PLC unmanned truss control method and system

Abstract

The invention provides a PLC unmanned truss control method and system, and relates to the technical field of truss control, and the method comprises the steps: S1, an upper computer inputs a target coordinate, a PLC generates a three-axis motion track based on an interpolation algorithm, and dynamically adjusts the speed curve of each axis; s2, the upper computer reads real-time state data of the PLC and writes a control instruction into the PLC according to the real-time state data; s3, if the sudden stop signal is detected to be triggered, cutting off the power supply of the servo driver, recording the fault type and the triggering time, generating a log file, and otherwise, entering the next step; s4, the PLC receives a task instruction of the upper computer, and motion parameters are dynamically adjusted according to feedback of the sensor; and S5, controlling each axis to micro-move through the upper computer, and recording the coordinates of the teaching points to generate a reproducible motion sequence. Through cooperative control of the PLC and the upper computer, a centralized management and decentralized execution mode is realized, and the risk of single-point failure is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of truss control, and in particular to a PLC unmanned truss control method and system. Background Art

[0002] With the rapid development of industrial automation technology, the limitations of traditional truss systems in terms of efficiency, precision, and flexibility have become increasingly apparent. Truss systems play a vital role in industrial automation and are widely used in scenarios such as material handling, assembly, and warehousing.

[0003] Traditional truss systems rely heavily on manual operation or simple fixed program control, which presents the following problems and shortcomings: insufficient efficiency and precision; manual operation is limited by workers' skill level and fatigue level, making it difficult to ensure stable efficiency and precision; and manual operation of truss systems presents certain safety hazards, such as misoperation and equipment failure, which may lead to personal injury.

[0004] Fixed program control lacks flexibility and is difficult to adapt to diverse production tasks and changing environmental conditions. Due to its poor adaptability, traditional truss systems struggle to quickly respond to production adjustments, such as changing motion trajectory, adjusting speed, and acceleration, limiting their application in complex production environments. Furthermore, due to the complex structure of traditional truss systems, they are prone to failure and require extensive maintenance, resulting in high maintenance costs. Summary of the Invention

[0005] The technical problem to be solved by the present invention is that the traditional truss system is complex and has a high risk of failure. In order to overcome the above defects of the existing technology, the present invention provides a PLC unmanned truss control method and system.

[0006] The present invention provides a PLC unmanned truss control method, comprising: S1. Motion trajectory planning: The host computer inputs the target coordinates, and the multi-axis motion control PLC generates the three-axis motion trajectory based on the interpolation algorithm and dynamically adjusts the speed curve of each axis; S2. Real-time data interaction: The host computer reads the real-time status data of the multi-axis motion control PLC and writes control instructions to the multi-axis motion control PLC according to the real-time status data; S3, Fault self-diagnosis and safety protection: If the emergency stop signal is detected, the servo drive power supply is cut off, and the fault type and trigger time are recorded and a log file is generated. Otherwise, proceed to the next step; S4. Dynamic scheduling of production tasks: The multi-axis motion control PLC receives task instructions from the host computer and dynamically adjusts motion parameters based on sensor feedback; S5, Human-computer interaction control: The host computer controls the micro-movement of each axis and records the coordinates of the teaching points to generate a reproducible motion sequence; Among them, the interpolation algorithm is as follows: the laser displacement sensor obtains the real-time height, the multi-axis motion control PLC compares the real-time height with the processing database, obtains the trajectory deviation value preset by the product model, and converts the trajectory deviation value into a compensation displacement.

[0007] Compared with the existing technology, the PLC unmanned truss control method proposed in this application has the following advantages: through the collaborative control of the multi-axis motion control PLC and the host computer, the "centralized management + decentralized execution" mode is realized, reducing the risk of single point failure; the modular communication interface design supports seamless compatibility of multiple industrial protocols and is suitable for the integration of equipment of different brands.

[0008] In a possible implementation, in step S1 , dynamically adjusting the velocity curve includes: generating an S-shaped velocity curve according to the motion process and the three-axis acceleration constraints; and coordinating the multi-axis motion phase difference through real-time interpolation calculation to confirm the trajectory accuracy.

[0009] Compared with the existing technology, the speed curve is guaranteed to be smooth by constraining the three-axis acceleration during the movement process and comparing the real-time height with the processing database.

