Mechanical arm control device and method for solving normal operation of socket by replacing human hands

Abstract

The invention discloses a mechanical arm control device and method for solving normal operation of a socket by replacing human hands, and relates to the technical field of industrial robots and electric appliance accessories. The device comprises a mechanical arm and a demonstrator connected with the mechanical arm, one end of the demonstrator is provided with an upper computer, and the upper computer is provided with a visual sensor, a pressure sensor and a current sensor. According to the invention, an automatic test scheme is provided, a mechanical arm is used for replacing a human hand to carry out normal operation test on the socket, and in application, under the combined action of related mechanisms and circuits, only clamping of the socket, connection of a test circuit, debugging of a test program, action of the mechanical arm and calibration of a tool sharp point need to be completed. And then analyzing image features of the socket through a visual sensor, and controlling a machine arm to position and test a target jack according to the image features.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial robots and electrical accessories, and in particular relates to a robotic arm control device and method for replacing human hands in solving the normal operation of a socket. Background Art

[0002] Robotic arms, with their potential to save labor costs and improve production efficiency, are becoming an ideal choice for automated testing at a growing number of testing organizations. As automated tools, robotic arms can automatically transfer items and perform various operations according to preset programs or specific needs, effectively reducing the manual burden. Advanced robotic arms can also mimic the flexible movements of human arms to perform more complex tasks. These devices are widely used in fields such as semiconductor production, industrial processes, medical treatment, military applications, and space research. Their core advantage lies in their ability to receive commands, precisely lock onto target points in three-dimensional space, and efficiently execute tasks.

[0003] Household and similar sockets, as key components of electrical connections, are widely used in homes, hotels, industrial production, offices, and outdoor charging stations. Their quality is inextricably linked to the convenience, safety, and health of people's daily lives. These products are now regulated under my country's CCC (China Compulsory Certification) system and must comply with relevant national standards. They must pass the rigorous compulsory certification process and obtain a CCC certificate before they can be legally circulated and sold on the market.

[0004] For plugs and sockets for household and similar purposes, my country currently implements the national general standard GB / T 2099.1-2021, "Plugs and sockets for household and similar purposes - Part 1: General requirements." Chapter 21, "Normal Operation," of this standard clearly outlines the test procedure for the normal operation (plugging life) test of sockets, allowing manufacturers to specify the test procedure starting at point 1, 2, or 3 on the diagram. When manual testing is selected at point 3, the plugging life test of the sockets, which relies heavily on manual operation, and the prolonged and repetitive plugging and unplugging motions, pose a significant risk of strain on the tester's hands. This strain not only manifests itself in fatigue and soreness in the finger joints, but can also cause muscle tension and discomfort in the wrists, forearms, and other areas. Therefore, when conducting such tests, in addition to focusing on the performance and quality of the sockets themselves, the health and safety of the testers should also be prioritized. Automated testing solutions should be explored to reduce the tester's workload, improve work efficiency, and protect their physical and mental well-being.

[0005] How to effectively complete the plugging and unplugging of sockets by robotic arms instead of human hands, and minimize the need for manual plugging and unplugging tests due to the failure of the socket's protective door to drive normally; how to design a fixture for the robotic arm to clamp the test plug; how to design a fixture for the installation clamp to clamp the socket; how to locate the position coordinates of the socket jack; how to plan and write the motion trajectory of the robotic arm joints in space; how to monitor whether the plug pin drives the socket protective door normally so that the plug and the socket are plugged in; how to monitor whether the power can be turned on and off normally after the plug is inserted into the socket; these are the problems we need to solve.

[0006] In view of this, the present invention is proposed. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a robotic arm control device and method for solving the normal operation of the socket instead of manual labor.

[0008] In order to solve the above technical problems, the basic concept of the technical solution adopted by the present invention is:

[0009] A robotic arm control device that replaces manual labor to solve the normal operation of a socket includes a robotic arm and a teaching pendant connected to the robotic arm. One end of the teaching pendant is equipped with a host computer, which is respectively equipped with a visual sensor, a pressure sensor, and a current sensor.

[0010] Optionally, the robotic arm includes a six-axis robotic arm, one end of which is equipped with an end rotating shaft, one end of which is equipped with a connecting base, one end of which is equipped with a test plug clamp mechanism and a pressure buffer mechanism, and the test plug clamp mechanism is equipped with a sample clamping fixture.

[0011] Optionally, the pressure buffer mechanism includes a bracket body installed on one side of the connection base, and one end of the bracket body is fixedly connected to a plurality of springs.

[0012] Optionally, the test plug fixture mechanism includes a test plug fixing mechanism, on which the test plug and the visual sensor are respectively mounted.

