Multi-sensor fusion based automatic de-moulding method for pot insulator

Abstract

The application discloses a multi-sensor fusion automatic demolding method for a basin type insulator, which is divided into two parts of a mold upper half part separation and a workpiece and mold separation, wherein a contact position with the workpiece is taken as a demarcation line, an upper half part is above the demarcation line, a lower half part is below the demarcation line, and the workpiece is jointly wrapped by a mold A and a mold B. The application effectively avoids the problems of workpiece damage and unclean demolding, improves production efficiency, and reduces safety risks.

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 based on 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 increasing. 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 achieve 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 basin insulator automatic demoulding method, which effectively avoids workpiece damage and unclean demoulding problems, improves production efficiency and reduces safety risks.

[0004] The technical solution employed in this invention is a multi-sensor fusion method for automatically demolding pot-type insulators. This method involves two major steps: disengaging the upper mold portion and separating the workpiece from the mold. The workpiece is enclosed by both molds A and B, with the upper portion above the contact point with the workpiece serving as the dividing line, and the lower portion below the dividing line serving as the lower portion.

[0005] The present invention is also characterized in that:

[0006] The upper part of the contact point between mold A and the workpiece is disengaged according to the following steps:

[0007] Step 1: Position the mold;

[0008] Step 2: Install the sensor;

[0009] Step 3: Control demoulding.

[0010] Step 1 is as follows: using the crown block, the solidified pot-type insulator mold is lifted to the moving platform, the other end of the moving platform is equipped with a gantry structure, the sliding rail of the moving platform is located at the lowermost middle position of the gantry structure, the solidified pot-type insulator mold can slide along the sliding rail to the position directly below the gantry structure to wait for demolding, a pair of overturning motors is symmetrically installed at the middle-lower part of the two side columns of the gantry structure, the overturning motors are electrically connected with the control unit, the output shaft of the overturning motor is connected with the mold B, the overturning motor controls the rotating power required when the mold B is separated from the pot-type insulator, a mechanical claw is installed at the inner surface of the upper middle part of the gantry structure, a camera is installed beside the mechanical claw, a workpiece demolding ejector pin penetrates through the upper middle part of the gantry structure and is connected with the mechanical claw, the mold B is also connected with the hydraulic system and the pneumatic system, and the solidified pot-type insulator mold A is fixed on the L-shaped support of the moving platform.

[0011] Step 2 is as follows: a center point is installed at each corner of the mold, and a top pin assembly is installed at the center point, the top pin assembly includes a pressure sensor and a top pin, the four top pins and the installation positions of the pressure sensors are symmetrically distributed, and the force condition of the mold can be uniformly monitored; the center position of the mold is accurately measured, a posture sensor is installed at the center position of the mold, 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 the inclination angle of the mold is accurately monitored in real time; the top pin in the top pin assembly is connected with the hydraulic system, the hydraulic system controls the force applied to the top pin in the top pin assembly during demolding, and is used for assisting demolding, the pressure at the main oil pipe after the outlet of the hydraulic pump of the hydraulic system can reflect the overall force applied by the hydraulic system, and a force sensor is installed on the hydraulic pipeline to measure the force applied by the hydraulic system. The signal output cables of the pressure sensors in the four top pin assemblies, the posture sensor and the force sensor on the hydraulic pipeline are connected according to the types of the input interfaces of the control unit, each sensor channel is numbered and marked at the control unit end, and the corresponding sensor range, zero point calibration, filtering parameter, sensor working mode and precision setting parameter are configured at the control unit end, so that the collected data can be accurately converted and analyzed, and the demolding process of the mold can be accurately monitored and controlled;

[0012] Step 3 is as follows: the mechanical claw is controlled by using the PID algorithm to simulate the action of manual operation, and the screws are disassembled, the mold is knocked, the mold is pulled open, and the workpiece is taken out.

[0013] Step 3 is implemented according to the following steps:

[0014] Step 3.1, disassembling the screws;

[0015] Step 3.2, knocking the mold:

[0016] Step 3.3, demolding operation.

