A manipulator control method and system for a high-speed packaging line

Abstract

A manipulator control method and system for a high-speed packaging line, the specific steps including: S1, initializing the manipulator; S2, establishing a basic data coordinate; S3, filtering the synchronous encoder; S4, establishing a coordinate curve; S5, merging the coordinate curves, and merging the running curves of the X-axis, Y-axis, and Z-axis in a spatial coordinate system with the absolute standby position of the coordinate curve established in S4 as the reference; S6, restoring the transfer belt modulus data; S7, according to the transfer belt modulus data restored in S6, parsing the merged coordinate curves in S5 in real time to move the positions of each axis of the manipulator. The beneficial effect of the present invention is to solve the problems of accuracy and efficiency in the process of transferring the medicine board from the discharge platform of the aluminum-plastic machine to the product chain of the cartoning machine in the connection part between the aluminum-plastic machine and the cartoning machine in the aluminum-plastic cartoning production line. Applied to the manipulator of the high-speed packaging line, the manipulator has greatly improved in terms of transfer speed and accuracy, and can be matched with the existing high-speed aluminum-plastic machines and high-speed cartoning machines.

Description

Technical Field

[0001] The present invention relates to the field of drug packaging in the pharmaceutical industry, and more specifically to a manipulator control method and system for a high-speed packaging line. Background Art

[0002] With the continuous development of the pharmaceutical industry, people have higher and higher requirements for the accuracy and efficiency of drug packaging machines. Taking a general aluminum-plastic box packaging production line as an example, the drug plates produced by the aluminum-plastic machine enter the connecting transfer belt through the discharge platform. The drug plates are in a single-layer and single-column state and are transported to the magazine of the box-packing machine by the conveyor belt. The operation stability during the transportation process is poor and the speed is slow, which cannot meet the requirements of high-speed operation. Summary of the Invention

[0003] The present invention overcomes the deficiencies in the prior art and provides a manipulator control method and system for a high-speed packaging line.

[0004] The purpose of the present invention is achieved by the following technical solutions.

[0005] A manipulator control method for a high-speed packaging line, the specific steps include:

[0006] S1. Initialize the manipulator, and perform zero initialization on the servo motors in the X, Y, and Z directions;

[0007] S2. Establish basic data coordinates, and sequentially establish the transfer belt modulus and the effective strokes of the X-axis, Y-axis, and Z-axis;

[0008] S3. Perform filtering processing on the synchronous encoder, and restore the position of the transfer belt according to the number of pulses corresponding to the encoder for a 1mm distance;

[0009] S4. Establish a coordinate curve;

[0010] S5. Merge the coordinate curves, and merge the running curves of the X-axis, Y-axis, and Z-axis in a spatial coordinate system with the absolute standby position of the coordinate curve established in S4 as the reference;

[0011] S6. Restore the transfer belt modulus data;

[0012] S7. According to the transfer belt modulus data restored in S6, parse the merged coordinate curves in S5 in real time to move the positions of each axis of the manipulator, so that the positions of each axis of the manipulator are synchronized with the transfer belt modulus position. When the transfer belt modulus reaches the plate-taking interval value, start to execute the drug plate grasping, and place the specified drug plate according to the transfer belt modulus position, and run in a loop.

[0013] The specific steps of S1 include: rotating the servo motor counterclockwise at a fixed speed to gradually approach the zero sensor. After sensing the zero sensor, continue to rotate at a low speed until the zero signal is lost and then stop running. Write the position of the servo motor as zero. After absolute positioning to the specified standby position, the initialization is completed.

[0014] The specific steps of S2 include:

[0015] S21. Establish the modulus of the transfer belt;

[0016] Obtain the modulus data of the transfer belt according to the maximum number of plates taken by the manipulator at one time * the width of the transfer conveyor belt station, and calculate the modulus value of the transfer belt.

[0017] m = a * b

[0018] Where, m is the modulus of the transfer belt, a is the number of plates taken, and b is the width of the transfer belt chain plate;

[0019] S22. Establish the effective stroke of the X-axis;

[0020] Obtain the effective stroke length according to the X-axis positive limit position minus the X-axis negative limit data;

[0021] S23. Establish the effective stroke of the Y-axis; Obtain the effective stroke angle according to the Y-axis positive limit minus the Y-axis negative limit data.

[0022] S24. Establish the effective stroke of the Z-axis; Obtain the effective stroke angle according to the Z-axis positive limit position minus the Z-axis negative limit data.

[0023] S3 uses the time-delay filtering method to collect data as a filtering processing means to prevent the encoder signal from jittering and causing the manipulator to run smoothly.

