A high-precision ratchet feeding control method, system, and storage medium

Abstract

This application relates to the field of automatic control technology, and discloses a high-precision ratchet feeding control method, system, and storage medium. The method includes: acquiring material parameters and extracting the material height and outer diameter dimensions from them; adjusting the limit stroke of a one-way limit unit according to the positive correlation of the material height to adapt to materials of different heights; when the material belt collection unit pulls the material belt, calculating the comprehensive material size based on the material height and outer diameter dimensions, and adjusting the material belt tension according to the positive correlation of the comprehensive material size; the material enters the stop sensing unit through the one-way limit unit and is limited by both to a precise position of the riveting and unloading unit; the stop sensing unit senses the material and generates sensing data, controls the riveting and unloading unit to press the material, and adjusts the pressing force according to the outer diameter of the material based on whether the comprehensive material size is within a preset first size range. This application improves the adaptability of the feeding system to materials of different sizes through multi-stage dynamic adaptation and adjustment.

Description

Technical Field

[0001] This application relates to the field of automatic control technology, and in particular to a high-precision ratchet feeding control method, system and storage medium. Background Technology

[0002] With the deep penetration of the concept of intelligent manufacturing, the requirements of various industries for production efficiency, assembly precision and product consistency continue to rise. In particular, in the fields of automobiles, electronics and precision machinery, the popularity of automated production lines has increased significantly. Among them, the fastener supply system of automated production is a key component of the assembly process, and its performance directly affects the operating efficiency of the entire production line.

[0003] Fasteners, as core connecting components in mechanical assembly, are crucial to the overall performance of products due to their assembly quality and efficiency. With the development of automation technology, automated fastener assembly has become an inevitable choice for industry upgrading. It can achieve the positioning and assembly of fasteners through the coordinated operation of mechanical structures, and is a key link in ensuring the quality of high-end manufactured products.

[0004] Most automatic fastener feeding systems on the market currently adopt a mechanical structure design, with fixed feeding parameters and a lack of adaptive adjustment capabilities. When production tasks switch to different specifications of fasteners or the assembly scenario changes, manual adjustments to the mechanical structure or replacement of parts are required, which is not only cumbersome but also time-consuming. Summary of the Invention

[0005] To improve the adaptability of the feeding system, this application provides a high-precision ratchet feeding control method, system, and storage medium.

[0006] In a first aspect, this application provides a high-precision ratchet feeding control method, which adopts the following technical solution:

[0007] A high-precision ratchet feeding control method is based on a unidirectional limit unit, a stop sensing unit, a riveting unloading unit, and a material strip collection unit sequentially arranged on the feeding line; the method includes the following steps:

[0008] Obtain material parameters, and extract the material height and outer diameter based on the material parameters; adjust the limit stroke of the unidirectional limit unit according to the positive correlation of the material height, the larger the material height, the longer the limit stroke, and the smaller the material height, the shorter the limit stroke.

[0009] The material collection unit pulls the material belt and calculates the overall size of the material based on its height and outer diameter. The tension of the material belt is adjusted according to the overall size of the material: the larger the overall size of the material, the greater the tension of the material belt, and the smaller the overall size of the material, the smaller the tension of the material belt.

[0010] After the material passes through the one-way limiting unit and enters the stop sensing unit, it is limited by the one-way limiting unit and the stop sensing unit to the position of aligning with the riveting and feeding unit;

[0011] After the stop sensing unit senses the material, it generates sensing data. Based on the sensing data, it controls the riveting and feeding unit to press the material and remove it from the material belt. If the overall size of the material is within the preset first size range, the pressing force of the riveting and feeding unit is adjusted negatively according to the outer diameter of the material. If the overall size of the material is greater than the value within the first size range, the pressing force of the riveting and feeding unit is adjusted positively according to the outer diameter of the material.