[0013] Optionally, the sample clamping fixture includes a fixed base, a lead screw is rotatably engaged on the fixed base, one end of the lead screw is fixedly connected to a handle, two movable clamps are threadedly engaged on the lead screw, and a guide nut is installed on the lead screw.

[0014] A method for controlling a robotic arm to replace manual labor in solving the normal operation of a socket, applicable to any of the robotic arm control devices described above, comprises the following steps:

[0015] S1. Connect the power terminals of the detection circuit to the terminals of the test sample, and clamp the test sample to the sample clamping fixture. Furthermore, it is necessary to perform visual positioning of the robotic arm to simulate manual insertion and removal. The specific method includes the following steps:

[0016] S11. Using a visual sensor mounted on a test plug fixture at the end of the robotic arm, take fixed-point photos and scan to establish a socket data model for a single-phase two-pole socket or a single-phase two-pole grounded socket.

[0017] S12. Based on the model data scanned by the visual sensor, the host computer calculates the position coordinates of the socket in the direction of the docking axis and calculates the pre-docking position and posture of the robot, which are defined as the coordinates of point A. The characteristic of the coordinates of point A is a certain distance directly in front of the socket;

[0018] S13, the host computer transmits the calculated coordinate data of point A to the teaching pendant, and the program of the teaching pendant controls the robot arm to move to the coordinate of point A;

[0019] S2. The load terminals of the detection circuit are connected to the test plug wires or terminals, and the test plug is installed in the test plug fixture;

[0020] S3. Use the teaching function of the robotic arm teach pendant to set tool parameters with the vertex of the ground pin of the test plug as the tool tip. Subsequent robotic arm movements are written and taught using the tool parameters set at the tool tip. The teaching program for the robotic arm to simulate manual insertion and removal specifically includes the following steps:

[0021] S31, the robot arm enters the teaching mode, and the system provides tool parameter settings, which include six items, among which offset X, offset Y, and offset Z describe the relative position between the tool tip and the flange surface, and angle A, angle B, and angle C describe the direction of the tip;

[0022] S32. If the insertion and removal are not smooth, the robotic arm is moved forward in a world coordinate motion manner, and the top of the pin of the test plug contacts the socket protection door, which is set as the coordinate of point B. The trajectory of reaching the coordinate of point B is recorded in the teaching program; if the insertion and removal are smooth, the test plug is withdrawn from the interior of the sample and reaches the position of point A. The robotic arm is moved back to the initial position in a joint coordinate motion and a world coordinate motion manner, and the test of the current position is terminated;

[0023] S33. Set the target number of cycles required for the test in the teaching program, and compare it with the actual number of cycles completed in S2. If the target number of cycles is not reached, move the robot arm in the world coordinate motion mode, and the test plug is withdrawn from the sample to point A, and then return to S2 to continue the action.

[0024] S4. Determine whether to replace the corresponding test plug based on the sample test requirements, and return to step 1 to connect the load terminals of the detection circuit to the test plug wires or terminals to continue testing. The robot arm simulates manual insertion and removal of the host computer control, specifically including the following steps:

[0025] S41. When the test plug on the robot arm is at the coordinate of point A, the robot arm runs the normal plugging and unplugging procedure through the control of the teach pendant;

[0026] S42: The robotic arm moves forward to perform the plugging and unplugging operation. The pressure sensor monitors the real-time pressure. The host computer monitors the real-time pressure change curve. When the pressure value does not reach the set maximum value, the socket protection door is normally driven to open, and the robotic arm continues to run the normal plugging and unplugging procedure through the teach pendant.

[0027] S43. The host computer monitors the current status through the current sensor. If the current sensor outputs a sample current connection signal, the plug and socket are normally connected successfully once; if the current sensor does not output a sample current connection signal, the plug and socket connection fails and an alarm is prompted.

[0028] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art. Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described below at the same time:

[0029] The present invention provides an automated testing solution that uses a robotic arm to replace manual labor to perform normal socket operation testing. In application, with the combined action of relevant mechanisms and circuits, only the socket clamping and test circuit connection, as well as the debugging of the test program and the calibration of the robotic arm and tool tip are required. A visual sensor is then used to analyze the image features of the socket, and the robotic arm is controlled to locate the target socket for testing based on the image features. For sockets whose protective doors cannot be easily or vertically driven, the test program simulates the shaking and forward and backward movements during manual insertion and removal. A host computer analyzes the data from the pressure sensor and current sensor during the normal operation test of the test plug on the socket. The pressure sensor identifies the insertion force of the plug when driving the protective door, and the characteristics of the insertion force variation curve are determined to determine whether the protective door is normally driven. The signal converted by the current sensor is used to determine whether the plug is normally powered when inserted into the socket, reducing the labor intensity of the tester and improving work efficiency. Based on the above, the present invention has good application prospects.