[0024] In S4, the five-point method is used to establish the coordinate data of the X-axis, Y-axis, and Z-axis. The coordinate curve formula is

[0025] q(t)=q0 + a1(t - t0)+a2(t - t0) 2 +a3(t - t0) 3 +a4(t - t0) 4 +a5(t - t0) 5

[0026] Where, q(t) is the value obtained from the actual position time; q0 is the starting position; a1 is the ending acceleration.

[0027] In S6, according to the electrical pulse signal of the transfer belt encoder and the running length of the transfer belt per revolution of the absolute encoder, calculate the moving distance of the transfer belt for each pulse electrical signal through the number of electrical pulses per revolution of the encoder.

[0028] The calculation formulas for the moving distance of each pulse of the transfer belt in S6 and the current moving distance of the transfer belt are as follows:

[0029] m1 = m ÷ pls

[0030] m2 = m1 * pls1

[0031] Wherein, pls is the encoder pulses per revolution; pls1 is the current number of encoder pulses; m is the moving distance of the transfer belt when the encoder rotates one week; m1 is the moving distance of the transfer belt for each pulse of the encoder; m2 is the current moving distance of the transfer belt.

[0032] A manipulator control system for a high-speed packaging line, the system includes:

[0033] A servo control module, which uses an external encoder installed on the cartoning machine as the main shaft to achieve cam synchronous control, so that the process of the manipulator picking and placing the board is completely synchronized with the cartoning machine and changes synchronously with the speed change of the cartoning machine;

[0034] An external encoder module, which is used to make the manipulator run synchronously with the cartoning machine, is configured as an external encoder in the process object, and serves as the main shaft of each servo station of the manipulator to drive each station to run synchronously with the cartoning machine;

[0035] A solenoid valve module, which is used to connect with the suction cups on the manipulator fixture to control the suction cups to work;

[0036] A translation servo positive and negative limit module, which uses an inductive sensor to protect the translation mechanism from being impacted.

[0037] The beneficial effects of the present invention are:

[0038] This solution solves the problems of accuracy and efficiency in the process of transferring the medicine board from the discharge platform of the aluminum-plastic machine to the product chain of the cartoning machine in the connection part between the aluminum-plastic machine and the cartoning machine in the aluminum-plastic cartoning production line. The present invention is applied to the manipulator of the high-speed packaging line, which greatly improves the transfer speed and accuracy of the manipulator, and can be matched with the existing high-speed aluminum-plastic machines and high-speed cartoning machines, so that the entire high-speed packaging line reaches the expected production efficiency. Brief Description of the Drawings

[0039] Figure 1 is a schematic structural diagram of the manipulator of the high-speed packaging line;

[0040] Figure 2 is a process flow chart of the manipulator control system of the high-speed packaging line;

[0041] In the figure: 1. Manipulator. Detailed Embodiments

[0042] The technical solutions of the present invention will be further described below through specific embodiments.

[0043] Embodiment

[0044] A control method for a manipulator used in a high - speed packaging line is a control method in which the manipulator completes material picking and placing according to the position signals of external encoders.

[0045] The specific steps include:

[0046] S1. Initialize the manipulator, and perform zero - point initialization on the servo motors in the X, Y, and Z directions;

[0047] S2. Establish the basic data coordinates, and successively establish the modulus of the transfer belt and the effective strokes of the X - axis, Y - axis, and Z - axis;

[0048] S3. Perform filtering processing on the synchronous encoder;

[0049] S4. Establish the coordinate curve;

[0050] S5. Merge the coordinate curves, and merge the running curves of the X - axis, Y - axis, and Z - axis in the form of a spatial coordinate system with the absolute standby position of the coordinate curve established in S4 as the reference;

[0051] S6. Restore the modulus data of the transfer belt;

[0052] S7. According to the modulus data of the transfer belt restored in S6, parse the coordinate curves merged in S5 in real - time to move the positions of each axis of the manipulator, so that the positions of each axis of the manipulator are synchronized with the positions of the transfer - belt modulus. When the transfer - belt modulus reaches the plate - picking interval value, start to execute the grasping of the medicine plate, and place the specified medicine plate according to the position of the transfer - belt modulus, and run in a cycle.

[0053] The specific steps of S1 include: Rotate the servo motor counter - clockwise at a fixed speed, gradually approach the zero - point sensor. When the zero - point sensor is sensed, continue to rotate at a low speed until the zero - point signal is lost and then stop running. Write the position of the servo motor as zero. After absolute positioning to the specified standby position, the initialization is completed.

