a designated safe area; Step g, cleaning the mold: Use an overhead crane to move mold B to the cleaning line for cleaning and maintenance in preparation for the next round of production.

[0013] The beneficial effect of the present invention is that the automatic demoulding method of pot-type insulators with multi-sensor fusion can realize fully automated demoulding operation, reduce manual intervention, reduce safety risks in work, and improve production efficiency and continuity of operations. By utilizing robust control algorithms and multi-sensor fusion technology, flexible force can be applied during the demoulding process to protect the workpiece from damage while ensuring a smooth demoulding process. The intelligent control strategy adopted in the process can adjust the demoulding force and posture according to the real-time feedback sensor data to achieve precise control. The design of the invention allows it to adapt to different mold and workpiece sizes, and has good versatility and adaptability. The mold after demoulding can be quickly moved to the cleaning line, which is convenient for cleaning and maintenance, and ensures the stability and reliability of the equipment. Overall, the automatic demoulding equipment of the invention realizes efficient, safe and reliable automated demoulding operations by integrating advanced sensing technology and control algorithms, and has significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is the technical roadmap of automatic demoulding equipment; Figure 2 It is a schematic diagram of the main structure of the automatic demoulding equipment.

[0015] In the figure, 1. mold A, 2. mold B, 3. gantry structure, 4. mobile platform, 5. flip motor, 6. mechanical claw, 7. camera, 8. air pressure system, 9. hydraulic system, 10. jackscrew assembly, 11. workpiece demoulding ejector rod, 12. L-shaped bracket, 13. jackscrew hole. DETAILED DESCRIPTION

[0016] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0017] The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0018] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

[0019] Step 1 is as follows: Use an overhead crane to lift the cured pot-type insulator mold to the mobile platform 4, and Figure 1 , Figure 2 A gantry structure 3 is set up at the other end of the mobile platform 4, and the slide rail of the mobile platform 4 is located at the bottom middle position of the gantry structure 3. The cured pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demoulding. A pair of flip motors 5 are symmetrically installed at the middle and lower parts of the two side columns of the gantry structure 3. The flip motor 5 is electrically connected to the control unit, and the output shaft of the flip motor 5 is connected to the mold B2 to control the rotational power required when the mold B2 is separated from the pot-type insulator. A mechanical claw 6 is also installed on the inner surface in the middle of the upper part of the gantry structure 3, and a camera 7 is installed next to the mechanical claw 6. The workpiece demoulding push rod 11 passes through the upper middle of the gantry structure 3 and is connected to the mechanical claw 6. The mold B2 is also connected to the hydraulic system 9 and the pneumatic system 8. The cured pot-type insulator mold A1 is fixed on the L-shaped bracket 12 of the mobile platform 4. The L-shaped bracket 12 has a stable support structure and can withstand the weight of the mold and the force that may be generated during the demoulding process.

[0020] Step 2 is as follows: Select a top screw assembly 10 with appropriate range and accuracy, and Figure 2 As shown in the position, use a measuring tool to measure the accurate installation center point at the four corners of the mold to install the top screw assembly 10, so that the installation positions of the four top screw assemblies 10 are symmetrically distributed to ensure that the force condition of the mold can be evenly monitored; accurately measure the center position of the mold, install the attitude sensor at the center position of the mold, ensure that the attitude sensor is installed horizontally, and the measurement coordinate axis of the attitude sensor is consistent with the actual coordinate axis of the mold, so as to accurately monitor the inclination angle of the mold in real time; the hydraulic system 9 is connected to the top screw, and the hydraulic system 9 is controlled to apply force to the top screw during the demoulding process to assist in demoulding. The pressure at the main oil pipe after the hydraulic pump outlet of the hydraulic system 9 can reflect the overall force applied by the hydraulic system 9. A force sensor is installed on the hydraulic pipeline here to measure the force applied by the hydraulic system 9. The signal output cables of the pressure sensors, attitude sensors and force sensors on the hydraulic pipelines in the four top screw assemblies 10 are connected according to the input interface type corresponding to the control unit, each sensor channel is numbered and marked on the control unit end, and the corresponding sensor range, zero point calibration, filtering parameters, sensor working mode, and accuracy setting parameters are configured on the control unit end, so as to accurately convert and analyze the collected data in the future, and realize accurate monitoring and control of the mold demolding process; Step 3 is as follows: By using the PID algorithm to control the mechanical claw 6 so that it can simulate the actions of manual operation, it can perform the operations of removing screws, knocking the mold, pulling open the mold and taking out the workpiece.

