Six-axis robot automatic lineation execution method and system based on path data and medium

Abstract

The invention relates to a six-axis robot automatic lineation execution method and system based on path data and a medium, and belongs to the technical field of robot control. In order to solve the problems that in the prior art, operation depends on a demonstrator, track adaptability is poor, and three-dimensional visual data cannot be fused, a standardized path data file is used as an input medium, a continuous posture track is reconstructed through a spherical linear interpolation algorithm, and after a standardized motion instruction is generated, a robot controller is directly connected through a two-channel communication protocol to execute lineation. According to the method, operation of a demonstrator is separated, one-key deployment of a PC end is supported, high-precision continuous lineation of the complex curved surface workpiece is achieved in combination with segmented buffer management and a real-time error detection mechanism, and the automation level and track stability of a flexible manufacturing scene are remarkably improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of robot control, and relates to a method, system and medium for executing automatic marking of a six-axis robot based on path data. Background Art

[0002] Six-axis industrial robots are widely used in manufacturing processes such as welding, assembly, and handling. High-precision marking is a pre-process for part positioning, machining marking, and quality inspection, directly affecting the accuracy of subsequent processes. Currently, mainstream marking execution solutions rely on two modes:

[0003] The first is manual teaching with a teach pendant, where the operator pulls the robot's end-point to record the trajectory. This method requires multiple trial and error corrections, is time-consuming, and has poor adaptability to complex surfaces, making it unsuitable for high-variety, low-volume production.

[0004] The second method is to use a preset path template, generating fixed trajectory instructions through offline programming. While this method avoids on-site teaching, the path parameters are fixed, requiring reprogramming when the workpiece topography or positioning status changes. This results in a long deployment cycle and lacks the ability to adjust in real time.

[0005] It is particularly noteworthy that with the development of 3D visual inspection and point cloud reconstruction technology, workpiece topography data can now be obtained in real time. However, existing robotic marking systems have difficulty integrating this data, resulting in an inability to dynamically generate trajectories based on the actual state of the workpiece. The core bottleneck lies in:

[0006] 1. Traditional control protocols are closed and cannot directly import external path data;

[0007] 2. The generation of motion commands relies on dedicated teaching equipment and cannot achieve direct control from the PC;

[0008] 3. The posture interpolation algorithm is missing, and the conversion of discrete path points can easily cause end jitter, affecting the continuity of the line drawing.

[0009] Therefore, there is an urgent need for an automatic marking execution solution that supports open path input, high-precision trajectory reconstruction, and can be run without a teach pendant, so as to adapt to the intelligent operation requirements of variable workpieces and reused trajectories in flexible manufacturing scenarios. Summary of the Invention

[0010] In view of this, an object of the present invention is to provide a method, system and medium for executing automatic marking of a six-axis robot based on path data.

[0011] In order to achieve the above object, the present invention provides the following technical solutions:

[0012] A six-axis robot automatic marking execution method based on path data includes the following steps:

[0013] S1: Read the standardized path data file, which contains the spatial position coordinates (x, y, z) and attitude quaternion (q x ,q y ,q z ,q w ), control code fields (cf1, cf4, cf6, cfx) and optional extended parameters;

[0014] S2: Spherical linear interpolation (SLERP) is used to smoothly transition the attitude quaternions of adjacent path points to generate a continuous attitude trajectory. The interpolation formula is:

[0015]

[0016] Where θ is the angle between Q1 and Q2, t∈[0,1];

[0017] S3: parsing the path data to generate standardized motion instructions, wherein the motion instructions include spatial position, interpolated posture and control parameters;

[0018] S4: Send motion instructions one by one to the six-axis robot controller through the dual-channel communication protocol, skipping the teach pendant operation to directly drive the robot to perform continuous marking movements.

[0019] Furthermore, the posture quaternion interpolation in S2 is used to avoid sudden changes in the posture of the end of the robotic arm, and the interpolation step size is adaptively adjusted according to the path curvature.

