Stacking method and stacking workstation thereof

Abstract

The invention relates to the technical field of palletizing robots, in particular to a palletizing method and a palletizing workstation thereof, and effectively prevents potential risks such as over-limit operation, overload and positioning errors of a mechanical arm through a multi-stage safety verification mechanism and dynamic closed-loop control. According to the invention, by means of the functions of self-adaptive speed reduction reset, abnormal pop-up prompt and one-key calibration, the possibility of misoperation and equipment damage is reduced, safe and stable operation in a man-machine cooperation environment is guaranteed, and meanwhile, the downtime caused by faults is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of palletizing robots, and in particular to a palletizing method and a palletizing workstation thereof. Background Art

[0002] Palletizing, the process of stacking packages, containers, or bulk materials onto pallets (or pallets) according to pre-set rules, is a critical process in logistics and manufacturing. Its core value lies in its ability to maximize stacking density, reduce storage and transportation space, and achieve standardized specifications for easier automated handling.

[0003] However, the existing technology for palletizing materials has the following technical problems:

[0004] 1. Traditional palletizing systems lack effective active protection mechanisms, relying solely on passive safeguards such as emergency stop buttons. These systems are unable to predict joint overruns or overload risks during robotic arm movement. This passive approach leads to frequent hardware damage, such as robotic arm collisions and motor burnouts. Fault location is also difficult, often requiring on-site disassembly and debugging by engineers, resulting in lengthy production line downtime and significant financial losses.

[0005] 2. The existing palletizing system used a rigid gripping strategy, making it difficult to adapt to the complex and changing characteristics of materials. The fixed vacuum pressure and gripping angle were unable to cope with common production conditions, such as cardboard boxes swelling due to moisture and oil stains on metal cans. This resulted in a high gripping failure rate for odd-shaped materials. Furthermore, debugging data lacked effective linkage with the system, requiring parameter reconfiguration for each line change. Cross-machine adaptation was time-consuming and severely impacted production efficiency.

[0006] 3. Traditional palletizing systems have a limited human-machine interface, lacking visual configuration of palletizing parameters and status feedback, making it difficult for operators to intuitively understand the palletizing progress. Furthermore, the robotic arm's reset process lacks intelligent control, creating safety risks associated with zero return operations. Furthermore, the exception handling process is cumbersome, increasing operational difficulty and the risk of error.

[0007] Existing technologies lack an effective closed-loop optimization mechanism, and debugging parameters cannot be synchronized back to the system. This results in repeated debugging for each exception handling, preventing the accumulation of experience and continuous optimization of the system. These issues seriously restrict the efficiency and quality of palletizing operations. Therefore, a palletizing method and palletizing workstation that can solve these problems are needed. Summary of the Invention

[0008] This invention provides a palletizing method and workstation. Through a multi-level safety verification mechanism (servo enable status detection, joint position compliance verification, and real-time vacuum pressure monitoring) and dynamic closed-loop control (load feedback linkage trajectory adjustment, automatic pause and calibration when position exceeds the limit), this method effectively prevents potential risks such as robotic arm overrun, overload, and positioning errors. In particular, the adaptive speed reduction and reset, abnormal pop-up window prompt, and one-click calibration functions reduce the possibility of operational errors and equipment damage, ensuring safe and stable operation in a human-machine collaborative environment while reducing downtime caused by failures.

[0009] The technical solution adopted by the present invention to solve the above technical problems is:

[0010] A palletizing method comprises the following steps:

[0011] Step S1: Execute stacking parameter configuration and status visual feedback through the human-computer interaction interface, including:

[0012] Automatically load the encoder parameters and multi-axis robot arm motion constraints according to the selected model;

[0013] Edit multi-layer palletizing patterns in a visual interface, and dynamically distinguish the palletizing status of completed and unfinished materials through preset identifiers;

[0014] Step S2: Execute multi-level safety verification and reset control of the multi-axis robot arm, including:

[0015] Detect the servo system enable status of the multi-axis robot and the compliance of the robotic arm joint position of the multi-axis robot;

[0016] When the multi-axis robot's arm triggers the zero return operation, an interactive confirmation process is generated based on the real-time position deviation. After confirmation, the multi-axis robot's arm is reset using an adaptive speed reduction algorithm.

[0017] Step S3: Dynamic closed-loop control and real-time abnormality monitoring, including:

[0018] Adjust the motion trajectory of the multi-axis robot arm based on the global speed parameter and load feedback signal;

[0019] Verify the position coordinate accuracy of the adsorption mechanism in real time. If it exceeds the limit, the calibration command will be triggered and the task will be suspended.

[0020] Step S4: Dynamically adjust the grasping strategy of the multi-axis robot's manipulator based on the material state;

[0021] Step S5: Correct the abnormal motion parameters of the multi-axis robot through the manual debugging mode in the human-computer interaction interface, and synchronize the debugged motion parameters back to the stacking configuration system to achieve closed-loop optimization.

[0022] Furthermore, step S1 specifically includes:

[0023] Step S1-1: Load the code disc size and the arm joint limit parameters of the multi-axis robot according to the selected model;

[0024] Step S1-2: In the touch-screen human-machine interface, define the material layout by dragging and dropping. If the distance between adjacent materials is less than the safety threshold, the material will be automatically marked in red.

[0025] Step S1-3: Generate yellow marks for materials that have completed palletizing, retain white marks for unfinished palletizing, and support switching display according to the layer number of each layer of palletizing.

[0026] Furthermore, step S2 includes:

[0027] Step S2-1: When detecting the servo enable state of the multi-axis robot, the vacuum pressure value of the adsorption mechanism at the end of the multi-axis robot arm is synchronously checked. If the pressure is abnormal, the robot is prohibited from starting.

[0028] Step S2-2: After the return to zero operation is triggered, a pop-up window displays the deviation distance between the current position of the multi-axis robot arm and the zero position and the estimated return to zero time;

[0029] Step S2-3: During the zero return process, if the joint position exceeds the limit, the zero return is paused and a pop-up window prompts the exceeded joint number.

[0030] Furthermore, step S3 includes the following sub-steps:

[0031] Step S3-1: adjusting the motion acceleration of the multi-axis robot's manipulator arm in real time according to the global speed parameters of the multi-axis robot, and calculating the remaining task time;

[0032] Step S3-2: Monitor the load current. If the load current exceeds the limit for three consecutive seconds, the multi-axis robot arm will automatically slow down to a safe value and generate a warning log.

[0033] Step S3-3: Collect the actual position coordinates of the adsorption mechanism. If the deviation from the preset position coordinates exceeds ±50 mm, highlight the abnormal point;

[0034] Step S3-4: After pausing the task, perform one-key calibration through the human-computer interaction interface. After the calibration is completed, the multi-axis robot automatically resumes operation.