[0017] Step 3.1 is implemented as follows:

[0018] First, the PID controller is initialized, setting the initial proportional Kp, integral Ki, and differential Kd parameters. A camera mounted on the inner surface of the gantry structure's top surface captures the position of the connecting screws between molds A and B. The position signals detected by the camera are transmitted to the control unit, which controls the robotic gripper to move to the position directly above each corresponding connecting screw. Pressure sensors in the screw assemblies at the four corners of the mold are then activated to detect the contact force between the mold and the screws in the assembly. Based on feedback from the pressure sensors, the PID algorithm is used to adjust the gripper's torque to precisely loosen the screws.

[0019] Step 3.2 is implemented as follows:

[0020] Use the camera to determine the specific location on the mold that needs to be knocked, including the mold gap and mold edge that the mechanical claw can penetrate, but avoid directly knocking on the surface where the workpiece and the mold are in contact; then control the mechanical claw to move above the knocking point, and by analyzing the force changes of the pressure sensor in the top screw assembly, adjust the force that changes in size and position due to external interference to the appropriate size and direction to ensure the accuracy and strength of the knocking, and adjust the knocking force and frequency of the mechanical claw 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, the posture and force of the mold can be detected in real time. 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 had a slight displacement, prepare for the next step of disengaging the mold.

[0021] Step 3.3 is implemented as follows:

[0022] 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 according to this 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 ejector screws in the ejector screw assembly to achieve precise control. When pushing open the upper half 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. To prevent the mold from tilting, once the posture sensor detects any tilting trend, the control unit responds quickly and adjusts the force application point and force of the ejector screws in the ejector screw assembly 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 half 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 await the next instruction.

[0023] The separation of the workpiece and the mold is carried out in the following steps:

[0024] Step a: Install the lifting ring: Install a special lifting ring at the center of the pot insulator, ensuring that the lifting ring is firmly connected to the pot insulator and can bear the weight of the insulator;

[0025] Step b, hang the workpiece: operate the overhead crane and slowly lift the lifting ring to make the basin insulator completely suspended and stable;

[0026] Step c, applying force with a jackscrew: insert the jackscrew in the jackscrew assembly into the jackscrew hole below the mold, and use the jackscrew in the jackscrew assembly to apply a uniform upward force to the bottom of the insulator to assist in separating the pot-type insulator from the mold B;

[0027] Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the intermolecular 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.

[0028] Step e, monitoring the force on the top screw in the top screw assembly: obtaining the force on 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;

[0029] Step f, removing the workpiece: When the control unit indicates 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;

[0030] 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.

[0031] The beneficial effect of the present invention is that the automatic demoulding method for pot-type insulators with multi-sensor fusion can realize fully automated demoulding operations, 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

[0032] Figure 1 It is the technical roadmap of automatic demoulding equipment;

[0033] Figure 2 It is a schematic diagram of the main structure of automatic demoulding equipment.

[0034] 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. Screw assembly, 11. Workpiece demoulding ejector pin, 12. L-shaped bracket, 13. Screw hole. DETAILED DESCRIPTION

[0035] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0036] The multi-sensor fusion automatic demoulding method for pot-type insulators of the present invention is divided into two parts: the disengagement of the upper half of the mold and the separation of the workpiece and 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 both mold A1 and mold B2.

[0037] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps:

[0038] Step 1: Position the mold;

[0039] Step 2: Install the sensor;

[0040] Step 3: Control demoulding.

[0041] Step 1 is as follows: Use an overhead crane to lift the solidified 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 solidified pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demolding. A pair of flip motors 5 are also symmetrically installed in 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. 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. A camera 7 is installed next to the mechanical claw 6. The workpiece demolding push rod 11 passes through the middle of the upper part 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 solidified 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 that can withstand the weight of the mold and the force that may be generated during the demolding process.

