A method for automatic loading and unloading of solar collector tubes

Abstract

A method for automatically loading and unloading solar collector tubes, relating to the field of automation technology, involves dividing a circular conveyor line into N sectors. Each sector contains two layers of collector tubes, inner and outer, with starting and gripping markers. Sensors detect these markers, and a robotic arm grips the collector tubes based on the detection signals and places them at the unloading station. The fixture includes a connecting seat, slide rail, mounting seat, pneumatic telescopic cylinder, and gripper cylinder. The mounting seat slides along the slide rail, the pneumatic telescopic cylinder controls the connection between the mounting seat and the connecting seat, and the gripper cylinder grips the collector tubes. The inflation and deflation of the pneumatic telescopic cylinder allows for free movement and rigid connection of the mounting seat, ensuring the stability and reliability of gripping and unloading. This invention's automatic loading and unloading method and fixture design improve the efficiency and reliability of automatic loading and unloading, providing a highly efficient and stable automated solution for solar collector tube production.

Description

Technical Field

[0001] This invention relates to the field of automation technology, and in particular to a method for automatically loading and unloading solar collector tubes. Background Technology

[0002] In the production process of solar collector tubes, the loading and unloading of the tubes on the circular conveyor line is crucial. Traditional manual loading and unloading methods have many drawbacks: firstly, manual operation is inefficient, unable to meet the demands of large-scale production, and involves high labor intensity, easily leading to worker fatigue and affecting production progress; secondly, the high temperature and harsh environment in the tube production workshop negatively impacts the physical and mental health of the operators. Therefore, it is necessary to develop robots capable of automated loading and unloading. The challenge lies in the fact that inaccurate precision control and other factors can easily cause scratches, bumps, and other damage to the surface of the collector tubes, reducing product quality, increasing the defect rate, and causing additional economic losses to the company. Furthermore, to meet production demands, the circular conveyor line is constantly running during the loading and unloading process. Existing robots, due to their inability to accurately follow the tubes, cannot guarantee precise positioning during the arrangement and placement of the tubes. Inaccurate following can directly lead to excessive stress on the collector tubes, causing them to break. Therefore, how to automate the loading and unloading of solar collector tubes, improve production efficiency, reduce labor costs, and minimize product damage has become an urgent problem for solar collector tube manufacturers. Summary of the Invention

[0003] To overcome the shortcomings of the prior art, the present invention discloses an automatic loading and unloading method for solar collector tubes.

[0004] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0005] A method for automatically loading and unloading solar collector tubes includes the following steps:

[0006] S1. Divide the ring-shaped transmission line into N sectors. In each sector, place two layers of heat collection tubes, inner and outer, at an angle. The number of heat collection tubes in the inner and outer layers is equal, and there is a gap between two adjacent heat collection tubes.

[0007] S2. Set a starting position marker at the starting position of the inner and outer layers of heat collection tubes in each sector, and set a grab marker every X heat collection tubes in the inner and outer layers.

[0008] S3. Real-time detection of the starting position markers and grasping markers of the inner and outer layers using two sensors;

[0009] S4. Install a robotic arm on the outside of the circular conveyor line, and install a clamp for gripping the heat collection tube on the execution end of the robotic arm.

[0010] S5. The robotic arm is in standby position in the initial position, waiting for the outer layer sensor to detect the outer layer starting position mark point. After the outer layer sensor is triggered, the robotic arm drives the gripper to grab the outer layer X heat collection tubes, place them in the unloading station and then reset. Wait for the outer layer sensor to detect the outer layer first grab mark point. After the outer layer sensor is triggered, the robotic arm grabs the outer layer X heat collection tubes again, places them in the unloading station and then resets.

[0011] S6. Wait for the inner layer sensor to detect the inner layer starting position mark. After the inner layer sensor is triggered, the robotic arm drives the clamp to grab the X inner layer heat collection tubes, place them at the unloading station and then reset.