[0021] Step 3 is implemented as follows: Step 3.1, remove the screws; Step 3.2, tap the mold: Step 3.3, demoulding operation.

[0022] Step 3.1 is implemented as follows: First, the PID controller is initialized and the initial parameters of the proportion Kp, integral Ki and differential Kd are set; then the camera 7 set on the top inner surface of the gantry structure 3 is used to collect the position of the connecting screws of the mold A and the mold B, and the position signal detected by the camera 7 is transmitted to the control unit, so as to control the mechanical claw 6 to move to the top of each corresponding connecting screw in turn; then the pressure sensor in the top screw assembly 10 at the four corners of the mold is started, and the pressure sensor in the top screw assembly 10 is activated to detect the contact force between the mold and the top screw in the top screw assembly 10; according to the feedback of the pressure sensor in the top screw assembly 10, the torque of the mechanical claw 6 is adjusted using the PID algorithm to achieve accurate screw loosening; Step 3.2 is implemented as follows: The camera 7 is used to determine the specific position on the mold that needs to be knocked, including the mold gap and mold edge that the mechanical claw can penetrate, but it is necessary to avoid directly knocking on the surface where the workpiece and the mold are in contact; then the mechanical claw 6 is controlled to move above the knocking point, and by analyzing the force change of the pressure sensor in the top screw assembly 10, the force whose size and action position have changed due to external interference is adjusted to a suitable size and direction to ensure the accuracy and strength of the knocking, and the knocking strength and frequency of the mechanical claw 6 are adjusted at all times to ensure the stability and performance of the system; by real-time monitoring of the data of the pressure sensor and posture sensor in the top screw assembly 10, the posture and force of the mold can be detected in real time, and the change of the sensor data indicates the separation state of the mold and the workpiece. When it is confirmed that the mold and the workpiece are properly separated, that is, when the pressure sensor in the top screw assembly 10 shows that the pressure between the mold and the workpiece has changed significantly and the posture sensor shows that the workpiece has slightly moved, prepare for the next step of disengaging the mold.

[0023] Step 3.3 is implemented according to the following steps: The camera 7 is used for visual recognition to accurately locate the mold, especially to identify the key positions on the edge of the upper half of the mold, namely, the mold gap and mold edge where the mechanical claw can penetrate. The mechanical claw moves to the initial demoulding position according to these feedback information; at this moment, the hydraulic system 9 is activated to provide power for the top screw in the top screw assembly 10. In the process of pushing the mold open, multiple sensors on the mold play a role. The pressure sensor in the top screw assembly 10 monitors the strength of the contact point between the top screw in the top screw assembly 10 and the mold in real time to ensure that the applied force is within a safe range. The posture sensor monitors the tilt angle and direction of the mold to prevent any mold tilt that may cause the workpiece to get stuck. The camera 7 provides real-time images to help analyze the relative position of the mold and the workpiece and the movement of the mold; by integrating these sensor data, the control unit applies The PID control algorithm dynamically adjusts the action of the push screws in the hydraulic system 9 and the push screw assembly 10 to achieve precise control; when pushing open the upper part of the mold, the control unit will calculate the required force and speed in real time to ensure that the mold is evenly stressed and avoid sudden or uneven force that causes damage to the workpiece or mold. In order to prevent the mold from tilting, once the posture sensor detects any tilting trend, the control unit will respond quickly and adjust the force application point and force of the push screw in the push screw assembly 10 to correct the mold posture and maintain the smoothness and synchronization of the demolding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and workpiece throughout the demolding process. When the upper part of the mold is completely separated and the various sensors confirm that the workpiece is not stuck or damaged, the mechanical claw 6 will stop the demolding action and move to a safe position to wait for the next instruction.