[0010] In one possible implementation, in step S2, the host computer is the master station and the multi-axis motion control PLC is the slave station, and the data interaction specifically includes: the host computer reads the real-time status data in the multi-axis motion control PLC holding register through the first function code; the host computer writes the control instructions of a single register to the multi-axis motion control PLC through the second function code; wherein the real-time status data includes the axis target coordinates, operating status and alarm code fields.

[0011] Compared with the prior art, the invention realizes reading or writing instructions to the multi-axis motion control PLC through different function codes.

[0012] In a possible implementation, step S3 also includes: over-limit detection: real-time detection of whether the encoder feedback value of each axis exceeds the preset soft limit range. If so, the servo driver drives the motor to decelerate and stop, otherwise, proceed to the next step; communication timeout detection: real-time detection of whether the communication times out and does not respond. If so, switch to the preset safety mode, otherwise, proceed to the next step; servo status monitoring: real-time detection of whether the torque and temperature data fed back by the driver have an overload risk. If so, the servo driver drives the motor to slow down, otherwise, proceed to the next step.

[0013] Compared with the existing technology, the multi-axis motion control PLC is ensured to be error-free during the trussing process by detecting multiple states.

[0014] In a possible implementation, step S4 specifically includes the following steps: S41, the host computer sends a task instruction to the multi-axis motion control PLC, the multi-axis motion control PLC calls a pre-stored parameter template, and switches the mode through the state machine; S2, the pressure sensor detects the material weight in real time and transmits it to the servo driver, the multi-axis motion control PLC dynamically adjusts the servo motor torque limit according to the material weight; S43, the multi-axis motion control PLC corrects the grasping coordinates in real time according to the positioning deviation of the visual system.

[0015] Compared with the existing technology, through the detection of different sensors, the multi-axis motion control PLC can make timely adjustments and corrections to ensure the accuracy of the grasping coordinates.

[0016] In a possible implementation, step S5 also includes debugging and optimization: hardware joint debugging: manually triggering the emergency stop button to confirm the execution of hardware joint debugging to verify the response of the emergency stop circuit; multi-axis synchronous calibration: measuring the actual displacement of the three axes, and synchronously calibrating to compensate for mechanical transmission errors; system load testing: simulating 24-hour full-load production to monitor the PLC CPU load rate and communication delay.

[0017] Compared with the existing technology, through multiple debugging, it is ensured that problems can be triggered in time when they occur, ensuring the stability of the entire PLC unmanned truss control system.

[0018] In one possible implementation, debugging optimization also includes fault diagnosis optimization: hierarchical processing of alarm content and implementation of differentiated response strategies; storage of fault records and support for classified retrieval, generation of fault trend reports and analysis of high-frequency abnormal events.

[0019] Compared with the existing technology, the fault records are classified to facilitate retrieval and problem discovery.

[0020] Another technical solution of the present invention is to provide a PLC-based automatic control truss system, comprising: Host computer, used for dynamic parameter configuration, equipment status visualization, production data analysis and historical data storage; Multi-axis motion control PLC, used for instruction processing, multi-axis coordination and closed-loop feedback control; An execution device, comprising a three-axis truss robot arm, a servo drive and a pneumatic clamp, for motion grasping operations, wherein the servo drive is connected to the pneumatic clamp via the three-axis truss robot arm, and the servo drive is electrically connected to the PLC; The communication network is used for data exchange between the multi-axis motion control type PLC and the host computer, and the host computer is electrically connected to the multi-axis motion control type PLC through the communication network.

[0021] Wherein, the pneumatic clamp includes a manipulator, a vacuum suction cup or a clamping claw, and the communication network includes industrial Ethernet and RS485 bus.

[0022] Compared with the existing technology, the PLC unmanned truss control system proposed in this application has the following advantages: through the collaborative control of the multi-axis motion control PLC and the host computer, the "centralized management + decentralized execution" mode is realized, reducing the risk of single point failure; the modular communication interface design supports seamless compatibility of multiple industrial protocols and is suitable for the integration of equipment of different brands.

[0023] In one possible embodiment, the multi-axis motion control PLC includes: an initialization module for hardware self-test, parameter loading and actuator reset; an I / O processing module for managing the input and output of digital / analog signals and I / O mapping table updates, and the initialization module is electrically connected to the I / O processing module; a multi-axis motion control module for realizing three-axis coordinated motion and servo motor adjustment based on encoder feedback, and the multi-axis motion control module is electrically connected to the I / O processing module.