[0012] S7. Wait for the outer layer sensor to detect the next gripping mark point on the outer layer. After the outer layer sensor is triggered, the robotic arm will grip the X outer layer heat collection tubes again, place them at the unloading station, and then reset.

[0013] S8. Wait for the inner layer sensor to detect the inner layer gripping mark point. After the inner layer sensor is triggered, the robotic arm drives the clamp to grip the X inner layer heat collection tubes, place them at the unloading station and then reset.

[0014] S9. Repeat steps S7 to S8 until all the heat collection tubes in the sector are removed.

[0015] Preferably, both the internal and external sensors in step S3 can be industrial cameras, proximity switches, or photoelectric sensors.

[0016] Preferably, the robotic arm's actuator is equipped with two grippers, one above and one below.

[0017] Preferably, the clamp comprises:

[0018] Connector, installed at the actuator end of the robotic arm;

[0019] Slide rails, with multiple slide rails spaced apart on the connecting seat;

[0020] The mounting base slides along the slide rail via a slider.

[0021] The pneumatic telescopic cylinder is located between the mounting base and the connecting base. By inflating, it extends the mounting base to a fixed position and maintains a rigid connection between the mounting base and the connecting base. By deflating, it allows the mounting base to be in a free state that can slide along the slide rail.

[0022] Gripper cylinders, multiple gripper cylinders are arranged in an array on the mounting base.

[0023] Preferably, the mounting base has two rows of gripper cylinders arranged in a staggered manner.

[0024] Preferably, the inner side of the gripper of the gripper cylinder is provided with a flexible protective pad.

[0025] Preferably, the gripper cylinder is provided with a contact switch on one side between the two grippers.

[0026] Preferably, the mounting base has a rhomboid structure.

[0027] By employing the technical solution described above, the present invention has the following beneficial effects:

[0028] This invention discloses an automatic loading and unloading method for solar collector tubes. By dividing a circular conveyor line into N sectors, and placing inner and outer layers of collector tubes at an angle within each sector while maintaining a pre-existing gap, the method ensures uniform distribution and stability of the collector tubes during transport, effectively preventing damage caused by collisions and improving the integrity rate of the collector tubes. During the automatic loading and unloading process, setting starting and gripping markers provides precise positioning data for the robotic arm, enabling it to accurately grip and place the collector tubes, greatly improving the accuracy and reliability of loading and unloading, and ensuring the smooth operation of subsequent production processes.

[0029] This invention further utilizes two sensors, one internal and one external, to detect the marked points in real time and transmit the position information to the central processing unit of the control system. This enables precise control of the entire loading and unloading process, allowing the robotic arm to flexibly adjust according to the actual position of the solar collector tubes, thereby further improving production efficiency and product quality. Specifically, when gripping the outer solar collector tube, this method grips it twice first, leaving sufficient space for gripping the inner solar collector tube. This effectively prevents accidental collisions and damage to the inner and outer solar collector tubes during gripping, further reducing the product defect rate and improving the company's economic benefits.

[0030] This invention further enables the mounting base to slide freely left and right along the slide rail via a slider-rail sliding engagement. When gripping the collector tube, the pneumatic telescopic cylinder exhausts air, placing the mounting base in a free state. Even if there is a small distance deviation between the gripper cylinder's claw and the collector tube, automatic displacement compensation can be achieved, preventing damage to the collector tube by the gripper cylinder's claw, effectively protecting the surface quality of the collector tube, and reducing the defect rate. The free movement of the mounting base automatically compensates for the displacement distance of the collector tube, eliminating the need for a robotic arm to follow, thus greatly reducing the control difficulty of the robotic arm, simplifying control system programming and debugging, and improving the system's intelligence level and operating efficiency. After the gripper cylinder clamps the collector tube and pulls out of the annular conveyor line, the pneumatic telescopic cylinder inflates, rigidly connecting the mounting base and the connecting seat. During the unloading process, the entire fixture and collector tube remain in a stable state, improving safety and reliability. Simultaneously, the pneumatic telescopic cylinder remains inflated, ensuring the gripper cylinder is precisely positioned in the gripping position, improving gripping accuracy and work efficiency. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the present invention;

[0032] Figure 2 This is a schematic diagram of the three-dimensional structure of the fixture;

[0033] Figure 3 This is a schematic diagram of the fixture's structure;

[0034] Figure 4 This is a top view of the fixture;

[0035] Figure 5 This is a schematic diagram of a structure in which two clamps are connected by a ramp.