[0024] The separation of the workpiece and the mold is carried out according to the following steps: Step a, install the lifting ring: install a special lifting ring at the center of the pot-type insulator, ensure that the lifting ring is firmly connected to the pot-type insulator and can bear the weight of the insulator; Step b, tighten the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop when the value of the pressure sensor begins to decrease and keep it stable; Step c, applying force with a top screw: inserting a top screw in the top screw assembly 10 into the top screw hole 13 below the mold, and applying a uniform upward force to the bottom of the insulator by using the top screw to assist in separating the pot-type insulator from the mold; Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the molecular attraction between the two surfaces is destroyed, the demoulding resistance is reduced, so as to ensure the complete demoulding of the insulator and prevent residues and defects on the mold.

[0025] Step e, monitoring the force on the top screw: obtaining the force condition of the top screw in the top screw assembly 10 through the force data of the monitoring pressure sensor in the top screw assembly 10 in real time, judging the separation state of the insulator and the mold, and ensuring the complete demolding of the insulator; Step f, removing the workpiece: when the control unit displays that the force on the top screw in the top screw assembly 10 is zero, it indicates that the insulator has completely separated from the mold, and the operator moves the insulator to a designated safe area smoothly and quickly; Step g, cleaning the mold: Use an overhead crane to move mold B2 to the cleaning line for cleaning and maintenance in preparation for the next round of production.

[0026] From the above, it can be seen that the multi-sensor fusion technology and robust control algorithm adopted by the present invention can ensure the accuracy of the demoulding process and the integrity of the workpiece. By simulating manual operation, the present invention can achieve automated demoulding, improve production efficiency and operation continuity. At the same time, the flexible force application strategy effectively avoids damage to the workpiece and improves the demoulding quality.

[0027] Example 1 The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0028] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

[0029] Example 2 The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0030] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 1 is as follows: Use an overhead crane to lift the cured pot-type insulator mold to the mobile platform 4, and Figure 1 , Figure 2A gantry structure 3 is set up at the other end of the mobile platform 4, and the slide rail of the mobile platform 4 is located at the bottom middle position of the gantry structure 3. The cured pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demoulding. A pair of flip motors 5 are symmetrically installed at the middle and lower parts of the two side columns of the gantry structure 3. The flip motor 5 is electrically connected to the control unit, and the output shaft of the flip motor 5 is connected to the mold B2 to control the rotational power required when the mold B2 is separated from the pot-type insulator. A mechanical claw 6 is also installed on the inner surface in the middle of the upper part of the gantry structure 3, and a camera 7 is installed next to the mechanical claw 6. The workpiece demoulding push rod 11 passes through the upper middle of the gantry structure 3 and is connected to the mechanical claw 6. The mold B2 is also connected to the hydraulic system 9 and the pneumatic system 8. The cured pot-type insulator mold A1 is fixed on the L-shaped bracket 12 of the mobile platform 4. The L-shaped bracket 12 has a stable support structure and can withstand the weight of the mold and the force that may be generated during the demoulding process.

[0031] Step 2: Install the sensor; Step 3: Control demoulding.

[0032] Example 3 The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0033] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 1 is as follows: Use an overhead crane to lift the cured pot-type insulator mold to the mobile platform 4, and Figure 1 , Figure 2A gantry structure 3 is set up at the other end of the mobile platform 4, and the slide rail of the mobile platform 4 is located at the bottom middle position of the gantry structure 3. The cured pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demoulding. A pair of flip motors 5 are symmetrically installed at the middle and lower parts of the two side columns of the gantry structure 3. The flip motor 5 is electrically connected to the control unit, and the output shaft of the flip motor 5 is connected to the mold B2 to control the rotational power required when the mold B2 is separated from the pot-type insulator. A mechanical claw 6 is also installed on the inner surface in the middle of the upper part of the gantry structure 3, and a camera 7 is installed next to the mechanical claw 6. The workpiece demoulding push rod 11 passes through the upper middle of the gantry structure 3 and is connected to the mechanical claw 6. The mold B2 is also connected to the hydraulic system 9 and the pneumatic system 8. The cured pot-type insulator mold A1 is fixed on the L-shaped bracket 12 of the mobile platform 4. The L-shaped bracket 12 has a stable support structure and can withstand the weight of the mold and the force that may be generated during the demoulding process.