[0042] Step 2 is as follows: Select a top screw assembly 10 with appropriate range and accuracy, and follow the steps below: Figure 2As shown, use measuring tools to measure the accurate installation center points 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, ensuring that the force 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. Connect the signal output cables of the pressure sensors, attitude sensors, and force sensors on the hydraulic pipeline in the four top screw assemblies 10 according to the corresponding input interface types of the control unit. Number and mark each sensor channel 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 that the collected data can be accurately converted and analyzed later to achieve precise monitoring and control of the mold demolding process.

[0043] 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 actions of removing screws, knocking the mold, pulling open the mold and removing the workpiece.

[0044] Step 3 is implemented as follows:

[0045] Step 3.1, remove the screws;

[0046] Step 3.2, tap the mold:

[0047] Step 3.3, demoulding operation.

[0048] Step 3.1 is implemented as follows:

[0049] First, the PID controller is initialized, and the initial proportional Kp, integral Ki, and differential Kd parameters are set. A camera 7, mounted on the top inner surface of the gantry structure 3, is then used to capture the position of the connecting screws between molds A and B. The position signals detected by the camera 7 are transmitted to the control unit, which controls the mechanical gripper 6 to move sequentially to the position directly above each corresponding connecting screw. The pressure sensors in the screw assemblies 10 at the four corners of the mold are then activated to detect the contact force between the mold and the screws in the screw assemblies 10. Based on the feedback from the pressure sensors in the screw assemblies 10, the torque of the mechanical gripper 6 is adjusted using the PID algorithm to precisely loosen the screws.

[0050] Step 3.2 is implemented as follows:

[0051] The specific position on the mold that needs to be knocked is determined by the camera 7, including the mold gap where the mechanical claw can penetrate and the edge of the mold, but direct knocking of the surface of the workpiece in contact with the mold is avoided; then the mechanical claw 6 is controlled to move above the knocking point, the force that changes in size and acting position due to external interference is adjusted to the appropriate size and orientation to ensure the accuracy and force of the knocking by analyzing the force change of the pressure sensor in the jack assembly 10, the knocking force and frequency of the mechanical claw 6 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 monitoring the data of the pressure sensor and the posture sensor in the jack assembly 10 in real time, 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 jack assembly 10 shows that the pressure of the mold and the workpiece has a relatively obvious change and the posture sensor shows that the workpiece has a slight displacement, the next step of preparing to disengage the mold is prepared.

[0052] Step 3.3 is implemented according to the following steps:

[0053] The mold is accurately positioned by visual recognition using the camera 7, especially the key positions of the upper edge of the mold, i.e., the mold gap where the mechanical claw can penetrate and the edge of the mold. The mechanical claw moves to the initial demolding position according to these feedback information. At this moment, the hydraulic system 9 is activated to provide power for the jacks in the jack assembly 10. During the process of jacking the mold, multiple sensors on the mold play a role. The pressure sensor in the jack assembly 10 monitors the force of the contact point between the jack in the jack assembly 10 and the mold in real time to ensure that the applied force is within a safe range. The posture sensor monitors the inclination angle and direction of the mold to prevent any mold inclination that may cause the workpiece to be 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 a PID control algorithm to dynamically adjust the actions of the hydraulic system 9 and the jacks in the jack assembly 10 to achieve precise control. When jacking 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 uniformly stressed and to avoid sudden or uneven force application that may cause damage to the workpiece or the mold. In order to prevent the mold from tilting, as soon as the posture sensor detects any tilting trend, the control unit will quickly respond to adjust the force point and force of the jacks in the jack assembly 10 to correct the posture of the mold and maintain the stability and synchronization of the demolding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and the workpiece during the entire demolding process. When the upper part of the mold is completely separated and the sensors confirm that the workpiece has not been stuck or damaged, the mechanical claw 6 will stop the demolding action and move to a safe position to wait for the next instruction.