[0035] Furthermore, step S4 includes:

[0036] Step S4-1: Real-time identification of material size using a laser profile sensor, estimation of material weight using the end force sensor of the adsorption mechanism, and determination of material surface characteristics based on vacuum pressure fluctuations and leakage rate of the adsorption mechanism;

[0037] Step S4-2: Dynamically adjust the vacuum pressure threshold of the adsorption mechanism and the gripping angle of the multi-axis robot arm according to the material size, material weight and material surface characteristics;

[0038] Step S4-3: Encrypt and store the updated parameters and synchronize them to the stack configuration system.

[0039] Furthermore, step S5 includes:

[0040] Step S5-1: In manual debugging mode, switch to the tool coordinate system to control the movement of the multi-axis robot arm, and limit the jog speed of the multi-axis robot arm to 10%-30% of the global speed of the multi-axis robot;

[0041] Step S5-2: After debugging is completed, a parameter modification comparison report is generated and synchronized to the stacking configuration system after hash encryption.

[0042] A palletizing workstation includes a support frame, a base and a multi-axis robot. The base is fixedly connected to the support frame, a touch-type human-machine interface and control buttons are installed on the base, and the multi-axis robot is installed on the base. An adsorption mechanism for grabbing and placing materials is installed on the multi-axis robot.

[0043] Furthermore, a multi-axis machine is a robot having multiple robotic arms connected in series.

[0044] The advantages of the present invention are:

[0045] 1. This invention effectively prevents potential risks such as over-limit operation, overload, and positioning errors in the robotic arm through a multi-level safety verification mechanism (servo enable status detection, joint position compliance verification, and real-time vacuum pressure monitoring) and dynamic closed-loop control (load feedback linkage trajectory adjustment, automatic pause and calibration when position exceeds the limit). In particular, the adaptive speed reduction reset, abnormal pop-up window prompt, and one-click calibration function reduce the possibility of operational errors and equipment damage, ensuring safe and stable operation in a human-machine collaborative environment, while also reducing downtime caused by failures.

[0046] 2. The palletizing method provided by this invention deeply integrates real-time perception and dynamic decision-making. Utilizing laser profile sensors, end-point force sensors, and vacuum pressure data, the system can identify material size, weight, and surface characteristics in real time and dynamically adjust the grasping strategy accordingly, significantly improving the robot's adaptability to different materials and its grasping success rate. Furthermore, the coordinated regulation of global speed and load feedback, strategy updates based on material status, and closed-loop optimization of debugging parameters enable the system to continuously learn and optimize, enabling it to cope with even more complex real-world conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0048] Figure 1 It is a structural schematic diagram of the palletizing workstation in the present invention;

[0049] like Figure 1 As shown, it includes: a support frame 1, a base 2, a touch-type human-machine interface 3, a control button 4, a multi-axis robot 5, and an adsorption mechanism 6. DETAILED DESCRIPTION

[0050] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0051] Example 1:

[0052] The present invention provides a palletizing method, comprising the following steps: step S1: performing palletizing parameter configuration and status visualization feedback through a human-computer interaction interface, including: automatically loading code plate parameters and motion constraints of the multi-axis robot 5 according to the selected machine model; editing multi-layer palletizing styles in the visualization interface, and dynamically distinguishing the palletizing status of completed and unfinished materials through preset identifiers; step S2: performing multi-level safety verification and reset control of the multi-axis robot 5, including: detecting the servo system enabling state of the multi-axis robot 5 and the compliance of the joint position of the multi-axis robot 5; when the multi-axis robot 5 triggers the zero return operation, the robot arm is reset based on the real-time position deviation. The difference generates an interactive confirmation process, and after confirmation, the robotic arm of the multi-axis robot 5 is reset with an adaptive speed reduction algorithm; step S3: dynamic closed-loop control and real-time abnormality monitoring, including: adjusting the motion trajectory of the robotic arm of the multi-axis robot 5 based on the global speed parameters and the load feedback signal; real-time verification of the position coordinate accuracy of the adsorption mechanism 6, if it exceeds the limit, triggering the calibration instruction and pausing the task; step S4: dynamically adjusting the robotic arm grasping strategy of the multi-axis robot 5 based on the material status; step S5: correcting the abnormal motion parameters of the multi-axis robot 5 through the manual debugging mode in the human-computer interaction interface, and reversely synchronizing the debugged motion parameters to the stacking configuration system to achieve closed-loop optimization.

[0053] Among them, the human-machine interface for palletizing parameter configuration and status visualization uses a graphical user interface to visualize parameter settings and operating status. Specifically, this utilizes a touch screen combined with a PLC communication protocol for bidirectional data transmission, mapping equipment operating data to interface elements in real time. This feature addresses the complex parameter configuration and opaque operating status issues of traditional systems. Multi-level safety verification and robotic arm reset control establishes a multi-layered protection mechanism through servo system status detection, joint position verification, and vacuum pressure monitoring. Specifically, Hall sensors combined with encoder feedback implement closed-loop position detection. This feature addresses the lack of predictive control of robotic arm motion risks by reducing the probability of equipment damage through real-time hardware status monitoring. Dynamic closed-loop control and real-time anomaly monitoring dynamically adjust the motion trajectory based on load feedback and perform position accuracy verification. Specifically, this utilizes a PID controller to adjust motor speed and a laser rangefinder for coordinate calibration. This feature addresses motion trajectory deviations through real-time parameter adjustments, ensuring stable palletizing accuracy. Dynamic material status adjustment of the robotic arm's grasping strategy optimizes grasping parameters in real time based on sensor data. Specifically, laser profile sensors and force sensors are deployed to collect material physical properties, and the gripping pressure is adjusted using a fuzzy control algorithm. This feature addresses the poor adaptability of fixed grasping strategies by enabling dynamic, multi-dimensional data-driven decision-making. Manual debugging mode synchronizes back to the stack configuration system, allowing system-level data updates after manual parameter intervention. Specifically, this feature utilizes the OPC UA protocol to establish a real-time communication link between debugging parameters and the database. This feature forms a closed-loop optimization mechanism for human-machine collaboration, enhancing the system's adaptability across various operating conditions.

[0054] The core innovation of this invention lies in the construction of an intelligent palletizing control system that integrates multi-level safety protection, dynamic parameter adjustment and two-way data linkage. Through the triple mechanisms of real-time monitoring of hardware status, adaptive grasping of material characteristics and human-machine collaborative parameter optimization, it systematically solves the problems of insufficient risk prediction of robot arm movement and rigid grasping strategy, thereby achieving a simultaneous improvement in equipment protection and operating efficiency.