[0034] Step 2: Install the sensor; Step 2 is as follows: Select a top screw assembly 10 with appropriate range and accuracy, and Figure 2 As shown in the position, use a measuring tool to measure the accurate installation center point at the four corners of the mold to install the top screw assembly 10, so that the installation positions of the pressure sensors in the four top screw assemblies 10 are symmetrically distributed to ensure that the stress condition of the mold can be evenly monitored; accurately measure the center position of the mold, install the posture sensor at the center position of the mold, ensure that the posture sensor is installed horizontally, and the measurement coordinate axis of the posture sensor is consistent with the actual coordinate axis of the mold, so as to accurately monitor the inclination angle of the mold in real time; the hydraulic system 9 is connected to the top screw, and the hydraulic system 9 is controlled to apply force to the top screw during the demoulding process to assist in demoulding. The pressure at the main oil pipe after the hydraulic pump outlet of the hydraulic system 9 can reflect the overall force applied by the hydraulic system 9. A force sensor is installed on the hydraulic pipeline here to measure the force applied by the hydraulic system 9. The signal output cables of the pressure sensors, attitude sensors and force sensors on the hydraulic pipelines in the four top screw assemblies 10 are connected according to the input interface type corresponding to the control unit, each sensor channel is numbered and marked on the control unit end, and the corresponding sensor range, zero point calibration, filtering parameters, sensor working mode, and accuracy setting parameters are configured on the control unit end, so as to accurately convert and analyze the collected data in the future, and realize accurate monitoring and control of the mold demolding process; Step 3: Control demoulding.

[0035] Example 4 The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0036] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

[0037] The separation of the workpiece and the mold is carried out according to the following steps: Step a, install the lifting ring: install a special lifting ring at the center of the pot-type insulator, ensure that the lifting ring is firmly connected to the pot-type insulator and can bear the weight of the insulator; Step b, tighten the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop and keep stable when the value of the pressure sensor in the top screw assembly 10 begins to decrease; Step c, applying force with the top screw: insert the top screw in the top screw assembly 10 into the top screw hole below the mold, and use the top screw assembly 10 to apply a uniform upward force to the bottom of the insulator to assist the separation of the pot-type insulator from the mold B; Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the molecular attraction between the two surfaces is destroyed, the demoulding resistance is reduced, so as to ensure the complete demoulding of the insulator and prevent residues and defects on the mold.

[0038] Step e, monitoring the force on the top screw: by real-time monitoring the force data of the pressure sensor in the top screw assembly 10, the force condition of the top screw in the top screw assembly 10 is obtained, the separation state of the insulator and the mold is determined, and the insulator is completely demolded; Step f, removing the workpiece: when the control unit displays that the force on the top screw in the top screw assembly 10 is zero, it indicates that the insulator has completely separated from the mold, and the operator moves the insulator to a designated safe area smoothly and quickly; Step g, cleaning the mold: Use an overhead crane to move mold B to the cleaning line for cleaning and maintenance in preparation for the next round of production.

[0039] From the above, it can be seen that the multi-sensor fusion technology and robust control algorithm adopted by the present invention can ensure the accuracy of the demoulding process and the integrity of the workpiece. By simulating manual operation, the present invention can achieve automated demoulding, improve production efficiency and operation continuity. At the same time, the flexible force application strategy effectively avoids damage to the workpiece and improves the demoulding quality.

[0040] Example 5 The multi-sensor fusion basin-type insulator automatic demoulding method of the present invention is divided into two major parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. The contact position with the workpiece is used as the dividing line, the part above the dividing line is the upper half, and the part below the dividing line is the lower half. The workpiece is wrapped by mold A1 and mold B2.

[0041] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

[0042] Step 3 is as follows: By using the PID algorithm to control the mechanical claw 6 so that it can simulate the actions of manual operation, it can perform the operations of removing screws, knocking the mold, pulling open the mold and taking out the workpiece.

[0043] Step 3 is implemented as follows: Step 3.1, remove the screws; Step 3.2, tap the mold: Step 3.3, demoulding operation.