[0024] In one possible embodiment, the multi-axis motion control PLC also includes: a communication protocol processing module for parsing host computer parameters and uploading real-time status data, the communication protocol processing module is electrically connected to the host computer; a safety and fault diagnosis module for realizing hardware-level emergency stop triggering, fault log recording and software-level anomaly detection, the safety and fault diagnosis module is electrically connected to the servo drive; a production task scheduling module, supporting application scenario switching and dynamic adjustment of motion parameters, the production task scheduling module is electrically connected to the host computer. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a flow chart of a PLC unmanned truss control method of the present invention. DETAILED DESCRIPTION

[0026] First, those skilled in the art should understand that these embodiments are merely used to explain the technical principles of the embodiments of the present application and are not intended to limit the scope of protection of the embodiments of the present application. Those skilled in the art may adjust them as needed to suit specific application scenarios.

[0027] In the description of the embodiments of this application, it should be noted that, unless otherwise specified or limited, the terms "connected" and "connection" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium. Those skilled in the art will understand the specific meanings of the above terms in the embodiments of this application based on the specific circumstances.

[0028] In the embodiments of the present application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Furthermore, a first feature being "above," "above," and "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0029] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] The following describes the first embodiment.

[0031] See also Figure 1 As shown, the embodiment of the present application discloses a PLC unmanned truss control method, comprising: S1. Motion trajectory planning: The host computer inputs the target coordinates, and the multi-axis motion control PLC generates the three-axis motion trajectory based on the interpolation algorithm and dynamically adjusts the speed curve of each axis; S2. Real-time data interaction: The host computer reads the real-time status data of the multi-axis motion control PLC and writes control instructions to the multi-axis motion control PLC according to the real-time status data; S3, Fault self-diagnosis and safety protection: If the emergency stop signal is detected, the servo drive power supply is cut off, and the fault type and trigger time are recorded and a log file is generated. Otherwise, proceed to the next step; S4. Dynamic scheduling of production tasks: The multi-axis motion control PLC receives task instructions from the host computer and dynamically adjusts motion parameters based on sensor feedback; S5, Human-computer interaction control: The host computer controls the micro-movement of each axis and records the coordinates of the teaching points to generate a reproducible motion sequence; Among them, the interpolation algorithm is: the laser displacement sensor obtains the real-time height, the PLC compares the real-time height with the processing database, obtains the trajectory deviation value preset by the product model, and converts the trajectory deviation value into a compensation displacement.

[0032] Differential compensation is not a standard interpolation (such as linear or circular interpolation), but a way to compensate the slave axis in real time based on the master axis. The motion trajectory of the slave axis = the trajectory of the master axis + the real-time compensation deviation.

[0033] In this embodiment, the main control loop of the multi-axis motion control PLC includes: periodically scanning input signals, performing logical operations, and updating output signals; coordinating the calling sequence of each submodule to ensure real-time and synchronization.

[0034] In step S1, dynamically adjusting the speed curve includes: generating an S-shaped speed curve according to the motion process and the three-axis acceleration constraints; and coordinating the multi-axis motion phase difference through real-time interpolation calculation to confirm the trajectory accuracy.

[0035] In step S2, the host computer is the master station and the multi-axis motion control PLC is the slave station. The data interaction specifically includes: the host computer reads the real-time status data in the multi-axis motion control PLC holding register through the first function code; the host computer writes the control instructions of a single register to the multi-axis motion control PLC through the second function code; wherein, the real-time status data includes the axis target coordinates, operating status and alarm code fields.

[0036] Specifically, real-time data interaction and protocol analysis: Modbus TCP communication is implemented with the PLC acting as a slave and the host computer as a master. Data exchange is accomplished through function codes (such as 03 for reading holding registers and 06 for writing single registers). The data frame includes fields such as axis target coordinates, operating status, and alarm codes. The communication cycle is ≤ 10ms, ensuring real-time command delivery.