[0054] The separation of the workpiece and the mold is carried out in the following steps:

[0055] Step a: Install the lifting ring: Install a special lifting ring at the center of the pot insulator, ensuring that the lifting ring is firmly connected to the pot insulator and can bear the weight of the insulator;

[0056] Step b, hoist the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop when the pressure sensor value begins to decrease and keep it stable;

[0057] Step c, applying force with the jackscrew: insert the jackscrew in the jackscrew assembly 10 into the jackscrew hole 13 below the mold, and use the jackscrew to apply a uniform upward force to the bottom of the insulator to assist in separating the pot-type insulator from the mold;

[0058] Step d, introducing compressed air: By introducing compressed air between the pot-type insulator and the mold, the intermolecular 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.

[0059] Step e, monitoring the force on the top screw: obtaining the force on the top screw in the top screw assembly 10 through the real-time force data of the monitoring pressure sensor in the top screw assembly 10, judging the separation state of the insulator and the mold, and ensuring the complete demolding of the insulator;

[0060] 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 been completely separated from the mold, and the operator moves the insulator smoothly and quickly to a designated safe area;

[0061] 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.

[0062] As can be seen from the above, the multi-sensor fusion technology and robust control algorithm employed in this invention ensure the accuracy of the demolding process and the integrity of the workpiece. By simulating manual operation, this invention enables automated demolding, improving production efficiency and operational continuity. Furthermore, the flexible force application strategy effectively avoids workpiece damage and improves demolding quality.

[0063] Example 1

[0064] The multi-sensor fusion automatic demoulding method for pot-type insulators of the present invention is divided into two parts: the disengagement of the upper half of the mold and the separation of the workpiece and 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 both mold A1 and mold B2.

[0065] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps:

[0066] Step 1: Position the mold;

[0067] Step 2: Install the sensor;

[0068] Step 3: Control demoulding.

[0069] Example 2

[0070] The multi-sensor fusion automatic demoulding method for pot-type insulators of the present invention is divided into two parts: the disengagement of the upper half of the mold and the separation of the workpiece and 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 both mold A1 and mold B2.

[0071] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps:

[0072] Step 1: Position the mold;

[0073] Step 1 is as follows: Use an overhead crane to lift the solidified 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 solidified pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demolding. A pair of flip motors 5 are also symmetrically installed in 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. 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. A camera 7 is installed next to the mechanical claw 6. The workpiece demolding push rod 11 passes through the middle of the upper part 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 solidified 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 that can withstand the weight of the mold and the force that may be generated during the demolding process.

[0074] Step 2: Install the sensor;

[0075] Step 3: Control demoulding.

[0076] Example 3

[0077] The multi-sensor fusion automatic demoulding method for pot-type insulators of the present invention is divided into two parts: the disengagement of the upper half of the mold and the separation of the workpiece and 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 both mold A1 and mold B2.

[0078] The upper part of the contact point between mold A1 and the workpiece is disengaged according to the following steps:

[0079] Step 1: Position the mold;

[0080] Step 1 is as follows: Use an overhead crane to lift the solidified 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 solidified pot-type insulator mold can slide along the slide rail to the position directly below the gantry structure 3 to wait for demolding. A pair of flip motors 5 are also symmetrically installed in 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. 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. A camera 7 is installed next to the mechanical claw 6. The workpiece demolding push rod 11 passes through the middle of the upper part 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 solidified 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 that can withstand the weight of the mold and the force that may be generated during the demolding process.

[0081] Step 2: Install the sensor;