[0020] Furthermore, the S4 specifically includes:

[0021] S41: establishing a dual-channel TCP / IP communication link for the command channel and the feedback channel;

[0022] S42: Send the MoveL command to the robot controller through the command channel and receive the execution status data in real time through the feedback channel;

[0023] S43: Calculate the trajectory tracking error based on the actual end position (x', y', z') and the expected position (x, y, z) in the feedback data:

[0024]

[0025] If ΔP>preset threshold δ, the correction mechanism is triggered.

[0026] Furthermore, the feedback data includes the joint angle ROBOT_JOINT, the end position ROBOT_POSITION and the execution flag, where ROBOT_POSITION = [x, y, z, q x ,q y ,qz ,q w ].

[0027] A six-axis robot marking execution system for implementing the method, comprising:

[0028] The path instruction parsing module is used to read the path data file and perform attitude interpolation calculation. Its output end is connected to the instruction input end of the PC control and communication module through the data bus;

[0029] A PC-side control and communication module, whose command output terminal is connected to the command interface of the robot controller via the TCP / IP protocol, and whose feedback input terminal is connected to the status output terminal of the robot controller;

[0030] An attitude synchronization and error detection module, wherein a first input terminal thereof is connected to a feedback data output terminal of the PC-side control and communication module, a second input terminal thereof is connected to a desired posture output terminal of the path instruction parsing module, and an error correction signal output terminal thereof is connected to a command reload interface of the PC-side control and communication module;

[0031] The log recording and exception recovery module is bidirectionally connected to the data recording interface of the path instruction parsing module, the communication log interface of the PC control and communication module, and the error recording interface of the posture synchronization and error detection module.

[0032] Furthermore, the path instruction parsing module includes a segment packaging unit for splitting the trajectory into data packets with a maximum of N path points in a single segment, and outputting them to the buffer of the PC control and communication module after syntax verification.

[0033] Furthermore, the control code fields (cf1, cf4, cf6, cfx) in the path data file are converted into robot joint limit marks and tool coordinate system identifiers through the path instruction parsing module, and embedded in the configuration parameter segment of the motion instruction.

[0034] Furthermore, when sending a motion instruction, the PC-side control and communication module dynamically adjusts the linear speed and interpolation type according to the optional extended parameters in the path data file, and the optional extended parameters include a mark status identifier.

[0035] Furthermore, the PC-side control and communication module has a built-in ring buffer for storing segmented and packaged motion instructions, and asynchronously transmitting them through a dual-channel communication link managed by independent threads. The dual channel includes a command channel of port 12305 and a feedback channel of port 12306.

[0036] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the automatic line marking execution method of a six-axis robot based on path data.

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

[0038] (1) The robot movement is directly driven by standardized path data files, completely skipping the manual operation of the teach pendant, eliminating the time cost of manual traction teaching and path reproduction, and realizing full-process automated deployment.

[0039] (2) It adopts a platform-independent path data medium structure, which supports the rapid import of trajectory data output by any 3D vision system or point cloud algorithm. It does not require the development of customized templates for different workpiece shapes, greatly improving the mixed-line production capacity of multiple varieties of workpieces.

[0040] (3) The posture reconstruction algorithm based on spherical linear interpolation effectively solves the problem of terminal posture mutation during the conversion of discrete path points, avoids trajectory jitter caused by Euler angle jumps during marking operations, and ensures the consistency of marking on complex surfaces.

[0041] (4) The dual-channel asynchronous communication mechanism works in conjunction with the segmented buffer management strategy to maintain a continuous and stable instruction flow even in scenarios with network fluctuations or controller delays, thus preventing trajectory interruptions and resulting in incomplete lines.

[0042] (5) Through the linkage mechanism of real-time posture feedback and trajectory error detection, execution deviations can be dynamically corrected; combined with the log-driven breakpoint resumption function, operations can be accurately resumed after abnormal interruptions, significantly reducing the scrap rate.

[0043] (6) Using the path data file as the intermediate carrier, the visual inspection, trajectory planning and robot execution links are connected to form a traceable, reusable and scalable flexible manufacturing technology chain, providing infrastructure support for the upgrade of intelligent manufacturing.