[0037] In step S3, it also includes: Over-limit detection: Real-time detection of whether the encoder feedback value of each axis exceeds the preset soft limit range. If so, the servo driver drives the motor to decelerate and stop. Otherwise, proceed to the next step. Communication timeout detection: Real-time detection of whether the communication has timed out and there is no response. If so, switch to the preset safety mode; otherwise, proceed to the next step; Servo status monitoring: Real-time detection of torque and temperature data fed back by the driver to see if there is an overload risk. If so, the servo driver drives the motor to slow down. Otherwise, proceed to the next step.

[0038] In this embodiment, step S4 specifically includes the following steps: S41: The host computer sends a task instruction to the multi-axis motion control PLC, which calls a pre-stored parameter template and switches modes through the state machine. S2, the pressure sensor detects the material weight in real time and transmits it to the servo driver. The multi-axis motion control PLC dynamically adjusts the servo motor torque limit according to the material weight; S43, multi-axis motion control PLC corrects the grasping coordinates in real time according to the positioning deviation of the visual system.

[0039] In this embodiment, step S5 also includes debugging and optimization: Hardware joint debugging: Manually trigger the emergency stop button to confirm the execution of hardware joint debugging to verify the emergency stop circuit response; Multi-axis synchronous calibration: measure the actual displacement of three axes and calibrate synchronously to compensate for mechanical transmission errors; System load test: simulates 24-hour full-load production and monitors PLC CPU load rate and communication delay.

[0040] Among them, debugging optimization also includes fault diagnosis optimization: hierarchical processing of alarm content and implementation of differentiated response strategies; storage of fault records and support for classified retrieval, generation of fault trend reports and analysis of high-frequency abnormal events.

[0041] In this embodiment, the Modbus TCP configuration includes: Hardware connection: The PLC is connected to the host computer through an industrial Ethernet switch. The network cable must comply with the Cat5e or Cat6 standard and ensure that the transmission bandwidth is ≥100Mbps.

[0042] Parameter settings: PLC IP address: statically assigned (such as 192.168.1.10), subnet mask 255.255.255.0.

[0043] Host computer IP address: The same network segment as the PLC (e.g. 192.168.1.20).

[0044] Port number: Default is 502, supports multi-channel parallel communication.

[0045] Data mapping includes: Register allocation: Map PLC internal data (such as axis coordinates and speed parameters) to Modbus holding registers (such as 40001-40050).

[0046] Function code configuration: The host computer uses function code 03 (read register) to obtain real-time status and function code 06 (write single register) to issue control instructions.

[0047] RS485 bus configuration includes: Physical layer: Use shielded twisted pair cable, terminal resistance 120Ω, baud rate setting 9600bps~115200bps (adjusted according to sensor type).

[0048] Protocol adaptation: Support Modbus RTU protocol, slave address allocation (such as sensor address 1~32), data frame format (8N1).

[0049] Communication redundancy and fault tolerance include: Dual network port redundancy design: PLC is equipped with dual Ethernet interfaces, and the primary and backup links automatically switch to ensure uninterrupted communication.

[0050] Heartbeat detection mechanism: The host computer and PLC periodically send heartbeat packets. If the heartbeat packets time out three times, it is determined as a communication failure, triggering an alarm and starting the backup link.

[0051] As a preferred embodiment of the present invention, the key function implementation process is as follows: Adopt multi-axis coordinated motion control and based on the built-in interpolation algorithm of PLC, realize linear, circular and compound trajectory planning of X / Y / Z axes; By inputting the target coordinates (such as grabbing points and placement points) through the host computer, the PLC automatically generates the optimal motion path and dynamically adjusts the speed curve of each axis to ensure smooth motion without overshoot; Data interaction and protocol analysis are implemented using Modbus TCP communication. The PLC acts as a slave and the host computer as a master. Data interaction is accomplished through function codes (e.g., 03 to read holding registers and 06 to write single registers). The data frame contains fields such as axis target coordinates, operating status, and alarm codes. The communication cycle is ≤10ms, ensuring real-time instruction delivery. As a preferred embodiment of the present invention, the process of fault self-diagnosis and safety protection is as follows: Fault self-diagnosis and safety protection: For hardware-level safety response, when the emergency stop signal is triggered, the independent safety circuit directly cuts off the servo drive power supply. At the same time, the PLC records the fault type (such as overload, over-limit) and the trigger time, and generates a log file for subsequent analysis. For software-level exception handling, over-limit detection is used to monitor the encoder feedback value of each axis in real time. If it exceeds the preset soft limit range, it will immediately trigger a deceleration stop and an alarm. Communication timeout detection: If the host computer command times out without a response, the PLC automatically switches to the preset safety mode (such as pausing movement, maintaining the current position). Servo status monitoring uses the torque and temperature data fed back by the driver to predict overload risks and reduce speed in advance for protection.