[0030] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The drawings described below are only some embodiments. A person skilled in the art can derive other drawings based on these drawings without inventive effort. In the drawings:

[0032] Figure 1 This is the control system architecture diagram of the robotic arm simulating the manual plugging and unplugging method;

[0033] Figure 2 It is a flowchart of the steps of the robotic arm simulating the human hand plugging and unplugging method;

[0034] Figure 3 This is a step-by-step diagram of the visual positioning method used by the robotic arm to simulate the insertion and removal method by human hands;

[0035] Figure 4 This is a diagram showing the steps of the teaching procedure for the robotic arm to simulate the manual insertion and removal method;

[0036] Figure 5 This is the upper computer control step diagram of the robotic arm simulating the manual plugging and unplugging method

[0037] Figure 6 It is a schematic diagram of the specific structure of the test plug fixture mechanism;

[0038] Figure 7 It is a schematic diagram of the specific structure of the sample clamping fixture;

[0039] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0040] 101-robotic arm, 102-teaching pendant, 103-host computer, 106-current sensor, 601-six-axis robotic arm, 602-end rotating shaft, 603-connecting base, 606-bracket body, 607-spring, 608-test plug fixing mechanism, 609-test plug, 701-fixed base, 702-lead nut, 703-screw, 704-handle, 705-movable clamp.

[0041] It should be noted that these drawings and textual descriptions are not intended to limit the conceptual scope of the present invention in any way, but rather to illustrate the concept of the present invention for those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0042] The present invention will now be described in further detail with reference to the accompanying drawings.

[0043] Example 1: Please refer to Figure 1-7As shown, in this embodiment, a robotic arm control device is provided to replace manual labor to solve the normal operation of the socket, including: a robotic arm 101, a teaching pendant 102 connected to the robotic arm 101, and a host computer 103 is installed at one end of the teaching pendant 102. The host computer 103 is respectively equipped with a visual sensor, a pressure sensor, and a current sensor 106.

[0044] The robotic arm 101 of this embodiment includes a six-axis robotic arm 601, one end of the six-axis robotic arm 601 is equipped with an end rotating shaft 602, one end of the end rotating shaft 602 is equipped with a connecting base 603, one end of the connecting base 603 is equipped with a test plug clamp mechanism and a pressure buffer mechanism, and the test plug clamp mechanism is equipped with a sample clamping fixture.

[0045] The pressure buffer mechanism of this embodiment includes a bracket body 606 installed on one side of the connecting base 603 , and a plurality of springs 607 are fixedly connected to one end of the bracket body 606 .

[0046] The test plug fixture mechanism of this embodiment includes a test plug fixing mechanism 608 , on which a test plug 609 and a visual sensor 605 are respectively mounted.

[0047] The sample clamping fixture of this embodiment includes a fixed base 701, on which a lead screw 703 is rotatably engaged. One end of the lead screw 703 is fixedly connected to a handle 704. Two movable clamps 705 are threadedly engaged on the lead screw 703, and a guide nut 702 is installed on the lead screw 703.

[0048] Example 2: A method for controlling a robotic arm to replace manual labor in solving the normal operation of a socket, applicable to any of the robotic arm control devices described above, comprising the following steps:

[0049] S1. Connect the power terminals of the detection circuit to the terminals of the test sample, and clamp the test sample to the sample clamping fixture. Furthermore, it is necessary to perform visual positioning of the robotic arm to simulate manual insertion and removal. The specific method includes the following steps:

[0050] S11. Using a visual sensor mounted on a test plug fixture at the end of the robotic arm, take fixed-point photos and scan to establish a socket data model for a single-phase two-pole socket or a single-phase two-pole grounded socket.

[0051] S12. Based on the model data scanned by the visual sensor, the host computer calculates the position coordinates of the socket in the direction of the docking axis and calculates the pre-docking position and posture of the robot, which are defined as the coordinates of point A. The characteristic of the coordinates of point A is a certain distance directly in front of the socket;

[0052] S13, the host computer transmits the calculated coordinate data of point A to the teaching pendant, and the program of the teaching pendant controls the robot arm to move to the coordinate of point A;

[0053] S2. The load terminals of the detection circuit are connected to the test plug wires or terminals, and the test plug is installed in the test plug fixture;

[0054] S3. Use the teaching function of the robotic arm teach pendant to set tool parameters with the vertex of the ground pin of the test plug as the tool tip. Subsequent robotic arm movements are written and taught using the tool parameters set at the tool tip. The teaching program for the robotic arm to simulate manual insertion and removal specifically includes the following steps:

[0055] S31, the robot arm enters the teaching mode, and the system provides tool parameter settings, which include six items, among which offset X, offset Y, and offset Z describe the relative position between the tool tip and the flange surface, and angle A, angle B, and angle C describe the direction of the tip;

[0056] S32. If the insertion and removal are not smooth, the robotic arm is moved forward in a world coordinate motion manner, and the top of the pin of the test plug contacts the socket protection door, which is set as the coordinate of point B. The trajectory of reaching the coordinate of point B is recorded in the teaching program; if the insertion and removal are smooth, the test plug is withdrawn from the interior of the sample and reaches the position of point A. The robotic arm is moved back to the initial position in a joint coordinate motion and a world coordinate motion manner, and the test of the current position is terminated;

[0057] S33. Set the target number of cycles required for the test in the teaching program, and compare it with the actual number of cycles completed in S2. If the target number of cycles is not reached, move the robot arm in the world coordinate motion mode, and the test plug is withdrawn from the sample to point A, and then return to S2 to continue the action.

[0058] S4. Determine whether to replace the corresponding test plug based on the sample test requirements, and return to step 1 to connect the load terminals of the detection circuit to the test plug wires or terminals to continue testing. The robot arm simulates manual insertion and removal of the host computer control, specifically including the following steps:

[0059] S41. When the test plug on the robot arm is at the coordinate of point A, the robot arm runs the normal plugging and unplugging procedure through the control of the teach pendant;

[0060] S42: The robotic arm moves forward to perform the plugging and unplugging operation. The pressure sensor monitors the real-time pressure. The host computer monitors the real-time pressure change curve. When the pressure value does not reach the set maximum value, the socket protection door is normally driven to open, and the robotic arm continues to run the normal plugging and unplugging procedure through the teach pendant.

[0061] S43. The host computer monitors the current status through the current sensor. If the current sensor outputs a sample current connection signal, the plug and socket are normally connected successfully once; if the current sensor does not output a sample current connection signal, the plug and socket connection fails and an alarm is prompted.

[0062] The present invention provides an automated testing solution that uses a robotic arm to replace manual labor to perform normal socket operation testing. In application, with the combined action of relevant mechanisms and circuits, only the socket clamping and test circuit connection, as well as the debugging of the test program and the calibration of the robotic arm and tool tip are required. A visual sensor is then used to analyze the image features of the socket, and the robotic arm is controlled to locate the target socket for testing based on the image features. For sockets whose protective doors cannot be easily or vertically driven, the test program simulates the shaking and forward and backward movements during manual insertion and removal. A host computer analyzes the data from the pressure sensor and current sensor during the normal operation test of the test plug on the socket. The pressure sensor identifies the insertion force of the plug when driving the protective door, and the characteristics of the insertion force variation curve are determined to determine whether the protective door is normally driven. The signal converted by the current sensor is used to determine whether the plug is normally powered when inserted into the socket, reducing the labor intensity of the tester and improving work efficiency. Based on the above, the present invention has good application prospects.

[0063] Example 3: A method and device for controlling a robotic arm that replaces manual labor to solve the problem of normal socket operation, characterized in that it includes a robotic arm, a teaching pendant and a host computer program that enable the robotic arm to perform normal socket operation movements, a test plug fixture, a detection circuit, a socket clamping fixture, a visual sensor, a pressure sensor, a current sensor, a teaching pendant, and a host computer.

[0064] The robotic arm described in this embodiment is a six-axis robotic arm.

[0065] The teaching program for the robot arm to perform the normal operation trajectory of the socket described in this embodiment is a series of instructions carefully designed through the robot arm teaching pendant software platform to accurately simulate the complex hand movements required by the operator during the normal operation of the socket. These movements not only include forward and backward movements in a straight line, but also simulate the shaking and fine-tuning of the robot arm when the protective door of the socket is difficult to drive during normal operation, so as to ensure that the test plug can be inserted into the socket normally. At the same time, a pressure sensor is used to connect to the host computer to monitor the insertion pressure of the test plug when driving the socket protective door. The pressure data is analyzed by an algorithm to determine whether the protective door is driven normally. After the test plug is inserted, the signal converted by the current sensor connected to the host computer is used to determine whether the test plug is normally energized when inserted into the socket.

[0066] When performing the socket normal operation test described in this embodiment, necessary items include: a test plug fixture, a detection circuit, and a socket clamping fixture.

[0067] The test plug fixture mechanism described in this embodiment includes a test plug fixing mechanism, a bracket body, a spring, a connecting base, a pressure sensor, and a visual sensor.