[0044] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0046] Figure 1 This is a flow chart of the automatic marking execution method of the six-axis robot in the present invention;

[0047] Figure 2 This is a diagram of the system module structure in the present invention. DETAILED DESCRIPTION

[0048] The following describes the embodiments of the present invention by means of specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0049] Among them, the accompanying drawings are only for illustrative purposes and represent only schematic diagrams rather than actual pictures, and should not be understood as limiting the present invention. In order to better illustrate the embodiments of the present invention, some parts of the accompanying drawings may be omitted, enlarged or reduced, and do not represent the dimensions of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted in the accompanying drawings.

[0050] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "front", "back", etc. indicating directions or positional relationships, they are based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0051] See also Figure 1 and Figure 2 The present invention is suitable for high-precision scenarios such as automatic marking, pre-assembly positioning, welding path pre-marking, and detection auxiliary marking of various complex curved surface parts. It is especially suitable for flexible processing platforms that combine point cloud drive and robot systems.

[0052] Example 1: Standard Path Driven Marking Process

[0053] 1.1 Path data loading

[0054] The vision system generates workpiece surface point cloud data, and the trajectory planning module outputs a route.json file containing 200 path points. Each point contains three-dimensional coordinates, quaternion posture and linear speed parameters.

[0055] 1.2 Posture Smooth Reconstruction

[0056] The path instruction parsing module reads the JSON file and uses the spherical linear interpolation algorithm to calculate the intermediate posture of adjacent points. The interpolation step size is set to 0.05 based on the curvature adaptation.

[0057] 1.3 Command Generation and Sending

[0058] Generate standardized MoveL instruction: MoveL p1,v100,cf1:=1,cf4:=0,z10

[0059] The PC communication module sends data to the ABB IRC5 controller through port 12305 and opens port 12306 to listen for feedback data.

[0060] 1.4 Dynamic Error Correction

[0061] The attitude synchronization module detects that the actual position deviation of a certain point is ΔP = 0.8mm (threshold δ = 0.5mm), triggering the repositioning command:

[0062] Pause the current track

[0063] Send MoveJ p_correct to correct joint angles

[0064] Resume from breakpoint

[0065] Example 2: Cross-platform multi-brand robot deployment

[0066] 2.1 System Initialization

[0067] The path instruction parsing module loads the KUKA compatible adapter and maps the control code field cfx:=5 in the JSON to KUKA's $VEL.CP=0.2.

[0068] 2.2 Segmented Buffer Execution

[0069] The 300-point trajectory is split into three segments (100 points each) and stored in the ring buffer after syntax verification.

[0070] The communication module sends the header asynchronously to the KUKAKR C4 controller.

[0071] 2.3 Dual-channel collaboration

[0072] The feedback channel returns ROBOT_POSITION data in real time, and the log module records the position and timestamp.

[0073] When the second segment is sent, the completion flag of the first segment has been returned through port 12306.

[0074] 2.4 Abnormal Recovery

[0075] The network interruption causes the third segment to fail to be sent, and the log module records the index of the last successful point (Index=215).

[0076] After reconnection, the remaining path segments are loaded directly from Index = 216.

[0077] Example 3: 3D Vision Adaptive Line Drawing

[0078] 3.1 Real-time path update

[0079] After the vision system detects blade deformation, it updates the JSON file and adds curvature compensation path points.

[0080] The path parsing module reloads files instantly and adjusts the interpolation step size to 0.02.

[0081] 3.2 Dynamic parameter execution

[0082] Recognize the extended parameters {"line speed":50,"flag status":2} in the JSON and generate the instruction: MoveL p_new,v50,cfx:=2.

[0083] 3.3 High-precision guarantee

[0084] The attitude synchronization module compares the actual posture in the blade flange coordinate system and automatically switches to low-speed mode (v20) when ΔP is greater than 0.3mm for three consecutive points.

[0085] 3.4 Full process traceability

[0086] The log module generates an operation report, including trajectory correction records, error triggering times, and segment execution time.