[0052] The process of dynamic scheduling of production tasks is as follows: In dynamic production task scheduling, after the host computer issues a task instruction (such as "loading and unloading mode"), the PLC calls pre-stored parameter templates (such as motion speed and gripping height) and implements seamless mode switching through the state machine. The servo motor torque limit is dynamically adjusted based on the material weight (feedback from the pressure sensor); based on the positioning deviation of the vision system, the gripping coordinates are corrected in real time to improve fault tolerance.

[0053] In terms of human-computer interaction, the host computer interface allows manual control of each axis's micro-motion, real-time recording of teach-point coordinates, and generation of motion sequences, supporting "one-click reproduction" operations. Debugging allows the PLC to upload operating data (such as axis vibration curves and communication delays) to the host computer, and trend charts and statistical reports are used to assist in optimizing control parameters.

[0054] As a preferred embodiment of the present invention, the process of communication configuration is as follows: Modbus TCP configuration, the PLC is connected to the host computer through an industrial Ethernet switch. The network cable must comply with the Cat5e or Cat6 standard to ensure that the transmission bandwidth is ≥100Mbps. The PLC IP address is statically assigned (such as 192.168.1.10), and the subnet mask is 255.255.255.0. The host computer IP address is in the same network segment as the PLC (such as 192.168.1.20). The default port number is 502, which supports multi-channel parallel communication. Register allocation maps PLC internal data (such as axis coordinates and speed parameters) to Modbus holding registers (such as 40001-40050). Function code configuration: The host computer uses function code 03 (read register) to obtain real-time status and function code 06 (write single register) to issue control instructions;

[0055] The RS485 bus uses shielded twisted-pair cable with a 120Ω termination resistor and a baud rate setting of 9600 bps to 115200 bps (depending on sensor type). It supports the Modbus RTU protocol, slave address assignment (e.g., sensor addresses 1 to 32), and data frame format (8N1).

[0056] As a preferred embodiment of the present invention, the process of debugging and optimization is as follows: Hardware joint debugging, check power supply stability, verify emergency stop circuit, manually trigger the emergency stop button, and confirm that the servo drive power supply is immediately cut off; Multi-axis synchronous calibration, measuring the actual displacement of the X / Y / Z axes and compensating for mechanical transmission errors (such as screw backlash).

[0057] System load test, continuous operation test: simulate 24 hours of full-load production, monitor PLC CPU load rate (target ≤80%), communication delay (≤10ms); Fault diagnosis optimization and alarm: Different alarm content adopts different processing strategies (such as speed reduction and immediate shutdown). Log analysis PLC stores the latest 1000 fault records and supports filtering by time and type. The host computer generates fault trend reports to assist in locating high-frequency problems (such as frequent over-limit of a certain axis).

[0058] The human-computer interaction debugging mode has been enhanced, adding the "single-step execution" function to gradually verify the motion logic.

[0059] The second embodiment will now be described.

[0060] This system adopts a hierarchical distributed architecture, with PLC as the core control unit, combined with the host computer monitoring layer, communication network layer and execution device layer to achieve full process automation control of the truss system. The specific architecture is as follows:

[0061] (1) Upper computer monitoring layer: Based on industrial computers or industrial servers, it is responsible for dynamic parameter configuration, equipment status visualization, production data analysis and historical data storage.

[0062] (2) Communication network layer: Efficient data interaction between PLC and host computer is achieved through industrial Ethernet (supporting Modbus TCP), and RS485 bus is integrated to connect sensors and actuators to ensure real-time performance and reliability.

[0063] (3) PLC control layer: A high-performance multi-axis motion control PLC (such as the Siemens S7-1200 series) is used to receive instructions from the host computer, coordinate the actions of the multi-axis servo motors, and collect sensor signals (such as position encoders and photoelectric switches) in real time for closed-loop feedback control.

[0064] (4) Execution equipment layer: including terminal actuators such as truss robotic arms, servo drive systems, and pneumatic clamps, which support linear motion and grasping operations and meet high-precision positioning requirements (repeat positioning accuracy of ±0.1mm).