[0082] Step 2 is as follows: Select the top screw assembly 10 with appropriate range and accuracy, and Figure 2The four corner positions of the mold are used to measure the accurate installation center point of the top pin assembly 10, so that the installation positions of the pressure sensors in the four top pin assemblies 10 are symmetrically distributed, and it is ensured that the stress of the mold can be uniformly monitored; the center position of the mold is accurately measured, and the attitude sensor is installed at the center position of the mold, so that the attitude sensor is installed horizontally, the measurement coordinate axis of the attitude sensor is consistent with the actual coordinate axis of the mold, and the inclination angle of the mold is monitored in real time and accurately; the hydraulic system 9 is connected with the top pin, the hydraulic system 9 is used for controlling the force applied to the top pin during the demolding process, and is used for assisting demolding; the pressure at the main oil pipe after the outlet of the hydraulic pump of the hydraulic system 9 can reflect the overall force applied by the hydraulic system 9, and the force sensor is installed on the hydraulic pipeline at this position to measure the force applied by the hydraulic system 9. The signal output cable of the pressure sensor, the attitude sensor and the force sensor on the hydraulic pipeline in the four top pin assemblies 10 is connected according to the type of the input interface of the control unit, each sensor channel is numbered and marked at the control unit end, and the corresponding sensor range, zero point calibration, filtering parameter, sensor working mode and precision setting parameter are configured at the control unit end, so that the collected data can be accurately converted and analyzed in the subsequent process, and the precise monitoring and control of the mold demolding process are realized.

[0083] Step 3, control demolding.

[0084] Example 4

[0085] The automatic demolding method of the basin type insulator by the multi-sensor fusion comprises two parts of mold upper half separation and workpiece and mold separation, wherein the contact position with the workpiece is taken as a boundary line, the upper half is above the boundary line, the lower half is below the boundary line, and the workpiece is wrapped by the mold A1 and the mold B2.

[0086] The upper half of the mold A1 and the workpiece contact point is separated according to the following steps:

[0087] Step 1, position the mold;

[0088] Step 2, install the sensor;

[0089] Step 3, control demolding.

[0090] The workpiece and the mold are separated according to the following steps:

[0091] Step a, install the lifting ring: a special lifting ring is installed at the center position of the basin type insulator, so that the lifting ring is firmly connected with the basin type insulator and can bear the weight of the insulator;

[0092] Step b, lift the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop and keep stable when the pressure sensor value in the top pin assembly 10 begins to decrease;

[0093] Step c, top wire force application: the top wire in the top wire assembly 10 is inserted into the top wire hole below the mold, and the top wire assembly 10 is used to apply uniform upward force to the bottom of the insulator, assisting the separation of the insulator and the mold B;

[0094] Step d, compressed air is introduced: compressed air is introduced between the insulator and the mold to destroy the intermolecular attraction on the surface of the two, reduce the demolding resistance, ensure the complete demolding of the insulator, and prevent residues and defects on the mold.

[0095] Step e, monitoring the force of the top wire: by monitoring the force data of the pressure sensor in the top wire assembly 10 in real time, the force of the top wire in the top wire assembly 10 is obtained, and the separation state of the insulator and the mold is judged to ensure the complete demolding of the insulator;

[0096] Step f, remove the workpiece: when the control unit shows that the force of the top wire in the top wire 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 the designated safe area;

[0097] Step g, clean the mold: use the crown to move the mold B to the cleaning line for cleaning and maintenance to prepare for the next production.

[0098] As can be seen from the above, the multi-sensor fusion technology and robust control algorithm adopted by the present application can ensure the accuracy of the demolding process and the integrity of the workpiece. By simulating manual operation, the present application can realize automatic demolding, improve production efficiency and continuity of operation. At the same time, the flexible force application strategy effectively avoids damage to the workpiece and improves the demolding quality.

[0099] Example 5

[0100] The multi-sensor fusion automatic demolding method for the insulator of the present application is divided into two parts: the upper half of the mold is separated and the workpiece is separated from the mold. Above the contact position with the workpiece is the upper half, and below the contact position is the lower half. The workpiece is wrapped by the mold A1 and the mold B2.

[0101] The upper half of the contact point between the mold A1 and the workpiece is separated according to the following steps:

[0102] Step 1, position the mold;

[0103] Step 2, install the sensor;

[0104] Step 3, control demolding.

[0105] Step 3 is as follows: by using the PID algorithm to control the mechanical claw 6, the mechanical claw 6 can simulate the action of manual operation, such as unscrewing, knocking the mold, pulling open the mold and taking out the workpiece.