[0054] The specific steps of S2 include:

[0055] S21. Establish the modulus of the transfer belt;

[0056] Obtain the modulus data of the transfer belt according to the maximum number of plates picked up by the manipulator at one time * the width of the transfer - belt conveyor station, and calculate the modulus value of the transfer belt,

[0057] m = a * b

[0058] where m is the modulus of the transfer belt, a is the number of plates picked up, and b is the width of the transfer - belt chain plate;

[0059] S22. Establish the effective stroke of the X - axis;

[0060] Obtain the effective stroke length by subtracting the X-axis reverse limit data from the X-axis positive limit position;

[0061] S23. Establish the Y-axis effective stroke; obtain the effective stroke angle by subtracting the Y-axis reverse limit data from the Y-axis positive limit.

[0062] S24. Establish the Z-axis effective stroke; obtain the effective stroke angle by subtracting the Z-axis reverse limit data from the Z-axis positive limit position.

[0063] S3 uses a delay filtering method to collect data as a filtering processing means to prevent the encoder signal from jittering and causing the manipulator to run smoothly.

[0064] In S4, the five-point method is used to establish the coordinate data of the X-axis, Y-axis, and Z-axis. The coordinate curve formula is

[0065] q(t)=q0+a1(t-t0)+a2(t-t0) 2 +a3(t-t0) 3 +a4(t-t0) 4 +a5(t-t0) 5

[0066] where q(t) is the value obtained at the actual position time; q0 is the starting position; a1 is the ending acceleration.

[0067] In S6, use the electrical pulse signal of the intermediate conveyor belt encoder. According to the running length of the intermediate conveyor belt per revolution of the absolute encoder, calculate the moving distance of the intermediate conveyor belt for each pulse electrical signal through the number of electrical pulses per revolution of the encoder.

[0068] The calculation formulas for the moving distance of the intermediate conveyor belt for each pulse and the current moving distance of the intermediate conveyor belt in S6 are:

[0069] m1=m÷pls

[0070] m2=m1*pls1

[0071] where pls is the number of encoder pulses per revolution; pls1 is the number of current encoder pulses; m is the moving distance of the intermediate conveyor belt for one revolution of the encoder; m1 is the moving distance of the intermediate conveyor belt for each pulse of the encoder; m2 is the current moving distance of the intermediate conveyor belt.

[0072] A manipulator control system for a high-speed packaging line, the system includes:

[0073] A servo control module, which uses an external encoder installed on the cartoning machine as the main shaft to achieve cam synchronous control, so that the process of the manipulator picking and placing the board is completely synchronized with the cartoning machine and changes synchronously with the speed change of the cartoning machine;

[0074] The external encoder module is used to synchronize the operation of the manipulator with the cartoning machine. It is configured as an external encoder in the technological object and serves as the main shaft of each servo station of the manipulator, driving each station to run synchronously with the cartoning machine.

[0075] The solenoid valve module is used to connect to the suction cups on the manipulator fixture to control the operation of the suction cups.

[0076] The translational servo positive and negative limit module uses inductive sensors to protect the translational mechanism from being impacted.

[0077] As Figure 1 shown, for the entire equipment controlled by the system in this implementation, a 380V AC power supply provides the main power. The three-phase five-wire standard power supply circuit has an in-built 380V to DC24V switching power supply for use by the servo control module, solenoid valve module, and sensor module.

[0078] The servo control module uses the Siemens motion controller 1511T in the entire equipment, equipped with a 1500 series IO expansion module. With the external encoder installed on the cartoning machine as the main shaft, it realizes cam synchronous control, enabling the manipulator to pick and place the board process to be completely synchronized with the cartoning machine and will change synchronously with the change in the speed of the cartoning machine for rational control.

[0079] The external encoder module is the link for the synchronous operation of the manipulator and the cartoning machine. It is configured as an external encoder in the technological object and serves as the main shaft of each servo station of the manipulator, driving each station to run synchronously with the cartoning machine.

[0080] The solenoid valve module is used to connect to the suction cups on the manipulator fixture to control the operation of the suction cups.

[0081] The translational servo positive and negative limit module contains two inductive sensors to protect the translational mechanism from being impacted.

[0082] As Figure 2 shown, the working process of a manipulator control system for a high-speed packaging line includes:

[0083] A1. Power on and initialize the system

[0084] A2. Detect the sensor signals. When the signals are abnormal, the system is locked and a system alarm is issued for prompt. If the signals are normal, enter the working system.

[0085] A3. Enter the working system. The manipulator moves to the normal working position and waits to pick and place the board.

[0086] A4. The external encoder signals cause each servo station of the manipulator to grasp and place the medicine board onto the product chain according to the CAM cam curve.

[0087] After completing the board placement work, the manipulator returns to the working waiting position, waits for the next encoder signal cycle, and performs periodic board picking and placing work.

[0088] The above has described the embodiments of the present invention in detail, but the content described is only the preferred embodiments of the present invention and cannot be considered as limiting the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of the present invention application shall still fall within the patent coverage scope of the present invention.