[0055] The operating process and principle of this invention are as follows: first, palletizing parameter configuration and status visual feedback are performed through the human-machine interface. Based on the selected machine model, the stacking parameters and the motion constraints of the multi-axis robot 5 are automatically loaded. The multi-layer palletizing pattern is edited in the visual interface, and pre-set identifiers dynamically distinguish between completed and unfinished materials. This step ensures correct configuration of system parameters and real-time visual status monitoring.

[0056] Next, multi-level safety verification and arm reset control for multi-axis robot 5 are performed. The system checks the servo system's enabled status and arm joint position compliance. When a return-to-zero operation is triggered, an interactive confirmation process is generated based on real-time position deviations. After confirmation, the arm reset is completed using an adaptive deceleration algorithm. This step ensures the safety and accuracy of the robot's operation.

[0057] Dynamic closed-loop control and real-time anomaly monitoring are then implemented. The robot's motion trajectory is adjusted based on global speed parameters and load feedback signals. The positional accuracy of the suction mechanism 6 is verified in real time. If the accuracy exceeds the limit, a calibration command is triggered and the task is paused. This step enables real-time optimization of the robot's motion and anomaly handling.

[0058] Furthermore, the robot arm's grasping strategy is dynamically adjusted based on the material state. This step improves the system's adaptability to different materials.

[0059] Finally, the abnormal motion parameters are corrected through manual debugging mode in the human-computer interface, and the debugged motion parameters are synchronized back to the stacking configuration system to achieve closed-loop optimization. This step ensures continuous optimization of the system and consistency of parameters.

[0060] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0061] On the human-machine interface, the operator selects a specific model, and the system automatically loads the corresponding encoder parameters and robot arm motion constraints. For example, the loaded encoder size is 1200mm × 1000mm, the robot arm joint 1 motion range is -180° to +180°, and the joint 2 motion range is -90° to +90°.

[0062] In the visual interface, drag and drop to define the material layout. The system automatically calculates the spacing between adjacent materials and performs safety checks. Completed palletizing is displayed in yellow, while unpalletized materials remain white. Operators can use the layer number toggle button to view the palletizing status of different layers.

[0063] Before starting a palletizing task, the system first checks the servo system enable status and the robot arm joint position. If an anomaly is detected, such as a joint exceeding a limit, the system will pop up a warning and prevent the start.

[0064] When the zero return operation is triggered, the system calculates the deviation between the current position and the zero position and displays the estimated zero return time. After the operator confirms, the robot arm resets in an adaptive deceleration mode, gradually increasing the speed as the deviation decreases.

[0065] During the palletizing process, the system continuously monitors the load feedback signal. If a sudden increase in load is detected, the system automatically reduces the robot arm's movement speed. Simultaneously, the position coordinates of the suction mechanism 6 are verified in real time. If the deviation exceeds a preset threshold, the system pauses the task and triggers a calibration process.

[0066] The system uses sensors to collect real-time material information, such as size, weight, and surface characteristics. Based on this data, it dynamically adjusts the suction pressure and gripping angle to accommodate different types of materials.

[0067] If an anomaly occurs, the operator can enter manual debugging mode through the human-machine interface. In this mode, the robot's movement speed is limited to 10%-30% of the global speed to ensure safety. Once debugging is complete, the modified parameters are automatically synchronized to the stack configuration system for subsequent task optimization.

[0068] Through the above scheme, the present invention realizes comprehensive safety protection and dynamic optimization of the palletizing process. The multi-level safety verification mechanism effectively prevents the risk of over-limit operation and overload of the robotic arm, and reduces the probability of equipment damage. Dynamic closed-loop control and real-time abnormality monitoring improve the stability and reliability of the system. The dynamic grasping strategy adjustment based on the material status improves the adaptability to different materials and reduces the grasping failure rate. The visual feedback and manual debugging functions of the human-computer interaction interface simplify the operation process and shorten the troubleshooting time. The automatic synchronization of parameters and the closed-loop optimization mechanism improve the learning ability and long-term performance of the system. These improvements work together to significantly improve the safety, efficiency and flexibility of the palletizing system, and solve the problems of safety hazards, poor adaptability and maintenance difficulties existing in traditional palletizing methods.

[0069] The present invention further proposes specific steps for executing palletizing parameter configuration through the touch-screen human-machine interface 3: loading the code plate size and the robot arm joint limit parameters according to the selected machine model; in the touch-screen human-machine interface 3, the material layout is defined by dragging operations, and if the distance between adjacent materials is less than the safety threshold, a red prompt is automatically displayed; a yellow mark is generated for the materials that have been completed palletizing, and a white mark is retained for the unfinished palletizing, and support is supported for switching the display according to the layer number of each layer of palletizing.

[0070] Among them, when loading the code plate size, the pallet size parameters corresponding to the model are matched through the preset database, and the robot arm joint limit parameters include the rotation angle range of each axis; the drag operation is implemented through graphical controls, and the coordinate data of the material layout is mapped to the stacking coordinate system in real time. The safety threshold is set according to the material size and 1.2 times the size of the robot arm end effector; color marking is achieved by overlaying a semi-transparent layer, and the layer number switching triggers the interface refresh through the drop-down menu.

[0071] Specifically, the operator drags the material icon to the target position on the touch interface, and the system calculates the distance between the edges of adjacent materials in real time. When the distance is less than the safety threshold, the adjacent area is automatically marked in red and a warning box pops up to prevent interference during the operation of the robotic arm due to overly dense layout. After completing single-layer palletizing, the system will update the corresponding material layer to yellow, and the unfinished part will remain white. The operator can view the status of each layer separately by switching the layer number drop-down menu. For example, when the safety threshold is set to 50mm, if the distance between the two materials is 45mm, the interface will immediately mark red and prohibit confirmation of the operation. It must be adjusted to compliance before continuing. Thus, through graphical interaction and dynamic feedback, the error rate of manual configuration is reduced and the efficiency of visual management of multi-layer palletizing is improved.

[0072] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0073] The touchscreen human-machine interface 3 automatically loads the encoder parameters and the arm motion constraints for the multi-axis robot 5 based on the selected model. Specifically, the system retrieves the corresponding encoder dimensions from the database based on the selected model, such as 1200mm in length, 1000mm in width, and 150mm in height. Simultaneously, the arm joint limit parameters for the multi-axis robot 5 are loaded, such as a first-axis rotation angle range of -170° to +170° and a second-axis rotation angle range of -90° to +130°.

[0074] Furthermore, operators define the material layout on the interface by dragging and dropping. The system calculates the distance between adjacent materials in real time. When the distance is less than a preset safety threshold (such as 50mm), the corresponding position is automatically marked in red to indicate potential risks.