[0068] The pressure buffer mechanism composed of the bracket body and the spring in the test plug fixture mechanism of this embodiment can help the robot arm avoid the pressure from being transmitted through the rigid structure when performing normal operation of the socket, and also provide a reliable pressure buffering effect for simulating the hand insertion action.

[0069] The visual sensor described in this embodiment is installed on the test plug fixture mechanism at the end of the robotic arm to perform fixed-point photography and scanning to establish a socket data model of a single-phase two-pole socket or a single-phase two-pole grounded socket.

[0070] In this embodiment, based on the model data scanned by the visual sensor, the host computer calculates the position coordinates of the jack in the docking axis direction and calculates the pre-docking position and posture of the robot, providing coordinate data for subsequent robotic arm movements.

[0071] The signal line of the pressure sensor described in this embodiment is connected between the analog signal input terminals of the host computer, serving as the input signal of the reaction fixture plugging and unplugging force in the host computer. The pressure sensor provides the pressure data generated by the robotic arm in the simulated hand insertion action during the test process. The pressure data is analyzed by algorithm to determine whether the socket protection door is driven normally.

[0072] The detection circuit in this embodiment includes a current sensor. The current sensor's signal line is connected between the analog signal input terminals of the host computer, providing an input signal reflecting the on / off current and magnitude when the sample is connected. The detection circuit provides a test power supply for the socket and a test load for the test plug.

[0073] The socket clamping fixture described in this embodiment consists of a fixed base, a lead nut, a screw, a handle, and a movable jaw. The two movable jaws slide together via guide rails. The screw, mounted between the fixed jaw body and the movable jaw, is rotatable but not axially movable, and engages with the screw nut mounted within the movable jaw and the fixed jaw body. Slots are provided on both sides of the base for connection to the fixing screws.

[0074] Example 4: Combination Figure 1-7 The present invention describes a method and device for controlling a robotic arm to replace manual labor in solving the problem of normal socket operation.

[0075] refer to Figure 1As shown, it shows a control system architecture diagram of a method for simulating human hand plugging and unplugging provided by a robotic arm in an implementation case of the present application; the control system includes the following (101-106): a robotic arm 101, a teach pendant 102, a host computer 103, a visual sensor, a pressure sensor, and a current sensor 106; the robotic arm 101 is connected to the teach pendant 102, the teach pendant 102 is connected to the host computer 103, and the host computer 103 is respectively connected to the visual sensor, the pressure sensor, and the current sensor 106; specifically, the host computer 103 completes the judgment of the action in the process of simulating hand plugging by processing the signals of the visual sensor, the pressure sensor, and the current sensor 106, and the host computer 103 exchanges data with the teach pendant 102. The teach pendant 102 and the host computer 103 can control the robotic arm 101 to simulate some movement modes and behaviors of humans when performing hand plugging actions.

[0076] refer to Figure 2 As shown, it shows a flowchart of the steps of the method for inserting and removing by simulating human hands provided by a robotic arm in an implementation case of the present application, including the following steps 201 to 203):

[0077] Step 201 is that before the test, the power supply terminal of the detection circuit is connected to the terminal of the test sample, and the test sample is clamped to the socket clamping fixture ( Figure 6 ); the load terminals of the detection circuit are connected to the test plug wires or terminals, and the test plug is installed in the test plug fixture ( Figure 5 ).

[0078] Step 202 is the test. The coordinates of the robot arm represent the spatial position and posture of the end tool tip. Since the tool is not installed until the robot arm leaves the factory, there must be parameters to specify the position and direction of the end tool tip, which are called tool parameters. Take the single-phase two-pole grounded test plug installed in the test plug fixture as an example. Use the teaching function of the robot arm teach pendant to set the tool parameters with the top of the ground pin of the test plug as the tool tip. Subsequent robot arm movements are written and taught based on the tool parameters set at the tool tip (refer to Figure 4 The robot arm simulates manual insertion and removal teaching program as shown in the flowchart. The robot arm enters automatic mode through the teach pendant and begins to move. When the number of trials is reached, the current position test is completed.

[0079] After the test, step 203 determines whether to replace the corresponding test plug based on the sample test requirements. The process then returns to step 201, where the load terminals of the detection circuit are connected to the test plug wires or terminals, to continue testing. If the test is complete, the sample is removed, the test plug is removed, and the robotic arm is reset.