Claims

1. A control method for a manipulator used in a high-speed packaging line, characterized in that, The specific steps include: S1. Initialize the manipulator and perform zero initialization on the servo motors in the X, Y, and Z directions; S2. Establish the basic data coordinates, and successively establish the modulus of the transfer belt and the effective strokes of the X-axis, Y-axis, and Z-axis; S3. Perform filtering processing on the synchronous encoder; S4. Establish the coordinate curve; S5. Merge the coordinate curves, and merge the running curves of the X-axis, Y-axis, and Z-axis in the form of a spatial coordinate system with the absolute standby position of the coordinate curve established in S4 as the reference; S6. Restore the modulus data of the transfer belt, and restore the position of the transfer belt according to the number of pulses of the encoder corresponding to a 1-mm distance; S7. According to the modulus data of the transfer belt restored in S6, parse the merged coordinate curves in S5 in real time to move the positions of each axis of the manipulator, so that the positions of each axis of the manipulator are synchronized with the position of the modulus of the transfer belt. When the modulus of the transfer belt reaches the plate-taking interval value, start to execute the grasping of the medicine plate, and place the specified medicine plate according to the position of the modulus of the transfer belt, and run in a cycle; The specific steps of S2 include: S21. Establish the modulus of the transfer belt; Obtain the modulus data of the transfer belt according to the maximum number of plates taken by the manipulator at one time * the width of the transfer conveyor belt station, and calculate the modulus value of the transfer belt, m = a * b where m is the modulus of the transfer belt, a is the number of plates taken, and b is the width of the transfer belt chain plate; S22. Establish the effective stroke of the X-axis; Obtain the effective stroke length by subtracting the X-axis reverse limit data from the X-axis forward limit position; S23. Establish the effective stroke of the Y-axis; Obtain the effective stroke angle by subtracting the Y-axis reverse limit data from the Y-axis forward limit position; S24. Establish the effective stroke of the Z-axis; Obtain the effective stroke angle by subtracting the Z-axis reverse limit data from the Z-axis forward limit position.

2. The manipulator control method for a high-speed packaging line according to claim 1, characterized in that, The specific steps of S1 include: Rotate the servo motor counterclockwise at a fixed speed, gradually approach the zero sensor. When the zero sensor is sensed, continue to rotate at a low speed until the zero signal is lost and then stop running. Write the position of the servo motor as zero. After absolute positioning to the specified standby position, the initialization is completed.

3. The manipulator control method for a high-speed packaging line according to claim 1, characterized in that: S3 uses the delay filtering method to collect data as the filtering processing means.

4. A manipulator control method for a high-speed packaging line according to claim 1, characterized in that: In S4, the five-point method is used to establish the coordinate system data of the X-axis, Y-axis, and Z-axis. The coordinate curve formula is, q(t)=q0+a1(t - t0)+a2(t - t0) 2 +a3(t - t0) 3 +a4(t - t0) 4 +a5(t - t0) 5 where q(t) is the value obtained from the actual position time; q0 is the starting position; a1 is the ending acceleration.

5. A manipulator control method for a high-speed packaging line according to claim 1, characterized in that: In S6, use the electrical pulse signal of the transfer belt encoder. According to the running length of the transfer belt per revolution of the absolute encoder, calculate the moving distance of the transfer belt for each pulse of the electrical signal of the encoder.

6. A manipulator control method for a high-speed packaging line according to claim 5, characterized in that, The calculation formulas for the moving distance of the transfer belt for each pulse and the current moving distance of the transfer belt in S6 are: m1 = m ÷ pls m2 = m1 * pls1 where pls is the number of pulses per revolution of the encoder; pls1 is the current number of encoder pulses; m is the moving distance of the transfer belt for one revolution of the encoder; m1 is the moving distance of the transfer belt for each pulse of the encoder; m2 is the current moving distance of the transfer belt.

7. A manipulator control system for a high-speed packaging line, characterized in that it is used to implement the manipulator control method for a high-speed packaging line described in any one of claims 1-6. The system includes: Servo control module, which uses an external encoder installed on the cartoning machine as the main shaft to achieve cam synchronous control, enabling the process of the manipulator picking and placing the board to be completely synchronized with the cartoning machine and changing synchronously with the speed change of the cartoning machine; External encoder module, which is used to make the manipulator run synchronously with the cartoning machine. It is configured as an external encoder in the technological object and serves as the main shaft of each servo station of the manipulator to drive each station to run synchronously with the cartoning machine; Solenoid valve module, which is used to connect to the suction cups on the manipulator fixture to control the operation of the suction cups; Translation servo positive and negative limit module, which uses inductive sensors to protect the translation mechanism from being impacted.

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