[0075] In addition, the system generates yellow marks for palletized materials, while unpalletized materials retain white marks. Operators can switch the display of the palletizing status of different layers using the interface buttons. For example, if the third layer is selected, the interface only displays the material layout and completion status of that layer.

[0076] Through the above-mentioned technical solution, the present invention enables rapid loading and visual configuration of palletizing parameters, thereby improving operational efficiency and reducing human error. Furthermore, the dynamic marking function enables operators to intuitively monitor palletizing progress, facilitating timely adjustments to production plans. The safe spacing reminder mechanism effectively prevents collision risks caused by improper material layout, enhancing overall production safety.

[0077] The present invention further proposes that when detecting the servo enable status of the multi-axis robot 5, the vacuum pressure value of the adsorption mechanism 6 at the end of the multi-axis robot 5 mechanical arm is synchronously checked, and if the pressure is abnormal, startup is prohibited; after triggering the zero return operation, a pop-up window is displayed to display the deviation distance between the current position of the multi-axis robot 5 mechanical arm and the zero position and the estimated zero return time; during the zero return process, if the joint position exceeds the limit, the zero return is paused and a pop-up window is displayed to prompt the exceeded joint number.

[0078] Among them, the detection of vacuum pressure value is realized through a pressure sensor, and the pressure threshold is pre-set according to the model of adsorption mechanism 6; the pop-up display content includes digital deviation amount, three-dimensional coordinate difference graph and countdown progress bar; the joint position out-of-limit judgment is based on the real-time comparison of joint encoder data and preset safety range.

[0079] Specifically, a vacuum pressure monitoring module is embedded in the servo enable status detection stage. When the pressure value is detected to be lower than the set threshold, the power output is immediately cut off to prevent startup with a fault. After the return to zero operation is started, the system automatically calculates the Euclidean distance between the end of the robot arm and the zero reference point, and generates an estimated time display interface in combination with the movement speed of each axis. During the reset movement, the encoder data of each joint is collected in real time and compared with the stored safe position parameters. When any joint angle exceeds the safe range, the movement is immediately interrupted and an error code pop-up window containing the joint number is generated. The abnormal pressure startup prohibition mechanism prevents material shedding accidents caused by failure of the adsorption mechanism 6; the deviation distance and time display enable the operator to predict the time cost of the reset process; the rapid positioning function of the joint overrun shortens the troubleshooting time and avoids damage to the mechanical structure due to continuous erroneous movement.

[0080] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0081] When checking the servo-enabled state of the multi-axis robot 5, the vacuum pressure value of the end-of-arm suction mechanism 6 of the multi-axis robot 5 is simultaneously verified. If the pressure is abnormal, the robot is prohibited from starting. Specifically, the servo drive's status feedback signal is used to detect whether the servo system is enabled, and the vacuum pressure sensor data of the end-of-arm suction mechanism 6 is collected simultaneously. When it is detected that the servo system is enabled and the vacuum pressure value is within a preset range, the robot is allowed to start operation. If the vacuum pressure falls below a set threshold, the system will issue an alarm and prevent the robot from starting to prevent grasping failure.

[0082] When the return-to-zero operation is triggered, a pop-up window displays the deviation between the current position of the multi-axis robot's five arms and the zero position, as well as the estimated return-to-zero time. For example, the encoder reads the current angle of each joint and compares it with the preset zero angle to calculate the spatial position deviation. The return-to-zero time is estimated based on the maximum velocity and acceleration parameters of each joint. This information is presented in a pop-up window on the human-machine interface, making it easier for the operator to understand the return-to-zero process.

[0083] During the zero return process, if a joint position exceeds a limit, the return is paused and a pop-up window indicates the exceeded joint number. In practice, the system monitors the position feedback of each joint in real time. If a joint exceeds a safe limit, an emergency stop signal is immediately triggered. A warning window also pops up on the human-machine interface, clearly identifying the specific joint number that has exceeded the limit, guiding maintenance personnel to quickly locate the problem.

[0084] Through the above-mentioned technical solution, the present invention achieves multi-level safety verification and intelligent return-to-zero control. Dual checks of servo enable status and vacuum pressure effectively prevent the robot from accidentally starting under abnormal conditions. Real-time position monitoring and over-limit protection during the return-to-zero process reduce the risk of mechanical collisions. Furthermore, intuitive information feedback enhances the operator's awareness of equipment status, facilitates the timely detection and handling of abnormal situations, and improves the safety and reliability of the overall system.

[0085] The present invention further proposes to adjust the acceleration of the robot arm's motion in real time based on the global speed parameters and calculate the remaining task time; monitor the load current, and if it exceeds the limit for 3 consecutive seconds, automatically slow down the robot arm to a safe value and generate a warning log; collect the actual position coordinates of the adsorption mechanism 6, and when the deviation from the preset position coordinates exceeds ±50mm, highlight the abnormal point; after pausing the task, perform one-button calibration through the human-computer interaction interface, and automatically resume operation after the calibration is completed.

[0086] The servo drive's control algorithm coordinates the global speed parameters with the robot's acceleration. The remaining task time is dynamically calculated based on the current speed and the remaining path length. Load current is monitored using a sliding time window mechanism. If the current exceeds the rated value for three consecutive sampling periods, a speed reduction command is triggered. The speed reduction amplitude is adjusted in stages based on the excess limit ratio. Position coordinate deviation is detected using a laser rangefinder and encoder data fusion. When the absolute value of the deviation exceeds 50mm, the abnormal point is marked in flashing red on the human-machine interface. A one-button calibration command activates the preset coordinate correction program, driving the robot along the reference path and updating the position parameters.

[0087] Specifically, during the robot's motion, the servo system collects real-time load current data from each joint's motor. If the load current exceeds a safety threshold for a sustained period of three seconds, the control module automatically reduces the robot's motion speed to 50%-70% of its original speed and logs the duration of the overrun and the reduction ratio. High-precision sensors provide real-time feedback on the position coordinates of the adsorption mechanism 6. If an X / Y axis deviation exceeding ±50mm is detected, the system immediately pauses the task and highlights the direction and distance of the deviation in a visual interface. After the operator clicks the calibration button on the touchscreen, the robot performs origin return, reference point alignment, and coordinate parameter updates. Upon completion of calibration, it automatically resumes the palletizing task from the point of suspension.

[0088] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0089] The robot adjusts the arm's acceleration in real time based on the global speed parameter and calculates the remaining task time. Specifically, the system dynamically calculates the maximum acceleration for each joint by reading the global speed parameter value set by the system. For example, when the global speed parameter is 80%, the upper limit of each joint's acceleration is set to 80% of the rated value. Simultaneously, based on the current acceleration and the remaining workload, the time required to complete the task is estimated in real time and displayed on the human-machine interface.