[0080] refer to Figure 3As shown, it shows a step diagram of a visual positioning method for a robotic arm simulating manual insertion and removal provided by an implementation case of the present application;

[0081] The visual sensor installed on the test plug fixture mechanism at the end of the robotic arm is used to take fixed-point photos and scans to establish a socket data model for a single-phase two-pole socket or a single-phase two-pole grounded socket. Based on the model data scanned by the visual sensor, the host computer calculates the position coordinates of the socket in the direction of the docking axis and calculates the robot's pre-docking position and posture, which are defined as point A coordinates. The characteristic of point A coordinates is a certain distance directly in front of the socket. The host computer transmits the calculated point A coordinate data to the teach pendant, and the program of the teach pendant controls the movement of the robotic arm to point A coordinates.

[0082] refer to Figure 4 As shown, it shows a flowchart of a teaching program for a robotic arm simulating manual insertion and removal provided by an implementation case of the present application, including the following steps (401-403):

[0083] In step 401, the robot arm enters the teaching mode, and the system provides tool parameter settings. The parameters include six items, among which offset X, offset Y, and offset Z describe the relative position between the tool tip and the flange surface, and angle A, angle B, and angle C describe the direction of the tip.

[0084] The position of the tool tip at the end of the test plug needs to be calibrated. The direction of the tool tip is parallel to the axis of the sixth axis, and the tool angle does not need to be set. The mobile robot moves the test plug from the initial position to the coordinates of point A (a certain distance in front of the socket) in the form of joint coordinate movement and world coordinate movement. Figure 3 The trajectory to point A is recorded in the teaching program.

[0085] Step 402: Divide plugging and unplugging into two situations:

[0086] The first one is the case where the plugging and unplugging is smooth: the robot arm is moved forward in the form of world coordinate motion, and the pin vertex of the test plug touches the socket protection door, which is set as the coordinate of point B. The trajectory of reaching the coordinate of point B is recorded in the teaching program. The robot arm is moved in the form of world coordinate motion, and the pin of the test plug continues to be inserted forward into the socket protection door. The pressure sensor displays the current pressure value through the host computer. The host computer sets a maximum value limit for the pressure value and judges it based on the current pressure value and the current sensor (the specific judgment is made by Figure 5 (described in [1]), the protective door is judged to be actuated normally. The actual cycle count is incremented by 1, the actual number of failures is reset to zero, and the robotic arm is controlled to move forward in world coordinate motion, so that the test plug is fully inserted into the sample and the coordinate posture is set at point C. The trajectory of reaching the coordinate posture at point C when the protective door is actuated normally, as well as the judgment method between the teach pendant and the host computer, are entered into the teaching program.

[0087] The second situation is the situation where the plugging and unplugging is not smooth: move the robot arm in the form of world coordinate motion, make the pin vertex of the test plug touch the socket protection door and set it as the coordinate posture of point B, and enter the trajectory of reaching the coordinate posture of point B into the teaching program. Move the robot arm forward in the form of world coordinate motion, so that the pin of the test plug is inserted forward into the socket protection door, and the pressure sensor displays the current pressure value through the host computer. The host computer sets a maximum limit for the pressure value and judges it based on the current pressure value and the current sensor (the specific judgment is made by Figure 5 In the description of the ). To determine whether the protection door cannot be driven normally, move the robot arm in the form of world coordinate motion, and swing it up and down and left and right at a certain angle for a corresponding number of times with the tool tip as the center. This process simulates the shaking and fine-tuning action of the sample protection door during manual insertion and removal when it is difficult to drive. During or after the action, the upper computer monitors the pressure value of the pressure sensor to protect the door drive signal. If the current sensor still does not output the sample current connection signal, it is determined that the protection door still cannot be driven normally (the specific judgment is made by Figure 5 ). The robotic arm is moved in a world coordinate motion manner, and the pin of the test plug continues to move forward or backward a certain distance. The pressure value continues to decrease or increase until it reaches a certain value, and the actual failure count is increased by 1. The number of failures is judged. If it has not reached the set number, the test continues. If it has reached it, the test stops in step 403. When continuing, the host computer outputs a sample current connection signal through the current sensor, then it is judged that the protective door is driving normally, the actual cycle count is increased by 1, and the robotic arm is moved in a world coordinate motion manner so that the test plug is fully inserted into the sample and the coordinate posture of point C is set. The trajectory and judgment method of reaching the coordinate posture of point C in the case where the protective door is not driven smoothly are recorded in the teaching program.

[0088] In step 403, the target number of test cycles to be completed is set in the teaching program. This is compared with the actual number of plugging and unplugging cycles completed in step 402. If the target number of cycles is not reached, the robot arm is moved in world coordinate motion, the test plug is withdrawn from the sample, and reaches point A. The process then returns to step 402 and continues. If the target number of cycles or the number set in step 402 is reached, the robot arm is moved in world coordinate motion, the test plug is withdrawn from the sample, and reaches point A. The robot arm is then moved back to its initial position using both joint coordinate motion and world coordinate motion, ending the test at the current position. The coordinate posture trajectory and determination method in step 403 are recorded in the teaching program.