[0106] Step 3 is implemented in particular as follows:

[0107] Step 3.1, unscrewing the screws;

[0108] Step 3.2, knocking the mold:

[0109] Step 3.3, demolding operation.

[0110] Step 3.1 is implemented in particular as follows:

[0111] First, initialize the PID controller, set the initial proportional Kp, integral Ki, and derivative Kd parameters; then use the camera 7 set on the inner surface of the top of the gantry structure 3 to collect the position of the connecting screws of the mold A and the mold B, and transmit the position signal detected by the camera 7 to the control unit, so as to control the mechanical gripper 6 to move to the top of each corresponding connecting screw in turn; then start the pressure sensor in the top pin assembly 10 at the four corners of the mold, activate the pressure sensor in the top pin assembly 10 to detect the contact force between the mold and the top pin in the top pin assembly 10; according to the feedback of the pressure sensor in the top pin assembly 10, adjust the torque of the mechanical gripper 6 using the PID algorithm to achieve precise unscrewing of the screws;

[0112] Step 3.2 is implemented in particular as follows:

[0113] Use the camera 7 to determine the specific position on the mold that needs to be knocked, including the mold gap that the mechanical gripper can penetrate and the mold edge, but avoid directly knocking the surface of the workpiece in contact with the mold; then control the mechanical gripper 6 to move to the knocking point above, adjust the force that changes in size and position due to external interference to the appropriate size and position to ensure the accuracy and force of the knocking, and adjust the knocking force and frequency of the mechanical gripper 6 at all times to ensure the stability and performance of the system; by monitoring the data of the pressure sensor and attitude sensor in the top pin assembly 10 in real time, the attitude 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 pin assembly 10 shows that the mold and the workpiece have a relatively obvious change in pressure and the attitude sensor shows that the workpiece has a slight displacement, the next step of preparing to disengage the mold is prepared.

[0114] Step 3.3 is implemented in particular as follows:

[0115] The camera 7 is used for visual recognition to accurately position the mold, especially to identify the key positions of the upper half edge of the mold, i.e. the positions where the mechanical claws can enter the mold gap and the mold edge. The mechanical claws move to the initial demolding position according to these feedback information. At this moment, the hydraulic system 9 is activated to provide power for the ejector pins in the ejector pin assembly 10. During the process of opening the mold, multiple sensors on the mold play a role. The pressure sensor in the ejector pin assembly 10 monitors the force of the contact point between the ejector pin and the mold in real time to ensure that the applied force is within the safe range. The attitude sensor monitors the inclination angle and direction of the mold to prevent any mold inclination that may cause the workpiece to be 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 to dynamically adjust the actions of the hydraulic system 9 and the ejector pin assembly 10 to achieve precise control. When opening the upper half of the mold, the control unit will calculate the required force and speed in real time to ensure that the mold is uniformly stressed and to avoid sudden or uneven force that may cause damage to the workpiece or the mold. In order to prevent the mold from tilting, as soon as the attitude sensor detects any tilting trend, the control unit will quickly respond to adjust the force point and intensity of the ejector pins in the ejector pin assembly 10 to correct the mold attitude and maintain the stability and synchronization of the demolding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and the workpiece during the entire demolding process. When the upper half of the mold is completely separated and the sensors confirm that the workpiece has not been stuck or damaged, the mechanical claws 6 will stop the demolding action and move to a safe position to wait for the next instruction.

[0116] The separation of the workpiece and the mold is implemented according to the following steps:

[0117] Step a, install the lifting ring: install a special lifting ring at the center of the basin-type insulator to ensure that the lifting ring is firmly connected to the basin-type insulator and can bear the weight of the insulator;

[0118] Step b, lift the workpiece: operate the overhead crane to slowly lift the lifting ring. Stop and keep stable when the pressure sensor value in the ejector pin assembly 10 starts to decrease;

[0119] Step c, ejector pin force: insert the ejector pin assembly 10 into the ejector pin hole below the mold to apply uniform upward force to the bottom of the insulator with the ejector pin assembly 10 to assist the separation of the basin-type insulator and the mold B;

[0120] Step d, introduce compressed air: introduce compressed air between the basin-type insulator and the mold to break the intermolecular attraction on the surface of the two, reduce the demolding resistance, and ensure the complete demolding of the insulator and prevent residues and defects on the mold.