[0036] In the diagram: 1. Connecting seat; 2. Slide rail; 3. Mounting seat; 4. Slider; 5. Pneumatic telescopic cylinder; 6. Gripper cylinder; 7. Flexible protective pad. Detailed Implementation

[0037] The present invention can be explained in detail through the following embodiments. The purpose of disclosing the present invention is to protect all technical improvements within the scope of the present invention. In the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "front", "rear", "left", "right" indicating the orientation or positional relationship, they are only corresponding to the drawings of this application for the convenience of describing the present invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation.

[0038] Example 1, in conjunction with Appendix Figure 1 A method for automatically loading and unloading solar collector tubes includes the following steps:

[0039] S1. The circular conveyor line is divided into N sectors. Within each sector, two layers of heat collection tubes are arranged at an angle, with an equal number of tubes in each layer. The circular conveyor line is an existing device that rotates and transports the heat collection tubes at a speed of 1 cm / s. For example, each sector can hold 48 heat collection tubes: 24 in the inner layer and 24 in the outer layer. This layout ensures the heat collection tubes are evenly distributed during transport. Simultaneously, a certain gap is reserved between adjacent heat collection tubes to prevent collisions during transport and to facilitate automatic loading and unloading.

[0040] S2. Starting point markers are set at the beginning positions of both the inner and outer layers of collector tubes in each sector. Additionally, a gripping marker is set at every X collector tube intervals in both the inner and outer layers. Taking a sector with 48 collector tubes as an example, if 6 tubes are gripped each time, a gripping marker is set every 6 collector tubes, for a total of 3 gripping markers. These markers play a crucial role in the entire automated loading and unloading process; they are the key basis for the robotic arm's identification and positioning. Through these markers, the robotic arm can accurately determine the gripping position each time, ensuring the precision of the gripping action, thereby improving the efficiency and reliability of the entire loading and unloading process.

[0041] S3. Two sensors, one internal and one external, are used to monitor the starting position markers and the gripping markers on both the inner and outer layers in real time. These two sensors are key components of the entire system, accurately capturing the position information of the markers and quickly transmitting this information to the central processing unit (CPU) of the control system. Depending on the actual needs, the sensors can be industrial cameras, proximity switches, or photoelectric sensors. It is crucial to ensure that the sensors can be triggered during installation of the sensors, starting position markers, and gripping markers. An industrial camera is preferred. Once triggered, the industrial camera can take a picture of the corresponding position and send it back to the CPU of the control system to calculate the deformation deviation of the rack holding the heat collection tubes on the circular conveyor line. The CPU then controls the robotic arm to automatically compensate for this deviation, further improving the accuracy of the gripping action.

[0042] S4. Install a robotic arm on the outside of the circular conveyor line, and install a gripper specifically designed for grasping the solar collector tubes at the actuator end of the robotic arm. This robotic arm can move flexibly in three-dimensional space and accurately reach the predetermined gripping position. Since the solar collector tubes are inserted at an angle into the corresponding supports of the circular conveyor line, during the gripping process, the robotic arm can first clamp the solar collector tubes, then move them along their angled direction. After the bottom of the solar collector tubes is detached from the circular conveyor line, the solar collector tubes are then removed. It is important to note that during the gripping process, the circular conveyor line is still rotating and moving at a speed of 1 cm / s; therefore, the robotic arm or gripper needs to be able to follow the movement of the circular conveyor line.