[0089] refer to Figure 5 As shown, it shows a diagram of the upper computer control steps of a robotic arm simulating manual insertion and removal provided by an implementation case of the present application;

[0090] The host computer uses the pressure value and current status provided by the pressure sensor and current sensor to determine whether the socket protection door is driven, and provides options for the robot arm to move. The following describes how the host computer determines whether the protection door is driven. Figure 5 middle:

[0091] When the test plug on the robotic arm is at point A, the robotic arm runs the normal plugging and unplugging program through the teach pendant control. The robotic arm moves forward to perform the plugging and unplugging action. The pressure sensor monitors the real-time pressure. The host computer monitors the real-time pressure change curve. If the pressure value continues to change, before the pressure value reaches the set maximum value, the socket protection door is driven to open normally, and the robotic arm continues to run the normal plugging and unplugging program through the teach pendant. The upper computer monitors the current status through the current sensor, and the current sensor outputs a sample current connection signal, then the plug and socket are normally connected successfully once; if the pressure value reaches the maximum value during continuous change, and the upper computer monitors the current status through the current sensor, and the current sensor does not output a sample current connection signal, then it is determined that the socket protection door cannot be driven open normally, and the upper computer controls the robot arm through the teach pendant to run the simulated manual insertion program; during the simulated manual insertion program, the pressure curve suddenly decreases drastically, for example, 80N suddenly decreases to 50N; the upper computer determines that the socket protection door is driven to open, and the robot arm runs the reset program through the teach pendant to realize that the plug is facing the socket; the robot arm continues to run the normal plug-in and unplug program through the teach pendant; the upper computer monitors the current status through the current sensor, and the current sensor outputs a sample current connection signal, then the plug and socket are normally connected successfully once; if the current sensor does not output a sample current connection signal, then the plug and socket connection fails and an alarm is prompted;

[0092] refer to Figure 6 As shown, it shows a specific structural schematic diagram of the test plug fixture mechanism provided by an embodiment of the present application.

[0093] like Figure 6 In the figure, the test plug fixture mechanism is installed on the end rotating shaft 602 of the six-axis robot arm 601 through the connecting base 603, and the connecting base is combined with the pressure sensor. The visual sensor is installed on the bracket body 606. The bracket body 606 and the spring 607 form a pressure buffer mechanism, and the 608-test plug fixing mechanism is used to fix the test plug 609.

[0094] refer to Figure 7 As shown, it shows a specific structural schematic diagram of a sample clamping fixture provided by an embodiment of the present application.

[0095] like Figure 7In the example, the sample clamping fixture is fixed on a vertical plane by a fixed base 701. The fixed base 701 has an arc groove to facilitate the small rotation of the sample clamping fixture as a whole. The two movable clamps 705 are clamped and loosened by the movable mechanism of the guide nut 702, the lead screw 703 and the handle 704 to clamp the test sample socket.

[0096] The present invention is not limited to the above-described embodiments. Any structural changes made under the guidance of the present invention, which have the same or similar technical solutions as the present invention, should be understood to fall within the scope of protection of the present invention. The technologies, shapes, and structural parts not described in detail in the present invention are all well-known technologies.

Claims

1. A mechanical arm control device that replaces manual labor to solve the normal operation of the socket, characterized in that: include: A mechanical arm (101), a teaching pendant (102) connected to the mechanical arm (101), a host computer (103) installed at one end of the teaching pendant (102), and a visual sensor, a pressure sensor, and a current sensor (106) installed on the host computer (103).

2. According to claim 1, a mechanical arm control device for replacing manual labor to solve the normal operation of the socket is characterized in that: The mechanical arm (101) comprises a six-axis mechanical arm (601), one end of the six-axis mechanical arm (601) is equipped with a terminal rotating shaft (602), one end of the terminal rotating shaft (602) is equipped with a connecting base (603), one end of the connecting base (603) is equipped with a test plug fixture mechanism and a pressure buffer mechanism, and the test plug fixture mechanism is matched with a sample clamping fixture.

3. According to claim 2, a mechanical arm control device for replacing manual labor to solve the normal operation of the socket is characterized in that: The pressure buffer mechanism comprises a bracket body (606) installed on one side of the connecting base (603), and one end of the bracket body (606) is fixedly connected to a plurality of springs (607).