[0065] This embodiment realizes the "centralized management + decentralized execution" mode through the collaborative control of PLC and host computer, reducing the risk of single point failure; the modular communication interface design supports seamless compatibility of multiple industrial protocols and is suitable for the integration of equipment from different brands.

[0066] Among them, the core PLC control layer specifically includes: PLC master control unit: integrated multi-axis motion control module, supports EtherCAT high-speed bus communication.

[0067] I / O expansion module: connects sensors (photoelectric, magnetic open, limit) and actuators (solenoid valve, motor driver).

[0068] Drive and execution module: Equipped with an absolute encoder servo motor (such as Panasonic A6 series), it supports high-precision position feedback (±0.05mm) and is suitable for truss X / Y / Z three-axis motion.

[0069] Servo drive system: Equipped with an absolute encoder servo motor to achieve high dynamic response and low vibration operation.

[0070] Pneumatic / electric grippers: support quick replacement and adapt to different material gripping requirements.

[0071] Among them, the security protection module: Emergency stop circuit: A hardware-level safety circuit independent of the PLC that directly cuts off the power supply when triggered.

[0072] Safety light curtains and area scanners: Real-time monitoring of the work area to prevent personnel from accidentally entering the danger zone.

[0073] Hardware innovations: Redundant power supply design (dual 24V DC input) improves system reliability; integrated industrial-grade anti-interference circuitry ensures stable operation in complex electromagnetic environments.

[0074] Initialization module: used to complete hardware self-test (such as servo drive and sensor status), load preset parameters (such as motion speed, acceleration, and axis limit values), and reset the actuator to a safe initial position when the system starts.

[0075] I / O processing module: used to manage digital input (DI) and output (DO) signals (such as photoelectric switches and emergency stop signals), process analog signals (such as position encoder feedback), and update the PLC's I / O mapping table in real time.

[0076] Multi-axis motion control module: used to achieve coordinated motion of the X / Y / Z axes and adjust the servo motor speed and position through encoder feedback.

[0077] Communication protocol processing module: used to parse the parameters sent by the host computer (such as target coordinates, production rhythm) and upload real-time status (such as axis position, fault code) to the monitoring interface.

[0078] Safety and fault diagnosis module: When the hardware-level emergency stop circuit is triggered, it is used to forcibly cut off the power supply and record the fault log, detect software-level anomalies (such as over-limit, communication timeout, servo overload), and automatically enter safety mode (such as deceleration stop, reset alarm).

[0079] Production task scheduling module: used to switch between different application scenarios (such as loading and unloading) and dynamically adjust motion parameters (such as grasping height and placement speed).

[0080] It realizes precise planning of truss motion trajectory, multi-axis collaborative control and real-time data interaction, significantly improving production efficiency and system reliability.

[0081] Specifically, a three-axis truss (a mechanical structure consisting of three linear axes, X, Y, and Z) is widely used in industrial automation for material handling operations. Its high precision and high efficiency make it a core device in many production scenarios. The following are several typical practical application cases:

[0082] 1. Loading and unloading of CNC machine tools Scenario: Metal processing workshops (such as automotive parts and precision mold production).

[0083] Application: A three-axis gantry, equipped with a robotic arm or suction cup, picks up blanks (such as metal blocks and castings) from the raw material area and precisely places them on the processing station of a CNC machine tool. After processing, the gantry removes the finished product and transfers it to the next process or finished product area.

[0084] Advantages: a: Replaces manual operation and enables 24-hour continuous production. b: Avoids machine downtime and improves equipment utilization.

[0085] 2. Injection molding automation Scenario: Plastic product production line (such as mobile phone cases and home appliance casings).

[0086] Application: After the injection molding machine opens the mold, the three-axis truss quickly grabs hot plastic parts (to avoid deformation) and transfers them to a cooling table or conveyor. It can also precisely place inserts (such as metal nuts) simultaneously.

[0087] Advantages: a. High-speed response, adapting to the short production cycle of injection molding machines. b. Reduces the safety risks of manual contact with high-temperature components.

[0088] 3. Stamping automated production line Scenario: Metal stamping workshop (such as automotive sheet metal parts and hardware).