[0043] S5. Initially, the robotic arm is in standby mode in the initial position, waiting for the outer layer sensor to detect the outer layer starting position marker. Taking 48 collector tubes per sector as an example, when the outer layer sensor is triggered, the robotic arm responds quickly, driving the gripper to accurately grasp the 6 outer layer collector tubes, and then smoothly place them at the unloading station before resetting. This process is precisely controlled by the control system to ensure accurate and smooth movements of the robotic arm, with the grasping and placing actions being seamless. Subsequently, after waiting for the outer layer sensor to detect the first outer layer grasping marker, and triggering the outer layer sensor again, the robotic arm repeats the above actions, grasping the 6 outer layer collector tubes again, placing them at the unloading station, and then resetting.

[0044] S6. Wait for the inner layer sensor to detect the inner layer starting position marker. After the inner layer sensor is triggered, the robotic arm drives the gripper to grab the 6 inner layer heat collector tubes, place them at the unloading station, and then reset. When grabbing the inner layer heat collector tubes, the robotic arm's movements are similar to those when grabbing the outer layer heat collector tubes, but the robotic arm's movements are adjusted accordingly for the position of the inner layer heat collector tubes to ensure that the grabbing task can be completed accurately.

[0045] S7. Wait for the outer layer sensor to detect the next gripping marker on the outer layer. After the outer layer sensor is triggered, the robotic arm grips the six outer layer collector tubes again and places them in the unloading station before resetting. The reason for gripping the outer layer collector tubes twice in each sector is to reserve sufficient gripping space for the inner layer collector tubes and prevent accidental collisions between the inner and outer layers of collector tubes during the gripping process, thus preventing damage.

[0046] S8. Wait for the inner layer sensor to detect the inner layer gripping mark point. After the inner layer sensor is triggered, the robotic arm drives the clamp to grip the 6 heat collection tubes of the inner layer, place them at the unloading station, and then reset.

[0047] S9. Repeat steps S7 to S8 until all solar collector tubes in the sector have been removed. Through these steps, this method enables automated loading and unloading of solar collector tubes, improving production efficiency, reducing manual intervention, and minimizing errors and risks associated with manual operation. It offers high practicality and reliability, providing an efficient and stable automated solution for the production of solar collector tubes.

[0048] It should be noted that this embodiment describes the method of feeding the heat collection tubes; when feeding, simply follow the reverse steps.

[0049] Example 2, in conjunction with Appendix Figures 1-5 A method for automatically loading and unloading solar collector tubes, differing from Embodiment 1 in that, based on Embodiment 1, to ensure the reliability of the robotic arm's clamping and prevent the collector tubes from breaking due to excessive local clamping force, a transition plate is provided at the execution end of the robotic arm, and two clamps, upper and lower, are installed on the transition plate, as shown in the attached figure. Figure 5 As shown, the heat collection tube is gripped by two clamps working together.

[0050] As attached Figures 2-5 As shown, the fixture includes a connecting seat 1, slide rails 2, and mounting base 3. The connecting seat 1 is mounted on the actuator end of the robotic arm and serves as a key component connecting the entire fixture to the robotic arm. Its stability and installation accuracy directly affect the overall performance of the fixture. Multiple slide rails 2 are spaced apart on the connecting seat 1, preferably two slide rails 2 spaced apart. This design not only facilitates installation but also effectively reduces usage costs and improves the economic efficiency of the fixture while ensuring its strength.

[0051] The mounting base 3 is slidably engaged with the slide rail 2 via a slider 4, meaning the mounting base 3 can slide freely left and right relative to the connecting base 1 along the slide rail 2. This sliding engagement design gives the mounting base 3 lateral flexibility, allowing for position adjustment according to actual working conditions. Multiple gripper cylinders 6 are arranged in an array on the mounting base 3. Through a reasonable layout, it is ensured that the gripper cylinders 6 are evenly stressed during operation, improving the stability and reliability of gripping.