[0121] Step e, monitoring the force on the top screw: obtaining 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;

[0122] 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 been completely separated from the mold, and the operator moves the insulator smoothly and quickly to a designated safe area;

[0123] 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.

[0124] As can be seen from the above, the multi-sensor fusion technology and robust control algorithm employed in this invention ensure the accuracy of the demolding process and the integrity of the workpiece. By simulating manual operation, this invention enables automated demolding, improving production efficiency and operational continuity. Furthermore, the flexible force application strategy effectively avoids workpiece damage and improves demolding quality.

[0125] Example 6

[0126] This specific use case demonstrates that the automated demolding equipment can precisely control the demolding process, reducing manual intervention and improving production efficiency and product quality. Furthermore, through real-time monitoring and a flexible force application strategy, it ensures the integrity of the insulator and the service life of the mold.

[0127] Next, the technical route of mold posture detection during the operation of the automatic demoulding device for pot-type insulators is introduced in detail.

[0128] 1. Arrange multiple pressure sensors in the top screw assembly (10) on the edges and corners of the mechanical claw and its contact with the mold. The distribution of the sensors should ensure that they can fully cover the contact surface of the mold to obtain uniform pressure measurement data.

[0129] 2. Each pressure sensor in the screw assembly 10 is connected to a data acquisition system to collect real-time pressure data from the contact surface between the mold and the workpiece. Preprocessing steps include filtering and calibration to eliminate noise and errors and ensure data accuracy.

[0130] 3. A Bayesian data fusion method (a common multi-sensor data fusion method that uses Bayes' theorem to fuse information from different sensors and calculate a posterior probability distribution. This typically involves multiplying the joint probability distributions and performing normalization operations) is used to comprehensively analyze the data from the pressure sensors in each screw assembly 10. By establishing a probabilistic model and combining prior knowledge with observed data, a fused value of the pressure data is calculated, which helps improve the accuracy of the mold stress state estimation.

[0131] 4. Posture sensors, such as gyroscopes and accelerometers, are installed in 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.

[0132] 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.

[0133] 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.

[0134] 7. Using intelligent robust control methods, 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.

[0135] 8. The actuator precisely controls the force applied to the mold and workpiece based on the control variable, ensuring sufficient force to separate the mold and workpiece without damaging the workpiece. Throughout the demolding process, the system continuously monitors and adjusts the force strategy until the mold and workpiece are completely separated.

Claims

1. The automatic demoulding method of pot-type insulator based on multi-sensor fusion is characterized by: It is divided into two parts: the disengagement of the upper half of the mold and the separation of the workpiece from the mold. 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 A (1) and mold B (2). The disengagement of the upper half of the mold A (1) at the contact point with the workpiece is specifically implemented according to the following steps: Step 1: Position the mold; The step 1 is specifically as follows: a crane is used to lift the solidified pot-type insulator mold onto a mobile platform (4), and a gantry structure (3) is mounted on the other end of the mobile platform (4); a mechanical claw (6) is also installed on the inner surface of the upper middle of the gantry structure (3), and a camera (7) is installed next to the mechanical claw (6); a workpiece demoulding rod (11) passes through the upper middle of the gantry structure (3) and is connected to the mechanical claw (6), and the mold B (2) is also connected to the hydraulic system (9) and the pneumatic system (8); Step 2: Install the sensor; The step 2 is specifically as follows: installing the top screw assembly (10) at the installation center point of the four corners of the mold, accurately measuring the center position of the mold, installing a posture sensor at the center position of the mold, 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), installing a force sensor on the hydraulic pipeline at this location to measure the force applied by the hydraulic system (9), and connecting the signal output cables of the pressure sensors, posture sensors and force sensors on the hydraulic pipeline in the four top screw assemblies (10) according to the corresponding input interface type of the control unit; Step 3: Control demoulding; The specific steps of step 3 are as follows: by using the PID algorithm to control the mechanical claw (6) so that it can simulate the actions of manual operation, perform screw removal, knocking the mold, pulling the mold open and removing the workpiece, and the specific steps of step 3 are as follows: Step 3.1, remove the screws; 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 camera (7) set on the inner surface of the top 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, thereby controlling the mechanical claw (6) to move to the top of each corresponding connecting screw in turn; then, the pressure sensors in the top screw assembly (10) at the four corners of the mold are started, and the pressure sensors in the top screw assembly (10) are 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 loosening of the screws; Step 3.2, tap the mold: Step 3.3, demoulding operation.