[0044] Step 3.1 is implemented as follows: First, the PID controller is initialized, and the initial proportional Kp, integral Ki, and differential Kd parameters are set; then, the camera 7 set on the top inner surface of the gantry structure 3 is used to collect the connection screw positions of the mold A and the mold B, and the position signal detected by the camera 7 is transmitted to the control unit, so as to control the mechanical claw 6 to move to the top of each corresponding connection screw in turn; then, the pressure sensor in the top screw assembly 10 at the four corners of the mold is started, and the pressure sensor in the top screw assembly 10 is activated to detect the contact force between the mold and the top screw in the top screw assembly 10; according to the feedback from the pressure sensor in the top screw assembly 10, the torque of the mechanical claw 6 is adjusted using the PID algorithm to achieve accurate screw loosening; Step 3.2 is implemented as follows: The camera 7 is used to determine the specific position on the mold that needs to be knocked, including the mold gap and mold edge that the mechanical claw can penetrate, but it is necessary to avoid directly knocking on the surface where the workpiece and the mold are in contact; then the mechanical claw 6 is controlled to move above the knocking point, and by analyzing the force change of the pressure sensor in the top screw assembly 10, the force whose size and action position have changed due to external interference is adjusted to a suitable size and direction to ensure the accuracy and strength of the knocking, and the knocking strength and frequency of the mechanical claw 6 are adjusted at all times to ensure the stability and performance of the system; by real-time monitoring of the data of the pressure sensor and posture sensor in the top screw assembly 10, the posture and force of the mold can be detected in real time, and the change of the sensor data indicates the separation state of the mold and the workpiece. When it is confirmed that the mold and the workpiece are properly separated, that is, when the pressure sensor in the top screw assembly 10 shows that the pressure between the mold and the workpiece has changed significantly and the posture sensor shows that the workpiece has slightly moved, prepare for the next step of disengaging the mold.

[0045] Step 3.3 is implemented according to the following steps: The camera 7 is used for visual recognition to accurately locate the mold, especially to identify the key positions on the edge of the upper half of the mold, that is, the mold gap and mold edge where the mechanical claw can penetrate. The mechanical claw moves to the initial demoulding position according to these feedback information; at this moment, the hydraulic system 9 is activated to provide power for the top screw in the top screw assembly 10. In the process of pushing the mold open, multiple sensors on the mold play a role. The pressure sensor in the top screw assembly 10 monitors the strength of the contact point between the top screw and the mold in real time to ensure that the applied force is within a safe range. The posture sensor monitors the tilt angle and direction of the mold to prevent any mold tilt that may cause the workpiece to get stuck. The camera 7 provides real-time images to help analyze the relative position of the mold and the workpiece and the movement of the mold; by integrating these sensor data, the control unit applies PI D control algorithm dynamically adjusts the action of hydraulic system 9 and top screw assembly 10 to achieve precise control; when pushing open the upper part of the mold, the control unit will calculate the required force and speed in real time to ensure that the mold is evenly stressed and avoid damage to the workpiece or mold due to sudden or uneven force. In order to prevent the mold from tilting, once the posture sensor detects any tilting trend, the control unit will respond quickly and adjust the force application point and force of the top screw in the top screw assembly 10 to correct the mold posture and maintain the stability and synchronization of the demolding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and workpiece during the entire demolding process. When the upper part of the mold is completely separated and the various sensors confirm that the workpiece is not stuck or damaged, the mechanical claw 6 will stop the demolding action and move to a safe position to wait for the next instruction.

[0046] The separation of the workpiece and the mold is carried out according to the following steps: Step a, install the lifting ring: install a special lifting ring at the center of the pot-type insulator, ensure that the lifting ring is firmly connected to the pot-type insulator and can bear the weight of the insulator; Step b, tighten the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop and keep stable when the value of the pressure sensor in the top screw assembly 10 begins to decrease; Step c, applying force with the top screw: insert the top screw assembly 10 into the top screw hole below the mold, and use the top screw assembly 10 to apply a uniform upward force to the bottom of the insulator to assist the pot-type insulator to separate from the mold B; Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the molecular attraction between the two surfaces is destroyed, the demoulding resistance is reduced, so as to ensure the complete demoulding of the insulator and prevent residues and defects on the mold.