[0090] The system monitors the load current. If the load current exceeds the limit for three consecutive seconds, the robot arm automatically slows down to a safe value and generates a warning log. The system samples the current value of each joint motor every 100 milliseconds. If the current value of a joint exceeds 120% of the rated value for 30 consecutive samples, the automatic speed reduction mechanism is triggered. During the speed reduction, the global speed parameter is reduced to 50% of the original value, and information such as the overload time and joint number is recorded in the system log.

[0091] The actual position coordinates of the suction mechanism 6 are collected. If the deviation from the preset position coordinates exceeds ±50mm, the abnormal point is highlighted. Furthermore, a laser ranging sensor is used to measure the distance between the end of the suction mechanism 6 and the reference surface in real time. If the difference between the measured value and the theoretical value exceeds ±50mm, the point is marked in red on the 3D model of the human-machine interface and a flashing prompt is displayed.

[0092] After pausing the task, a one-click calibration is performed through the human-computer interaction interface. After the calibration is completed, the robotic arm automatically resumes operation. Among them, after the operator clicks the "one-click calibration" button, the system automatically performs the following steps: first, the robotic arm moves to the preset calibration reference point; then, the coordinates of the reference point are accurately located through the visual system; finally, the kinematic parameters of the robotic arm are automatically corrected according to the deviation between the actual coordinates and the theoretical coordinates. After the calibration is completed, the system automatically resumes the working state before the pause. Through the above technical solution, the present invention realizes real-time monitoring and adaptive adjustment of the robotic arm movement. Thereby, the safety and stability of the palletizing process are improved. Furthermore, through the automatic speed reduction and one-click calibration functions, the need for manual intervention is reduced and the autonomous operation capability of the system is improved. At the same time, real-time position coordinate verification and visual display of abnormal points enable operators to quickly identify and deal with potential problems, thereby improving the efficiency of fault diagnosis and processing.

[0093] The present invention further proposes real-time identification of material size through a laser profile sensor, estimation of material weight through the end force sensor of the adsorption mechanism 6, and determination of material surface characteristics based on the vacuum pressure fluctuation and leakage rate of the adsorption mechanism 6; dynamic adjustment of the vacuum pressure threshold and the gripping angle of the robotic arm of the adsorption mechanism 6 according to the material size, weight and surface characteristics; and encryption and storage of the updated parameters and synchronization to the stacking configuration system.

[0094] Among them, the laser contour sensor is installed at the end of the robotic arm, which generates three-dimensional point cloud data by scanning the material's outline and calculates the material's length, width and height dimensions in real time; the end force sensor is integrated in the flange of the adsorption mechanism 6, collects the axial pressure data at the moment of grasping and converts it into material weight; the vacuum pressure sensor monitors the internal pressure change curve of the adsorption mechanism 6, and combines the leakage rate threshold to determine whether the material surface is smooth or has holes; the vacuum pressure threshold is set based on the material weight and surface roughness classification, and the grasping angle is dynamically adjusted according to the length and width ratio of the material to ensure that the adsorption surface is aligned with the center of gravity of the material; the encrypted storage uses the AES-256 algorithm to encrypt the parameter file, and transmits the encrypted data packet to the database of the stacking configuration system through the industrial Ethernet protocol.

[0095] Specifically, the laser profile sensor scans the material surface at a rate of 50 frames per second, generates point cloud data, and then reconstructs the three-dimensional model of the material through a triangulation algorithm, and outputs the dimensional data to the control unit; the end force sensor records the pressure peak when the adsorption mechanism 6 contacts the material, and calculates the material weight in combination with the preset acceleration parameters; the vacuum pressure sensor monitors the adsorption pipeline pressure with a sampling period of 10ms, and determines that there is a leak when the pressure drop rate exceeds 0.5kPa / s; the control unit adjusts the horizontal grasping angle of the robot arm according to the material size, and adopts the diagonal grasping mode when the aspect ratio of the material is greater than 2:1; the vacuum pressure threshold is set according to weight classification, for example, materials below 1kg are set to -60kPa, and materials between 1-5kg are set to -80kPa; the updated parameters are encrypted and written to the database, and the encrypted parameter file of the corresponding model is automatically called when changing production lines, and loaded into the robot arm control system after decryption.

[0096] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0097] A laser profile sensor, mounted at the end of the multi-axis robot's arm (5), scans the material's contour in real time. A force sensor, integrated within the suction mechanism (6), measures the material's weight. A pressure sensor monitors vacuum pressure fluctuations.

[0098] Material dimensions are calculated using laser profile sensor scanning data. Material weight is calculated by subtracting the weight of the suction mechanism 6 from the end force sensor reading. Material surface characteristics are determined based on vacuum pressure fluctuation amplitude and leakage rate. A fluctuation amplitude greater than 5% and a leakage rate exceeding 10% / min are considered rough surfaces.

[0099] Based on the recognition results, the system automatically adjusts the parameters: for materials with larger sizes, the vacuum pressure threshold is increased by 10%; for materials weighing more than 5kg, the gripping angle of the robot arm is changed to 45°; for materials with rough surfaces, the vacuum pressure threshold is increased by 20%.

[0100] The updated parameters are stored using the AES-256 encryption algorithm and synchronized to the stack configuration system server via the HTTPS protocol. The stack configuration system decrypts the encrypted data and updates the corresponding material type's grabbing strategy.

[0101] The present invention realizes the real-time perception of material characteristics and dynamic adjustment of grasping strategies. Laser profile sensors, end force sensors and vacuum pressure monitoring provide comprehensive material information, enabling the system to accurately identify the size, weight and surface characteristics of different materials. Based on these real-time data, the system automatically optimizes the vacuum pressure threshold and grasping angle, significantly improving the adaptability to various materials. In particular, for materials that are oversized, heavy or have a rough surface, the risk of grasping failure and falling is effectively reduced through corresponding parameter adjustments. In addition, the parameter encryption storage and synchronization mechanism ensures data security, while realizing strategy sharing between different devices, improving the learning ability and adaptability of the overall system. This closed-loop optimization method greatly improves the flexibility and reliability of the palletizing process, reduces the need for manual intervention, and improves production efficiency.

[0102] The present invention further proposes that in manual debugging mode, the tool coordinate system is switched to control the movement of the robotic arm of the multi-axis robot 5, and the jog speed of the robotic arm of the multi-axis robot 5 is limited to 10%-30% of the global speed of the multi-axis robot 5; after debugging is completed, a parameter modification comparison report is generated and synchronized to the stack configuration system after hash encryption.