4. According to claim 2, a mechanical arm control device for replacing manual labor to solve the normal operation of the socket is characterized in that: The test plug fixture mechanism comprises a test plug fixing mechanism (608), on which a test plug (609) and a visual sensor (605) are respectively mounted.

5. According to claim 4, a mechanical arm control device for replacing manual labor to solve the normal operation of the socket is characterized in that: The sample clamping fixture comprises a fixed base (701), a lead screw (703) is rotatably mounted on the fixed base (701), one end of the lead screw (703) is fixedly connected to a handle (704), two movable clamps (705) are threadedly mounted on the lead screw (703), and a guide nut (702) is mounted on the lead screw (703).

6. A method for controlling a mechanical arm to replace manual labor to solve the normal operation of a socket, applicable to the mechanical arm control device according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. The power supply terminal of the detection circuit is connected to the terminal of the test sample, and the test sample is clamped to the sample clamping fixture; S2. The load terminals of the detection circuit are connected to the test plug wires or terminals accordingly, and the test plug is installed in the test plug fixture mechanism; S3, using the teaching function of the robot arm teaching pendant, setting tool parameters with the vertex of the ground pin of the test plug (609) as the tool tip, and writing and teaching programs with the tool parameters set with the tool tip for subsequent robot arm (101) actions; S4. Determine whether to replace the corresponding test plug (609) according to the sample test requirements, and return to step 1 to connect the load terminals of the detection circuit to the test plug wire or terminal to continue testing.

7. A method for controlling a mechanical arm to replace manual labor to solve the normal operation of a socket according to claim 6, characterized in that: In S1, it is also necessary to perform visual positioning of the robotic arm to simulate human hand insertion and removal. The specific method includes the following steps: S11, taking fixed-point photos and scanning by means of a visual sensor installed on a test plug fixture mechanism at the end of the mechanical arm (101), and establishing a socket data model of a single-phase two-pole socket or a single-phase two-pole socket with grounding; S12. Based on the model data scanned by the visual sensor, the host computer calculates the position coordinates of the socket in the direction of the docking axis and calculates the pre-docking position and posture of the robot, which are defined as the coordinates of point A. The feature of the coordinates of point A is a certain distance directly in front of the socket; S13, the host computer transmits the calculated coordinate data of point A to the teaching pendant (102), and the program of the teaching pendant controls the robot arm to move to the coordinate of point A.

8. The method for controlling a mechanical arm to replace manual labor to solve the normal operation of a socket according to claim 6, characterized in that: In S3, the robot arm simulates manual insertion and removal teaching program, which specifically includes the following steps: S31, the robot arm enters the teaching mode, and the system provides tool parameter settings, which include six items, among which offset X, offset Y, offset Z describe the relative position between the tool tip and the flange surface, and angle A, angle B, angle C describe the direction of the tip; S32, when the plugging and unplugging is not smooth, the robot arm (101) is moved forward in a world coordinate motion mode, the pin vertex of the test plug (609) is brought into contact with the socket protection door and set as the coordinate of point B, and the trajectory of reaching the coordinate of point B is recorded in the teaching program; S33. Set the target number of cycles required for the test in the teaching program, and compare it with the actual number of cycles completed in S2. If the target cycle is not reached, move the robot arm (101) in the form of world coordinate motion, and the test plug (609) withdraws from the sample, reaches point A, and returns to S2 to continue the action.

9. The method for controlling a mechanical arm to replace manual labor to solve the normal operation of a socket according to claim 8, characterized in that: When the plugging and unplugging is successful in S32, the test plug (609) is withdrawn from the sample and reaches point A. The mobile robot arm (101) returns to the initial position by means of joint coordinate motion and world coordinate motion, thus ending the test of the current position.

10. The method for controlling a mechanical arm to replace manual labor to solve the normal operation of a socket according to claim 8, characterized in that: In S4, the robot arm simulates the human hand to plug and unplug the host computer control, which specifically includes the following steps: S41, when the test plug (109) on the robot arm (101) is at the coordinate of point A, the robot arm controls the normal plugging and unplugging procedure through the teaching pendant (102); S42, the robotic arm (101) moves forward to perform the plugging and unplugging action, the pressure sensor monitors the real-time pressure, the host computer (103) monitors the real-time pressure change curve, and when the pressure value does not reach the set maximum value, the socket protection door is normally driven to open, and the robotic arm (101) continues to run the normal plugging and unplugging program through the teaching pendant; S43, the host computer (103) monitors the current state through the current sensor (106). If the current sensor (106) outputs a sample current connection signal, the plug and socket are normally connected successfully once; if the current sensor (106) does not output a sample current connection signal, the plug and socket connection fails and an alarm is prompted.

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