[0089] Application: A three-axis truss, combined with vacuum cups or grippers, moves sheet metal from the stack into the stamping press die. After stamping, the workpiece is removed and stacked in the finished product area or transferred to the next stamping station.

[0090] Advantages: a. High-speed continuous operation, matching the high-speed rhythm of the stamping machine (e.g., 15-30 stampings per minute). b. Avoiding manual intervention in dangerous stamping areas, ensuring safety.

[0091] 4. Palletizing and sorting in logistics warehousing Scenario: Warehouses and packaging workshops (such as food and daily chemical products).

[0092] Application: The three-axis truss grabs the boxes and bagged goods on the assembly line according to preset rules and stacks them into standard stacks.

[0093] Combined with a visual system, product categories can be identified and sorted to different areas.

[0094] Advantages: a. Simple structure. b. Lower cost than six-axis robots. c. Suitable for objects with regular shapes.

[0095] 5. Electronic component assembly and testing Scenario: Electronics manufacturing (such as circuit boards and semiconductor packaging).

[0096] Application: Grab the circuit boards from the conveyor belt and bring them to the test station, where they are sorted and placed after functional testing.

[0097] Precision pick and place of tiny components (such as chips, capacitors) to placement machines or assembly stations.

[0098] Advantages: a. High repeatability (up to ±0.1mm) to avoid manual operation errors. b. Anti-static design to protect sensitive electronic components.

[0099] This embodiment has the following advantages: Efficiency: The beat is controllable and suitable for high-speed production lines.

[0100] Flexibility: The end tooling (gripper, suction cup, etc.) can be customized to suit different materials.

[0101] Safety: Replaces manual participation in high-risk processes (such as high temperature and stamping).

[0102] Cost: Compared with multi-joint robots, the three-axis truss structure is simple and has low maintenance costs.

[0103] These cases demonstrate the core role of the three-axis truss in standardized, high-volume production scenarios, and are particularly suitable for material handling scenarios that require linear motion and high repeatability.

[0104] This embodiment uses Siemens S7-1200 PLC and Panasonic servo drive to write and design PLC program, including I / O allocation table, program framework, key function implementation, communication configuration, debugging and optimization.

[0105] This embodiment of a PLC-based automated truss system integrates programmable logic controllers (PLCs), multi-axis motion control technology, and industrial communication protocols to create an efficient, stable, and highly integrated automated truss control solution. Using a Siemens S7-1200 PLC as the core control unit, combined with host computer collaborative management, modular hardware design, and industrial Ethernet communication (Modbus TCP), the system achieves precise truss motion trajectory planning, multi-axis coordinated control, and real-time data exchange, significantly improving production efficiency and system reliability.

[0106] In the description of the embodiments of the present application, it should be noted that in the description of the present application, terms such as "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or component must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present application.

[0107] In the description of the present application, the description with reference to the terms "one embodiment", "some embodiments", "in the present embodiment", "specific example", or "some examples" means that the specific features, mechanisms, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, mechanisms, materials or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0108] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A PLC unmanned truss control method, characterized in that: include: S1. Motion trajectory planning: The host computer inputs the target coordinates, and the multi-axis motion control PLC generates the three-axis motion trajectory based on the interpolation algorithm and dynamically adjusts the speed curve of each axis; S2. Real-time data interaction: The host computer reads the real-time status data of the multi-axis motion control PLC and writes control instructions to the multi-axis motion control PLC according to the real-time status data; S3, Fault self-diagnosis and safety protection: If the emergency stop signal is detected, the servo drive power supply is cut off, and the fault type and trigger time are recorded and a log file is generated. Otherwise, proceed to the next step; S4. Dynamic scheduling of production tasks: The multi-axis motion control PLC receives task instructions from the host computer and dynamically adjusts motion parameters based on sensor feedback; S5, Human-computer interaction control: The host computer controls the micro-movement of each axis and records the coordinates of the teaching points to generate a reproducible motion sequence; Among them, the interpolation algorithm is: the laser displacement sensor obtains the real-time height, the PLC compares the real-time height with the processing database, obtains the trajectory deviation value preset by the product model, and converts the trajectory deviation value into a compensation displacement.

2. The PLC unmanned truss control method according to claim 1, characterized in that: In step S1, dynamically adjusting the speed curve includes: Generate an S-shaped velocity curve based on the motion process and three-axis acceleration constraints; The trajectory accuracy is confirmed by real-time interpolation calculation and coordination of multi-axis motion phase differences.