[0103] Among them, the tool coordinate system control ensures the accuracy of motion parameter adjustment during debugging by using the adsorption mechanism 6 at the end of the robot arm as the origin of the coordinate system; the inching speed limit range is dynamically calculated based on the global speed parameters to avoid collision or positioning deviation due to excessive speed during manual operation; the parameter modification comparison report generates a log file containing the modification time, operator and specific values ​​by comparing the data differences before and after debugging; hash encryption uses the SHA-256 algorithm to irreversibly encrypt the report to ensure the security of data transmission and storage.

[0104] Specifically, in manual debugging mode, the jog speed of the robot arm is limited to 10%-30% of the global speed. For example, when the global speed is 100mm / s, the upper limit of the jog speed is 30mm / s. By reducing the movement speed, the debugging accuracy is improved and the risk of misoperation is reduced. After the debugging is completed, the system automatically generates a comparison report containing parameters such as position, acceleration and gripping angle before and after the modification, and generates a unique checksum through encryption using a hash algorithm to prevent data tampering. The encrypted report is synchronized to the stacking configuration system. After the system parses it, it updates the parameter database of the corresponding model to achieve closed-loop optimization of the debugging data and system configuration. This process avoids possible errors in manually recording parameters, and at the same time, the encryption mechanism ensures the security of data during cross-system transmission, shortening the parameter configuration time when switching between different models.

[0105] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0106] In manual commissioning mode, the motion of the multi-axis robot 5's arm is controlled by switching to the tool coordinate system. Specifically, the operator selects the "Manual Commissioning" option on the touchscreen human-machine interface 3, and the system automatically switches to the tool coordinate system. In this mode, the operator can directly control the position and posture of the robot's end effector without having to consider the motion of individual joints.

[0107] Furthermore, the system limits the robot's jog speed to 10%-30% of the global speed. For example, if the global speed is set to 100 mm / s, the maximum jog speed in manual commissioning mode is limited to 10-30 mm / s. This speed limit mechanism effectively prevents the risk of collisions caused by operational errors.

[0108] After debugging is complete, the system automatically generates a parameter modification comparison report. This report details the parameter changes before and after debugging, including but not limited to the position, speed, acceleration, and other parameters of each joint of the robot arm. This allows the operator to clearly understand the specific modifications during the debugging process.

[0109] Finally, the system performs hash encryption on the generated parameter modification report. The encrypted data is securely transmitted to the pallet configuration system via the internal network to achieve synchronous parameter updates. This encryption synchronization mechanism ensures the security and consistency of parameter modifications. Through the above technical solution, the present invention achieves precise debugging and parameter optimization of the multi-axis robot 5 palletizing system. The tool coordinate system control and speed limit in the manual debugging mode improve the accuracy and safety of debugging. The generation and encryption synchronization of the parameter modification comparison report ensures the traceability of the debugging results and the consistency of the system. This closed-loop optimization mechanism significantly improves the adaptability and stability of the palletizing system, and effectively solves the problems of cumbersome and inefficient parameter debugging of traditional palletizing systems.

[0110] The present invention further proposes a palletizing workstation, including a support frame 1, a base 2 and a multi-axis robot 5. The base 2 is fixedly connected to the support frame 1, a touch-type human-machine interface 3 and a control button 4 are installed on the base 2, the multi-axis robot 5 is installed on the base 2, and an adsorption mechanism 6 for grabbing and placing materials is installed on the multi-axis robot 5.

[0111] Among them, the fixed connection between the support frame 1 and the base 2 forms a rigid bearing structure, ensuring the stability of the multi-axis robot 5 during operation; the touch-type human-machine interface 3 is integrated into the operating surface of the base 2, supporting the input of stacking parameters and real-time status visualization; the control button 4 is linked to the touch interface for start, pause and reset operations; the multi-axis robot 5 communicates with the touch interface through the internal cable of the base 2, receives motion instructions and feeds back operating data; the adsorption mechanism 6 is installed on the end robotic arm of the multi-axis robot 5, connected to the external air source through a vacuum pipeline, and its gripping surface is equipped with a pressure sensor to monitor the adsorption status.

[0112] Specifically, the operator uses the touchscreen human-machine interface 3 to set the number of palletizing layers, material dimensions, and safety thresholds, and the system automatically generates the corresponding robotic arm motion trajectory. While the multi-axis robot 5 is performing palletizing tasks, the controller built into the base 2 collects real-time vacuum pressure data from the suction mechanism 6 and dynamically displays the pressure curve via the touchscreen interface. If a pressure anomaly is detected, the control button 4 triggers an emergency stop signal, halting the multi-axis robot 5 and locking its current state. The suction mechanism 6 adjusts the vacuum pressure threshold based on the surface characteristics of the material. For example, for rough-surfaced cartons, the pressure is raised to a range of -80kPa to -90kPa, while for smooth metal cans, the pressure is adjusted to a range of -70kPa to -75kPa. Heat dissipation channels are incorporated into the base 2 to ensure that the temperature rise of the servo motors of the multi-axis robot 5 does not exceed 45°C during continuous operation. During debugging, the touchscreen interface is used to switch to manual mode, and the control button 4 is used to jog the position of the robotic arm end, maintaining a position error within ±1mm. The adjusted parameters are automatically synchronized to the pallet configuration system.

[0113] As a preferred embodiment, the solution of the present invention is specifically implemented as follows:

[0114] A palletizing workstation includes a support frame 1, a base 2, and a multi-axis robot 5. The base 2 is fixedly connected to the support frame 1 by bolts. A touchscreen human-machine interface 3 and control buttons 4 are mounted on the base 2. The touchscreen human-machine interface 3 uses a 10.4-inch capacitive screen with a resolution of 1024x768 pixels. The control buttons 4 include function keys such as start, stop, and emergency stop. The multi-axis robot 5 is mounted on the base 2 and is a six-axis articulated robot. A suction mechanism 6 for grasping and releasing materials is mounted at the end of the multi-axis robot 5. The suction mechanism 6 uses a vacuum suction cup structure and includes four suction cups with a diameter of 60 mm. Through the above technical solution, the present invention realizes a palletizing workstation with a compact structure and convenient operation. The fixed connection between the support frame 1 and the base 2 provides a stable foundation, ensuring the operating accuracy of the multi-axis robot 5. The provision of the touchscreen human-machine interface 3 and control buttons 4 facilitates parameter setting and real-time monitoring by the operator. The combined use of the multi-axis robot 5 and the suction mechanism 6 improves the flexibility and efficiency of palletizing operations. The overall design meets the needs of industrial automation production lines for palletizing, effectively improving production efficiency.

[0115] Figure 1 It is a structural diagram of the palletizing workstation in the present invention, as shown in FIG. Figure 1 As shown, the present invention further proposes that the multi-axis robot 5 adopts a robot having multiple robotic arms connected in sequence to form a multi-axis linkage structure.