[0087] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. A six-axis robot automatic marking execution method based on path data, characterized by: The following steps are involved: S1: Read the standardized path data file, which contains the spatial position coordinates (x, y, z) and attitude quaternion (q x ,q y ,q z ,q w ), control code fields (cf1, cf4, cf6, cfx) and optional extended parameters; S2: Spherical linear interpolation (SLERP) is used to smoothly transition the attitude quaternions of adjacent path points to generate a continuous attitude trajectory. The interpolation formula is: Where θ is the angle between Q1 and Q2, t∈[0,1]; S3: parsing the path data to generate standardized motion instructions, wherein the motion instructions include spatial position, interpolated posture and control parameters; S4: Send motion instructions one by one to the six-axis robot controller through the dual-channel communication protocol, skipping the teach pendant operation to directly drive the robot to perform continuous marking movements.

2. The method for executing automatic marking of a six-axis robot based on path data according to claim 1, characterized in that: The attitude quaternion interpolation in S2 is used to avoid sudden changes in the attitude of the end of the robotic arm, and the interpolation step size is adaptively adjusted according to the path curvature.

3. The method for executing automatic marking of a six-axis robot based on path data according to claim 1, characterized in that: The S4 specifically includes: S41: establishing a dual-channel TCP / IP communication link for the command channel and the feedback channel; S42: Send the MoveL command to the robot controller through the command channel and receive the execution status data in real time through the feedback channel; S43: Calculate the trajectory tracking error based on the actual end position (x', y', z') and the expected position (x, y, z) in the feedback data: If ΔP>preset threshold δ, the correction mechanism is triggered.

4. The method for executing automatic marking of a six-axis robot based on path data according to claim 1, characterized in that: The feedback data includes the joint angle ROBOT_JOINT, the end position ROBOT_POSITION and the execution flag, where ROBOT_POSITION = [x, y, z, q x ,q y ,q z ,q w ].

5. A six-axis robot marking execution system for implementing the method according to any one of claims 1 to 4, characterized in that: include: The path instruction parsing module is used to read the path data file and perform attitude interpolation calculation. Its output end is connected to the instruction input end of the PC control and communication module through the data bus; A PC-side control and communication module, whose command output terminal is connected to the command interface of the robot controller via the TCP / IP protocol, and whose feedback input terminal is connected to the status output terminal of the robot controller; An attitude synchronization and error detection module, wherein a first input terminal thereof is connected to a feedback data output terminal of the PC-side control and communication module, a second input terminal thereof is connected to a desired posture output terminal of the path instruction parsing module, and an error correction signal output terminal thereof is connected to a command reload interface of the PC-side control and communication module; The log recording and exception recovery module is bidirectionally connected to the data recording interface of the path instruction parsing module, the communication log interface of the PC control and communication module, and the error recording interface of the posture synchronization and error detection module.

6. The six-axis robot marking execution system according to claim 5, characterized in that: The path instruction parsing module includes a segmentation and packaging unit, which is used to split the trajectory into data packets with a maximum of N path points in a single segment, and output them to the buffer of the PC control and communication module after syntax verification.

7. The six-axis robot marking execution system according to claim 5, characterized in that: The control code fields (cf1, cf4, cf6, cfx) in the path data file are converted into robot joint limit marks and tool coordinate system marks by the path instruction parsing module, and embedded in the configuration parameter segment of the motion instruction.

8. The six-axis robot marking execution system according to claim 5, characterized in that: When sending a motion instruction, the PC-side control and communication module dynamically adjusts the linear speed and interpolation type according to the optional extended parameters in the path data file, and the optional extended parameters include a mark state identifier.

9. The six-axis robot marking execution system according to claim 5, characterized in that: The PC-side control and communication module has a built-in ring buffer for storing segmented and packaged motion instructions, and asynchronously transmitting them through a dual-channel communication link managed by independent threads. The dual channels include a command channel at port 12305 and a feedback channel at port 12306.

10. A computer-readable storage medium storing a computer program, characterized in that: When the program is executed by a processor, the six-axis robot automatic marking execution method based on path data according to any one of claims 1 to 4 is implemented.

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