2. The multi-sensor fusion pot-type insulator automatic demoulding method according to claim 1 is characterized in that: In the step 1, the slide rail of the mobile platform (4) is located at the bottom middle position of the portal structure (3), and the solidified pot-type insulator mold can slide along the slide rail to the position directly below the portal structure (3) to wait for demoulding. A pair of flip motors (5) are also symmetrically installed at the middle and lower parts of the two side columns of the portal 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 B (2) to control the rotational power required when the mold B (2) is separated from the pot-type insulator, and the solidified pot-type insulator mold A (1) is fixed on the L-shaped bracket (12) of the mobile platform (4).

3. The multi-sensor fusion automatic demoulding method for pot-type insulators according to claim 2, characterized in that: In the step 2, the top screw installation positions in the four top screw assemblies (10) are symmetrically distributed to ensure that the stress condition of the mold can be evenly monitored; the attitude sensor is ensured to be 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 assembly (10), and the hydraulic system (9) is controlled to apply force to the top screw during the demoulding process to assist in demoulding, and 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 later, thereby realizing accurate monitoring and control of the mold demoulding process.

4. The multi-sensor fusion automatic demoulding method for pot-type insulators according to claim 3, characterized in that: The step 3.2 is specifically implemented according to the following steps: The camera (7) is used to determine the specific position on the mold that needs to be struck, 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 to above the striking point, and by analyzing the force change of the pressure sensor in the top screw assembly (10), the force that changes in size and position of action 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 to ensure the stability and performance of the system; by real-time monitoring the data of the pressure sensor and posture sensor in the top screw assembly (10), the posture and force of the mold are detected in real time, and the change in 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.

5. The multi-sensor fusion automatic demoulding method for pot-type insulators according to claim 4, 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 and 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 based on these feedback information; at this moment, the hydraulic system (9) is activated to provide power to the top screw in the top screw assembly (10). In the process of opening the mold, multiple sensors on the mold play a role. The pressure sensor in the top screw assembly (10) monitors the force 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 PID control The control algorithm dynamically adjusts the action of the hydraulic system (9) and the top screw in the top screw assembly (10) to achieve precise control; when the upper part of the mold is pushed open, 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 top screw in the top screw assembly (10) to correct the mold posture and maintain the smoothness and synchronization of the demoulding process. This continuous monitoring and adjustment ensures the safety and integrity of the mold and workpiece throughout the 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.

6. The multi-sensor fusion basin insulator automatic demoulding method according to claim 5, characterized in that: The separation of the workpiece and the mold is specifically carried out according to the following steps: Step a: Install the lifting ring: Install a special lifting ring at the center of the pot insulator, ensuring that the lifting ring is firmly connected to the pot insulator and can bear the weight of the insulator; Step b, hoist the workpiece: operate the overhead crane, slowly lift the lifting ring, and stop when the pressure sensor value begins to decrease and keep it stable; Step c, applying force with a top screw: inserting the top screw assembly (10) into the top screw hole below the mold, and using the top screw in the top 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 intermolecular 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 judged, 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 moves the insulator smoothly and quickly 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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