3. The PLC unmanned truss control method according to claim 1, characterized in that: In step S2, the host computer is the master station and the multi-axis motion control PLC is the slave station. The data interaction specifically includes: The host computer reads the real-time status data in the multi-axis motion control PLC holding register through the first function code; The host computer writes the control instruction of a single register to the multi-axis motion control PLC through the second function code; The real-time status data includes the axis target coordinates, operating status, and alarm code fields.

4. The PLC unmanned truss control method according to claim 1, characterized in that: In step S3, it also includes: Over-limit detection: Real-time detection of whether the encoder feedback value of each axis exceeds the preset soft limit range. If so, the servo driver drives the motor to decelerate and stop. Otherwise, proceed to the next step. Communication timeout detection: Real-time detection of whether the communication has timed out and there is no response. If so, switch to the preset safety mode; otherwise, proceed to the next step; Servo status monitoring: Real-time detection of torque and temperature data fed back by the driver to see if there is an overload risk. If so, the servo driver drives the motor to slow down. Otherwise, proceed to the next step.

5. The PLC unmanned truss control method according to claim 1, characterized in that: In step S4, the following steps are specifically included: S41: The host computer sends a task instruction to the multi-axis motion control PLC, which calls a pre-stored parameter template and switches modes through the state machine. S2, the pressure sensor detects the material weight in real time and transmits it to the servo driver. The multi-axis motion control PLC dynamically adjusts the servo motor torque limit according to the material weight; S43, multi-axis motion control PLC corrects the grasping coordinates in real time according to the positioning deviation of the visual system.

6. The PLC unmanned truss control method according to claim 1, characterized in that: In step S5, debugging and optimization are also included: Hardware joint debugging: Manually trigger the emergency stop button to confirm the execution of hardware joint debugging to verify the emergency stop circuit response; Multi-axis synchronous calibration: measure the actual displacement of three axes and calibrate synchronously to compensate for mechanical transmission errors; System load test: simulates 24-hour full-load production and monitors PLC CPU load rate and communication delay.

7. The PLC unmanned truss control method according to claim 6, characterized in that: Debugging optimization also includes fault diagnosis optimization: Process alarm content in a hierarchical manner and implement differentiated response strategies; Store fault records and support classified retrieval, generate fault trend reports and analyze high-frequency abnormal events.

8. A PLC-based automatic control truss system, characterized in that: include: Host computer, used for dynamic parameter configuration, equipment status visualization, production data analysis and historical data storage; Multi-axis motion control PLC, used for instruction processing, multi-axis coordination and closed-loop feedback control; An execution device, comprising a three-axis truss robot arm, a servo drive and a pneumatic clamp, for motion grasping operations, wherein the servo drive is connected to the pneumatic clamp via the three-axis truss robot arm, and the servo drive is electrically connected to the PLC; The communication network is used for data exchange between the multi-axis motion control type PLC and the host computer, and the host computer is electrically connected to the multi-axis motion control type PLC through the communication network.

9. Wherein, the pneumatic clamp includes a manipulator, a vacuum suction cup or a clamping claw, and the communication network includes industrial Ethernet and RS485 bus.

10. The PLC-based automatic control truss system according to claim 8, characterized in that: The multi-axis motion control type PLC includes: Initialization module, used for hardware self-test, parameter loading and actuator reset; An I / O processing module, configured to manage the input and output of digital / analog signals and update an I / O mapping table, wherein the initialization module is electrically connected to the I / O processing module; The multi-axis motion control module is used to realize X / Y / Z axis coordinated motion and servo motor adjustment based on encoder feedback. The multi-axis motion control module is electrically connected to the I / O processing module.

11. The PLC-based automatic control truss system according to claim 9, characterized in that: The multi-axis motion control type PLC also includes: A communication protocol processing module, used for parsing host computer parameters and uploading real-time status data, wherein the communication protocol processing module is electrically connected to the host computer; A safety and fault diagnosis module, used to implement hardware-level emergency stop triggering, fault log recording, and software-level anomaly detection, the safety and fault diagnosis module being electrically connected to the servo drive; The production task scheduling module supports application scenario switching and dynamic adjustment of motion parameters, and the production task scheduling module is electrically connected to the host computer.

Images