[0052] A pneumatic telescopic cylinder 5 is installed between the mounting base 3 and the connecting base 1. The pneumatic telescopic cylinder 5 can be mounted on the mounting base 3, with its piston rod extended and securely connected to the connecting base 1 via a bracket; or the pneumatic telescopic cylinder 5 can be mounted on the connecting base 1, with its piston rod extended and securely connected to the mounting base 3 via a bracket. As a key driving component of the clamp, the pneumatic telescopic cylinder 5 functions to move the mounting base 3 to a fixed position by inflating and extending it, maintaining a rigid connection between the mounting base 3 and the connecting base 1, ensuring the entire clamp and heat collection tube remain stable during the unloading process; and to allow the mounting base 3 to slide freely along the slide rail 2 by deflating it, enabling automatic displacement compensation based on the position of the heat collection tube during clamping.

[0053] In this way, when gripping the collector tube, the robotic arm first sends the clamp to the gripping position, and then the pneumatic telescopic cylinder 5 is vented, so that the mounting base 3 is in a free state that can slide along the slide rail 2; then the robotic arm moves until the collector tube enters between the two jaws of the gripper cylinder 6; during this process, since the mounting base 3 is in a free state, even if there is a small distance deviation between the jaws of the gripper cylinder 6 and the collector tube, it can be automatically compensated for when the jaws of the gripper cylinder 6 touch the collector tube, thereby preventing the jaws of the gripper cylinder 6 from damaging the collector tube, effectively protecting the surface quality of the collector tube, reducing the defect rate, and improving production efficiency.

[0054] It is worth noting that during the gripping process, the annular conveyor line remains in a rotating and moving state at 1 cm / s. The free movement of the mounting base 3 can automatically compensate for the displacement distance of the heat collection tube without requiring the robotic arm to follow. This greatly reduces the control difficulty of the robotic arm, simplifies the programming and debugging process of the control system, and improves the intelligence level and operating efficiency of the entire system. After the gripper cylinder 6 clamps the heat collection tube and pulls it upward out of the annular conveyor line, the pneumatic telescopic cylinder 5 is inflated, thus making the mounting base 3 and the connecting base 1 in a rigid connection state. Then, the robotic arm is controlled to place the heat collection tube at the unloading station. This ensures that the entire fixture and heat collection tube remain stable during the unloading process, thereby improving safety and reliability. At the same time, before the next gripping action, the pneumatic telescopic cylinder 5 remains inflated, ensuring that the gripper cylinder 6 is accurately positioned in the gripping position, improving the gripping accuracy and work efficiency.

[0055] It should be noted that before the pneumatic telescopic cylinder 5 exhausts air, both ends of the mounting base 3 need to be at the same horizontal height to prevent the mounting base 3 from automatically sliding to the lower side under its own gravity after the pneumatic telescopic cylinder 5 exhausts air, which would cause a large positional deviation between the gripper cylinder 6 and the corresponding heat collection tube, affecting the gripping accuracy and working efficiency.

[0056] Example 3, in conjunction with Appendix Figures 2-5 A method for automatically loading and unloading solar collector tubes, based on embodiment 1 or 2, includes two rows of upper and lower gripper cylinders 6 arranged on the mounting base 3, with the two rows of gripper cylinders 6 staggered. This effectively handles densely packed collector tubes and avoids interference between adjacent gripper cylinders 6. The inner side of the gripper of each gripper cylinder 6 is provided with a flexible protective pad 7. This effectively protects the collector tubes and prevents the gripper cylinders 6 from pinching or scratching them.

[0057] Furthermore, a contact switch (not shown in the figure) is provided on one side of the gripper cylinder 6 corresponding to the two grippers. When gripping the heat collector tube, the heat collector tube can trigger the contact switch when it is in a suitable position between the two grippers, thereby sending a clamping signal to activate the gripper cylinder 6. The two grippers clamp the heat collector tube, which can prevent the gripper cylinder 6 from being too far away from the heat collector tube and unable to clamp effectively, or from being too close to the heat collector tube and hitting it.

[0058] Furthermore, the mounting base 3 has a rhomboid structure. This effectively reduces the weight of the mounting base 3, while eliminating non-functional parts and increasing the safe range of movement of the mounting base 3.