[0116] Multiple robotic arms are connected in series via joints to form a continuous kinematic chain. The rotational axes of each robotic arm are staggered at preset angles, and high-precision speed reducers are installed at the connections between adjacent robotic arms. Furthermore, the end robotic arm is rigidly connected to the suction mechanism 6 via a flange. The flange surface is equipped with an array of locating pin holes. The bottom surface of the suction mechanism 6 is equipped with a group of vacuum suction cups, with the spacing between the suction cups corresponding to the array of locating pin holes.

[0117] Specifically, the sequentially connected robotic arms adopt a six-axis serial structure, with each axis corresponding to the base 2 rotation, upper arm pitch, elbow extension, wrist flip, end rotation, and adsorption mechanism 6 posture adjustment functions. The drive motor of each robotic arm transmits torque through a harmonic reducer, and the reduction ratio is set in the range of 1:120 to 1:160. When performing the stacking task, the rotation axis of the base 2 drives the subsequent robotic arms to rotate as a whole. The upper arm pitch axis and elbow extension axis are linked to form a lifting motion in the vertical plane. The wrist flip axis and the end rotation axis cooperate to adjust the spatial posture of the adsorption mechanism 6. The adsorption mechanism 6 can be quickly replaced through an array of positioning pin holes, and the vacuum suction cup group selects the corresponding mounting hole position according to the material size. This structure realizes the six-degree-of-freedom movement of the end effector through multi-axis spatial decoupling. When grasping special-shaped materials, the adsorption angle and grasping height can be adjusted synchronously, improving the spatial adaptability of the stacking process.

[0118] As a preferred embodiment, the solution of the present invention is specifically implemented as follows: the stacking workstation includes a support frame 1 and a rectangular welded base 2, and the base 2 is rigidly connected to the support frame 1 via anchor bolts. The multi-axis robot 5 is composed of six rotary articulated robotic arms, each of which is connected to the transmission via a harmonic reducer, and a vacuum adsorption mechanism 6 is configured at the end. Among them, the first robotic arm is fixedly connected to the flange of the base 2, and the second to sixth robotic arms are sequentially connected to form a series structure via cross roller bearings. Each joint is equipped with an absolute encoder for position feedback. The touch-type human-machine interface 3 uses an industrial-grade capacitive screen and is embedded in the operating side of the base 2. The control buttons 4 include a green start button and a red emergency stop button, which are connected to the PLC controller via a waterproof connector.

[0119] This invention effectively solves the technical defect of traditional palletizing robotic arms, which have limited operating range due to insufficient degrees of freedom of movement. The six-axis serial robotic arm structure enables the end effector to have six degrees of freedom in space, enabling oblique grasping of complex stacks and three-dimensional obstacle avoidance. The combined structure of the harmonic reducer and cross-roller bearings between the robotic arms enhances the axial load-bearing capacity while ensuring transmission accuracy, avoiding mechanical vibration during continuous movement of multiple joints. As a result, the workstation can adapt to the needs of multi-layer staggered palletizing of pallets of different sizes, significantly reducing the risk of material collision caused by insufficient range of motion of the robotic arm.

[0120] The present invention further proposes a palletizing workstation, comprising a support frame 1, a base 2 and a multi-axis robot 5. The base 2 is fixedly connected to the support frame 1, and a touch-type human-machine interface 3 and a control button 4 are installed on the base 2. The multi-axis robot 5 is installed on the base 2. An adsorption mechanism 6 for grabbing and placing materials is installed on the multi-axis robot 5. The multi-axis robot 5 is a robot with multiple robotic arms connected in sequence. Specifically, the base 2 is fastened to the support frame 1 by bolts, and a counterweight is welded to the bottom of the support frame 1 to reduce the risk of center of gravity shift. The touch-type human-machine interface 3 communicates with the multi-axis robot 5 controller via the CAN bus, and the control button 4 uses a waterproof membrane switch, which is divided into speed adjustment and emergency stop function keys. Absolute encoders are installed at the joints of the six robotic arms of the multi-axis robot 5, and the end robotic arm is connected to the adsorption mechanism 6 via a quick-change interface. The suction cup array is made of silicone material, and the vacuum generator is controlled on and off by a solenoid valve. The tandem arrangement of six robotic arms allows the end effector to achieve a range of motion of ±1500mm, ±800mm, and ±600mm in the X, Y, and Z axes, respectively. The suction mechanism 6 can navigate obstacles based on a pre-set path when grasping materials. When performing multi-layer palletizing tasks, the robotic arms adjust the gripping angle through multi-joint linkage, and the suction cup array automatically selects the number of openings based on the material size. The vacuum pressure threshold is set between -60kPa and -80kPa.

[0121] As a preferred embodiment, the present invention is implemented as follows: a multi-axis robot 5 comprises a base joint, an upper arm rotation joint, an lower arm pitch joint, and a wrist swivel joint, connected in series. The base joint is bolted to the base 2 via a flange, and power is transmitted between the joints using a harmonic reducer. The arm bodies of each robot arm are constructed from hollow aluminum alloy profiles, internally housing servo motor drive circuitry and vacuum lines. Furthermore, the wrist swivel joints are equipped with flange mounting surfaces at their ends, providing pneumatic communication with the adsorption mechanism 6 via quick-change connectors. The axial positioning pins of the quick-change connectors utilize a conical self-locking structure.

[0122] This invention effectively improves the rigidity and positioning accuracy of the multi-axis robotic arm's kinematic chain. The hollow aluminum alloy arm reduces rotational inertia while maintaining structural strength, and the conical self-locking quick-change connector ensures a reliable seal for the air connection. The multi-stage series configuration of the harmonic reducer enables the robotic arm to achieve wide spatial coverage during palletizing operations while precisely controlling the attitude angle of the terminal suction mechanism (6), thereby avoiding positioning errors caused by cumulative joint errors and ensuring the required verticality of material stacking during multi-layer palletizing operations.

[0123] The present invention further proposes that the multi-axis machine is a robot having a plurality of robotic arms connected in sequence.

[0124] Multiple robotic arms are installed in series, with the end of each arm connected to the head of the next via a rotary joint, forming a chain structure. Each arm is equipped with an independent servo drive module, which communicates with a central controller via a bus. The joint rotation range of the robotic arms is set to ±180 degrees, and the end arms are equipped with a suction mechanism 6. Anti-collision sensors are installed between adjacent robotic arms to monitor the distance in real time and limit their movement trajectory.