[0047] Step e, monitoring the force of the top screw: obtaining the force condition of the top screw in the top screw assembly 10 by monitoring the force data of the pressure sensor in the top screw assembly 10 in real time, judging the separation state of the insulator and the mold, and ensuring the complete demolding of the insulator; Step f, removing the workpiece: when the control unit displays that the force on the top screw in the top screw assembly 10 is zero, it indicates that the insulator has completely separated from the mold, and the operator moves the insulator to a designated safe area smoothly and quickly; Step g, cleaning the mold: Use an overhead crane to move mold B2 to the cleaning line for cleaning and maintenance in preparation for the next round of production.

[0048] From the above, it can be seen that the multi-sensor fusion technology and robust control algorithm adopted by the present invention can ensure the accuracy of the demoulding process and the integrity of the workpiece. By simulating manual operation, the present invention can achieve automated demoulding, improve production efficiency and operation continuity. At the same time, the flexible force application strategy effectively avoids damage to the workpiece and improves the demoulding quality.

[0049] Example 6 Through this specific use case, it can be seen that the automatic demoulding equipment can accurately control the demoulding process, reduce manual intervention, and improve production efficiency and product quality. At the same time, through real-time monitoring and flexible force application strategies, the integrity of the insulator and the service life of the mold are ensured.

[0050] Next, the technical route of mold posture detection during the operation of the automatic demoulding device for pot-type insulators is introduced in detail.

[0051] 1. Arrange multiple pressure sensors in the screw assembly (10) on the mechanical claw and its edges and corners where it contacts the mold. The distribution of the sensors should ensure that they can fully cover the contact surface of the mold so as to obtain uniform pressure measurement data.

[0052] 2. The pressure sensor in each screw assembly 10 is connected to the data acquisition system to collect the pressure data of the contact surface between the mold and the workpiece in real time. The preprocessing step includes filtering and calibration to eliminate noise and errors and ensure the accuracy of the data.

[0053] 3. A Bayesian data fusion method (a common multi-sensor data fusion method that fuses information from different sensors based on the Bayesian theorem to calculate the posterior probability distribution. This usually includes the product of the joint probability distribution and normalization operations) is used to comprehensively analyze the data from the pressure sensors in each top screw assembly 10. By establishing a probability model, combining prior knowledge and observation data, and calculating the fusion value of the pressure data, it helps to improve the estimation accuracy of the stress state of the mold.

[0054] 4. Posture sensors, such as gyroscopes and accelerometers, are installed at the center of the robot palm and the mold. The two work together to monitor the posture changes of the mold in real time. These sensors can detect the tilt angle and direction of the mold in space.

[0055] 5. The data obtained by the posture sensor is secondary fused with the fusion value of the pressure sensor in the top screw assembly 10 to further correct the stress state of the mold. This step helps to more accurately estimate the actual posture and force distribution of the mold.

[0056] 6. Based on the secondary fusion data, the system calculates the final demoulding amount estimate, which reflects the actual degree of separation between the mold and the workpiece and is a key parameter for controlling the demoulding process.

[0057] 7. Using the intelligent robust control method, the control strategy of the actuator is dynamically adjusted according to the estimated value of the demolding amount. The control system will output appropriate control quantities, such as the pressure and flow of the hydraulic cylinder, to achieve flexible force application.

[0058] 8. The actuator performs precise force control based on the control amount to ensure that the force between the mold and the workpiece is sufficient to separate the two without causing damage to the workpiece. During the entire demolding process, the system will continuously monitor and adjust the force strategy until the mold and the workpiece are completely separated.

Claims

1. The multi-sensor fusion basin insulator automatic demoulding method is characterized by: It is divided into two major parts: the upper part of the mold is disengaged and the workpiece is separated from the mold. The contact position with the workpiece is used as the dividing line. The part above the dividing line is the upper part, and the part below the dividing line is the lower part. The workpiece is wrapped by mold A (1) and mold B (2).

2. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 1 is characterized in that: The upper part of the contact point between the mold A (1) and the workpiece is disengaged in accordance with the following steps: Step 1: Position the mold; Step 2: Install the sensor; Step 3: Control demoulding.

3. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 2 is characterized in that: The step 1 is specifically as follows: using an overhead crane to lift the cured pot-type insulator mold onto a mobile platform (4); a gantry structure (3) is mounted on the other end of the mobile platform (4); a slide rail of the mobile platform (4) is located at the bottom middle position of the gantry structure (3); the cured pot-type insulator mold can slide along the slide rail to a position directly below the gantry structure (3) to wait for demoulding; a pair of flip motors (5) are symmetrically installed at the middle and lower parts of the two side columns of the gantry structure (3); the flip motors (5) are electrically connected to the control unit; the flip motors (5) The output shaft is connected to the mold B (2) to control the rotational power required when the mold B (2) is separated from the pot-type insulator. A mechanical claw (6) is also installed on the inner surface of the middle of the upper part of the gantry structure (3). A camera (7) is installed next to the mechanical claw (6). The workpiece demoulding ejector (11) passes through the middle of the upper part of the gantry structure (3) and is connected to the mechanical claw (6). The mold B (2) is also connected to the hydraulic system (9) and the pneumatic system (8) to fix the cured pot-type insulator mold A (1) on the L-shaped bracket (12) of the mobile platform (4).

4. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 3 is characterized in that: The step 2 is specifically as follows: installing the top screw assembly (10) at the installation center points of the four corners of the mold, so that the top screw installation positions in the four top screw assemblies (10) are symmetrically distributed, ensuring that the force condition of the mold can be evenly monitored; accurately measuring the center position of the mold, installing a posture sensor at the center position of the mold, ensuring that the posture sensor is installed horizontally, the measurement coordinate axis of the posture sensor is consistent with the actual coordinate axis of the mold, and real-time and accurate monitoring of the inclination angle of the mold; the hydraulic system (9) is connected to the top screw assembly (10), and during the demoulding process, the hydraulic system (9) is controlled to apply force to the top screw to assist in demoulding, and the main oil after the hydraulic pump outlet of the hydraulic system (9) is The pressure at the pipe can reflect the overall force applied by the hydraulic system (9). A force sensor is installed on the hydraulic pipeline to measure the force applied by the hydraulic system (9). The signal output cables of the pressure sensors, the posture sensors in the four screw assemblies (10) and the force sensor on the hydraulic pipeline are connected according to the input interface type corresponding to the control unit. Each sensor channel is numbered and marked on the control unit end, and the corresponding sensor range, zero point calibration, filtering parameters, sensor working mode, and accuracy setting parameters are configured on the control unit end so that the collected data can be accurately converted and analyzed later, thereby realizing accurate monitoring and control of the mold demoulding process.

5. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 4 is characterized in that: The step 3 is specifically as follows: by using a PID algorithm to control the mechanical claw (6) so that it can simulate the actions of manual operation, and perform the operations of removing screws, knocking the mold, pulling open the mold, and removing the workpiece.

6. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 5 is characterized in that: The step 3 is specifically implemented according to the following steps: Step 3.1, remove the screws; Step 3.2, tap the mold: Step 3.3, demoulding operation.

7. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 6 is characterized in that: The step 3.1 is specifically implemented according to the following steps: First, the PID controller is initialized and the initial proportional Kp, integral Ki and differential Kd parameters are set; then, the position of the connecting screws of the mold A and the mold B is collected by using a camera (7) arranged on the inner surface of the top of the gantry structure (3), and the position signal detected by the camera (7) is transmitted to the control unit, thereby controlling the mechanical claw (6) to move to the top of each corresponding connecting screw in turn; then, the pressure sensor in the top screw assembly (10) at the four corners of the mold is started, and the pressure sensor in the top screw assembly (10) is activated to detect the contact force between the mold and the top screw in the top screw assembly (10); according to the feedback of the pressure sensor in the top screw assembly (10), the torque of the mechanical claw (6) is adjusted using the PID algorithm to achieve accurate screw loosening.

8. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 7 is characterized in that: The step 3.2 is specifically implemented according to the following steps: The specific position on the mold to be struck is determined by using a camera (7), including the mold gap and mold edge where the mechanical claw (6) can penetrate, but it is necessary to avoid directly striking the surface of the workpiece in contact with the mold; then the mechanical claw (6) is controlled to move above the striking point, and by analyzing the force change of the pressure sensor in the top screw assembly (10), the force whose size and action position have changed due to external interference is adjusted to a suitable size and direction to ensure the accuracy and strength of the striking, and the striking strength and frequency of the mechanical claw (6) are adjusted at all times, thereby ensuring the stability and performance of the system; by real-time monitoring of the data of the pressure sensor and the posture sensor in the top screw assembly (10), the posture and force of the mold are detected in real time, and the change of the sensor data indicates the separation state of the mold and the workpiece. When it is confirmed that the mold and the workpiece are properly separated, that is, when the pressure sensor in the top screw assembly (10) shows that the pressure between the mold and the workpiece has changed significantly and the posture sensor shows that the workpiece has slightly moved, preparations are made for the next step of disengaging the mold.

9. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 8, characterized in that: The step 3.3 is specifically implemented according to the following steps: The camera (7) is used for visual recognition to accurately locate the mold, especially to identify the key position of the edge of the upper half of the mold, that is, the mold gap and the mold edge where the mechanical claw can penetrate. The mechanical claw moves to the initial demoulding position according to these feedback information; at this moment, the hydraulic system (9) is activated to provide power for the push screw in the push screw assembly (10). In the process of pushing the mold open, multiple sensors on the mold play a role. The pressure sensor in the push screw assembly (10) monitors the strength of the contact point between the push screw and the mold in real time to ensure that the applied force is within a safe range. The posture sensor monitors the tilt angle and direction of the mold to prevent any mold tilt that may cause the workpiece to get stuck. The camera (7) provides real-time images to help analyze the relative position of the mold and the workpiece and the movement of the mold; by integrating these sensor data, the control unit applies PID The control algorithm dynamically adjusts the action of the push screw in the hydraulic system (9) and the push screw assembly (10) to achieve precise control. When pushing open the upper part of the mold, the control unit calculates the required force and speed in real time to ensure that the mold is evenly stressed and avoid damage to the workpiece or mold due to sudden or uneven force. In order to prevent the mold from tilting, once the posture sensor detects any tilting trend, the control unit will respond quickly and adjust the force point and force of the push screw in the push screw assembly (10) to correct the mold posture and maintain the stability and synchronization of the demoulding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and the workpiece during the entire demoulding process. When the upper part of the mold is completely separated and the various sensors confirm that the workpiece is not stuck or damaged, the mechanical claw (6) will stop the demoulding action and move to a safe position to wait for the next instruction.

10. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 9, characterized in that: The separation of the workpiece and the mold is specifically implemented according to the following steps: Step a, install the lifting ring: install a special lifting ring at the center of the pot-type insulator, ensure that the lifting ring is firmly connected to the pot-type insulator and can bear the weight of the insulator; Step b, tighten the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop when the value of the pressure sensor begins to decrease and keep it stable; Step c, applying force with a push screw: inserting the push screw assembly (10) into the push screw hole below the mold, and using the push screw in the push screw assembly (10) to apply a uniform upward force to the bottom of the insulator, thereby assisting the separation of the pot-type insulator from the mold B; Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the molecular attraction between the two surfaces is destroyed, the demoulding resistance is reduced, so as to ensure the complete demoulding of the insulator and prevent residues and defects on the mold; Step e, monitoring the force on the top screw: by real-time monitoring the force data of the pressure sensor in the top screw assembly (10), the force condition of the top screw in the top screw assembly (10) is obtained, the separation state of the insulator and the mold is determined, and the complete demoulding of the insulator is ensured; Step f, removing the workpiece: when the control unit displays that the force on the top screw in the top screw assembly (10) is zero, it indicates that the insulator has completely separated from the mold, and the operator smoothly and quickly moves the insulator to a designated safe area; Step g, cleaning the mold: Use an overhead crane to move mold B to the cleaning line for cleaning and maintenance in preparation for the next round of production.

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