[0059] The parts of this invention not described in detail are prior art. It will be apparent to those skilled in the art that this invention is not limited to the details of the above exemplary embodiments, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and are intended to encompass all changes falling within the meaning and scope of equivalents within this invention.

Claims

1. A method for automatically loading and unloading solar collector tubes, which, in conjunction with a circular conveyor line, achieves automatic loading and unloading; characterized in that, Includes the following steps: S1. Divide the ring-shaped transmission line into N sectors. In each sector, place two layers of heat collection tubes, inner and outer, at an angle. The number of heat collection tubes in the inner and outer layers is equal, and there is a gap between two adjacent heat collection tubes. S2. Set a starting position marker at the starting position of the inner and outer layers of heat collection tubes in each sector, and set a grab marker every X heat collection tubes in the inner and outer layers. S3. Real-time detection of the starting position markers and grasping markers of the inner and outer layers using two sensors; S4. Install a robotic arm on the outside of the circular conveyor line, and install a clamp for gripping the heat collection tube on the execution end of the robotic arm. S5. The robotic arm is in standby position in the initial position, waiting for the outer layer sensor to detect the outer layer starting position mark point. After the outer layer sensor is triggered, the robotic arm drives the gripper to grab the outer layer X heat collection tubes, place them in the unloading station and then reset. Wait for the outer layer sensor to detect the outer layer first grab mark point. After the outer layer sensor is triggered, the robotic arm grabs the outer layer X heat collection tubes again, places them in the unloading station and then resets. S6. Wait for the inner layer sensor to detect the inner layer starting position marker. After the inner layer sensor is triggered, the robotic arm drives the clamp to grab the X inner layer heat collection tubes, place them at the unloading station and then reset. S7. Wait for the outer layer sensor to detect the next gripping mark point on the outer layer. After the outer layer sensor is triggered, the robotic arm will grip the X outer layer heat collection tubes again, place them at the unloading station, and then reset. S8. Wait for the inner layer sensor to detect the inner layer gripping mark point. After the inner layer sensor is triggered, the robotic arm drives the clamp to grip the X inner layer heat collection tubes, place them at the unloading station and then reset. S9. Repeat steps S7 to S8 until all the heat collection tubes in the sector are removed.

2. The method for automatic loading and unloading of solar collector tubes as described in claim 1, characterized in that: In step S3, both the internal and external sensors are industrial cameras, proximity switches, or photoelectric sensors.

3. The method for automatic loading and unloading of solar collector tubes as described in claim 1, characterized in that: The robotic arm's actuator is equipped with two grippers, one above and one below.

4. The method for automatic loading and unloading of solar collector tubes as described in any one of claims 1 to 3, characterized in that: The clamp includes: Connector (1), installed on the actuator end of the robotic arm; Slide rails (2), multiple slide rails (2) are spaced apart on the connecting seat (1); Mounting base (3) slides with slide rail (2) via slider (4); A pneumatic telescopic cylinder (5) is located between the mounting base (3) and the connecting base (1). By inflating and extending, the mounting base (3) is moved to a fixed position, and the mounting base (3) and the connecting base (1) are kept in a rigid connection. By deflating, the mounting base (3) is in a free state that can slide along the slide rail (2). Gripper cylinders (6), multiple gripper cylinders (6) are arranged in an array on the mounting base (3).

5. The method for automatic loading and unloading of solar collector tubes as described in claim 4, characterized in that: The mounting base (3) has two rows of gripper cylinders (6) arranged on it, and the two rows of gripper cylinders (6) are staggered.

6. The method for automatic loading and unloading of solar collector tubes as described in claim 4, characterized in that: The gripper cylinder (6) has a flexible protective pad (7) on the inner side of the gripper.

7. The method for automatic loading and unloading of solar collector tubes as described in claim 4, characterized in that: The gripper cylinder (6) has a contact switch on one side between the two grippers.

8. The method for automatic loading and unloading of solar collector tubes as described in claim 4, characterized in that: The mounting base (3) has a rhomboid structure.

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