[0125] Specifically, the central controller decomposes the motion paths of each robotic arm according to the preset palletizing trajectory and calculates the target angles of each joint using an inverse kinematics algorithm. When the end adsorption mechanism 6 needs to reach a specific position, multiple robotic arms coordinately adjust their angles to expand the working coverage. For example, when the palletizing height exceeds the lifting limit of a single arm, the lower robotic arm maintains a fixed angle, and the upper robotic arms unfold sequentially to form a stepped structure. The anti-collision sensor triggers a deceleration signal when the distance between the robotic arms is less than 50 mm, and the central controller replans the path. As a result, the coordinated movement of multiple robotic arms can achieve precise control of multiple degrees of freedom within a limited space, avoid dead zones in motion, and improve the stacking efficiency of complex pallets.

[0126] As a preferred embodiment, the solution of the present invention is specifically implemented as follows: the multi-axis robot 5 is composed of a plurality of robotic arms connected in sequence, each of which is connected in series through a rotary joint, and a vacuum adsorption mechanism 6 is installed at the end. The rotary joint is driven by a servo motor, and the plurality of robotic arms respectively correspond to a plurality of degrees of freedom of motion, forming a continuous motion chain in the base coordinate system. Furthermore, an absolute encoder is built into the joint of each robotic arm to feed back the position signal to the control system in real time, forming a fully closed-loop motion control. The present invention forms a motion chain structure by forming a plurality of robotic arms connected in sequence, thereby realizing the spatial posture adjustment capability of multiple degrees of freedom. This structure enables the adsorption mechanism 6 to approach the material at any angle, avoiding the problem of gripping path interference caused by the limitation of a single motion plane. At the same time, the redundant degree of freedom design of the robotic arm can automatically avoid the joint limit area, maintain trajectory continuity and positioning accuracy in complex stacking scenarios, and effectively reduce the gripping failure rate caused by insufficient range of motion of the robotic arm.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A palletizing method, characterized in that: The following steps are involved: Step S1: Execute stacking parameter configuration and status visual feedback through the human-computer interaction interface, including: Automatically loading the encoder parameters and the motion constraints of the multi-axis robot (5) according to the selected machine model; Edit multi-layer palletizing patterns in a visual interface, and dynamically distinguish the palletizing status of completed and unfinished materials through preset identifiers; Step S2: Executing multi-level safety verification and manipulator reset control of the multi-axis robot (5), including: Detecting the servo system enable state of the multi-axis robot (5) and the compliance of the mechanical arm joint positions of the multi-axis robot (5); When the mechanical arm of the multi-axis robot (5) triggers a zero return operation, an interactive confirmation process is generated based on the real-time position deviation, and after confirmation, the mechanical arm of the multi-axis robot (5) is reset using an adaptive speed reduction algorithm; Step S3: Dynamic closed-loop control and real-time abnormality monitoring, including: Adjusting the motion trajectory of the manipulator arm of the multi-axis robot (5) based on the global speed parameter and the load feedback signal; Verify the position coordinate accuracy of the adsorption mechanism (6) in real time, and if it exceeds the limit, trigger the calibration instruction and suspend the task; Step S4: dynamically adjusting the gripping strategy of the multi-axis robot (5) based on the material state; Step S5: Correct the abnormal motion parameters of the multi-axis robot (5) through the manual debugging mode in the human-machine interaction interface, and synchronize the debugged motion parameters back to the stack configuration system to achieve closed-loop optimization.

2. A palletizing method according to claim 1, characterized in that: The step S1 specifically includes: Step S1-1: Loading the code disc size and the mechanical arm joint limit parameters of the multi-axis robot (5) according to the selected model; Step S1-2: In the touch-screen human-machine interface (3), define the material layout by dragging and dropping. If the distance between adjacent materials is less than the safety threshold, the material will be automatically marked in red. Step S1-3: Generate yellow marks for materials that have completed palletizing, retain white marks for unfinished palletizing, and support switching display according to the layer number of each layer of palletizing.

3. A palletizing method according to claim 1, characterized in that: The step S2 comprises: Step S2-1: When detecting the servo enabled state of the multi-axis robot (5), the vacuum pressure value of the adsorption mechanism (6) at the end of the mechanical arm of the multi-axis robot (5) is synchronously checked, and if the pressure is abnormal, the startup is prohibited; Step S2-2: After the return to zero operation is triggered, a pop-up window displays the deviation distance between the current position of the multi-axis robot (5) and the zero position and the estimated return to zero time; Step S2-3: During the zero return process, if the joint position exceeds the limit, the zero return is paused and a pop-up window prompts the exceeded joint number.

4. A palletizing method according to claim 1, characterized in that: The step S3 includes the following sub-steps: Step S3-1: adjusting the motion acceleration of the manipulator of the multi-axis robot (5) in real time according to the global speed parameter of the multi-axis robot (5), and calculating the remaining task time; Step S3-2: monitoring the load current, and if the load current exceeds the limit for three consecutive seconds, automatically decelerating the robotic arm of the multi-axis robot (5) to a safe value and generating a warning log; Step S3-3: Collect the actual position coordinates of the adsorption mechanism (6), and highlight the abnormal point when the deviation from the preset position coordinates exceeds ±50mm; Step S3-4: After pausing the task, a one-key calibration is performed through the human-computer interaction interface. After the calibration is completed, the multi-axis robot (5) automatically resumes operation.

5. A palletizing method according to claim 1, characterized in that: The step S4 comprises: Step S4-1: Real-time identification of material size using a laser profile sensor, estimation of material weight using a terminal force sensor of the adsorption mechanism (6), and determination of material surface characteristics based on vacuum pressure fluctuations and leakage rate of the adsorption mechanism (6); Step S4-2: Dynamically adjusting the vacuum pressure threshold of the adsorption mechanism (6) and the gripping angle of the multi-axis robot (5) according to the material size, material weight and material surface characteristics; Step S4-3: Encrypt and store the updated parameters and synchronize them to the stack configuration system.

6. A palletizing method according to claim 1, characterized in that: The step S5 comprises: Step S5-1: In manual debugging mode, switch to the tool coordinate system to control the movement of the manipulator arm of the multi-axis robot (5), and limit the jog speed of the manipulator arm of the multi-axis robot (5) to 10%-30% of the global speed of the multi-axis robot (5); Step S5-2: After debugging is completed, a parameter modification comparison report is generated and synchronized to the stacking configuration system after hash encryption.

7. A palletizing workstation, characterized in that: The invention comprises a support frame (1), a base (2) and a multi-axis robot (5), wherein the base (2) is fixedly connected to the support frame (1), a touch-type human-machine interface (3) and a control button (4) are installed on the base (2), the multi-axis robot (5) is installed on the base (2), and an adsorption mechanism (6) for grasping and releasing materials is installed on the multi-axis robot (5).

8. A palletizing workstation according to claim 7, characterized in that: The multi-axis machine is a robot having a plurality of robotic arms connected in series.

Images