[0012] By adopting the above technical solution, the material height and outer diameter are extracted from the material parameters. The limit stroke of the unidirectional limit unit is adjusted according to the positive correlation of the material height, ensuring that the limit stroke accurately adapts to materials of different heights and avoiding inaccurate limiting. When the material belt collection unit pulls the material belt, it calculates the comprehensive size of the material based on the material height and outer diameter, and adjusts the belt tension according to its positive correlation to prevent improper tension from damaging the material or hindering the conveying, ensuring stable belt pulling. After the material enters the stop sensing unit through the unidirectional limit unit, it is limited by both to the position aligned with the riveting and unloading unit, ensuring accurate positioning. The stop sensing unit generates sensing data to control the riveting and unloading unit to press the material, and also adjusts the pressing force according to the range of the material's comprehensive size, negatively or positively correlated with the material's outer diameter, to prevent the material from falling off or being damaged. This improves the adaptability of the feeding system to materials of different sizes and achieves high-precision feeding.

[0013] Optionally, the method further includes the following steps:

[0014] The image sensor installed on the unidirectional limiting unit acquires material images, identifies the main material body from the material images, calculates the pixel difference between the current main material body and the previous main material body, and calculates the first comparison value based on the pixel difference and the preset pixel reference value.

[0015] Update the historical height dimension using the last material height dimension, and update the historical outer diameter dimension using the last material outer diameter dimension;

[0016] The difference between the current material height dimension and the historical height dimension is calculated as the height difference; the difference between the current material outer diameter dimension and the historical outer diameter dimension is calculated as the outer diameter difference.

[0017] The combined difference is calculated based on the height difference and the outer diameter difference;

[0018] The second comparison value is calculated based on the comprehensive difference and the preset reference difference;

[0019] A comprehensive comparison value is calculated based on the first comparison value and the second comparison value. If the comprehensive comparison value is greater than the preset reference comparison value, the historical height dimension is updated using the current material height dimension, and the historical outer diameter dimension is updated using the current material outer diameter dimension.

[0020] By adopting the above technical solutions, on the one hand, the pixel difference of image recognition is used to supplement the dimension of size data, making the judgment of material differences more comprehensive; on the other hand, by setting the update threshold through comprehensive comparison value, the historical data is avoided from being updated frequently due to small size fluctuations, ensuring the stability of the historical size benchmark, thereby improving the accuracy of subsequent adjustments such as limit stroke and tension based on historical data, and further enhancing the adaptability of the feeding system to changes in material size and the feeding accuracy.

[0021] Optionally, the method further includes the following steps:

[0022] The one-way limiting unit includes a rotatably connected one-way limiting rod and an elastic reset member for resetting the one-way limiting rod;

[0023] Vibration data is acquired by a vibration sensor installed on a one-way limit bar based on the material parameters.

[0024] The spectral data is calculated using a spectral conversion algorithm based on the vibration data.

[0025] Extract the frequency fluctuation range and the corresponding fluctuation energy value from the spectral data;

[0026] Calculate the frequency span value of the frequency fluctuation range;

[0027] If the frequency span of the frequency fluctuation range is outside the preset reference span range and the fluctuation energy value is outside the preset reference fluctuation range, the material normal label will be eliminated and a material abnormality warning will be issued; otherwise, a material normal label will be generated.

[0028] By adopting the above technical solution, the vibration characteristics are used to reflect the interaction state between the material and the one-way limiting rod. Spectrum analysis can accurately capture abnormal vibration characteristics, enabling effective monitoring of whether the material is abnormal. When the material has dimensional deviations or abnormal postures, it will cause vibrations beyond the normal range. The system can identify and issue warnings in a timely manner, preventing abnormal materials from entering subsequent processes.

[0029] Optionally, the method further includes the following steps:

[0030] Based on the normal material identification, the curvature of the stop surface of the stop plate in the stop sensing unit is adjusted according to the negative correlation of the material's outer diameter. The larger the material's outer diameter, the smaller the curvature; the smaller the material's outer diameter, the larger the curvature.

[0031] Alternatively, the spacing between the stop plates in the stop sensing unit can be adjusted according to the outer diameter of the material. The larger the outer diameter of the material, the larger the spacing between the plates, and the smaller the outer diameter of the material, the smaller the spacing between the plates.

[0032] By adopting the above technical solution, it is ensured that materials with different outer diameters can be stably limited to the position of the aligned riveting feeding unit, which improves the adaptability and stability of the stop positioning and avoids material deviation or jamming caused by the fixed stop structure.

[0033] Optionally, the method further includes the following steps:

[0034] Based on the normal material identification, the pressing area in the riveting and feeding unit is adjusted according to the negative correlation between the material height and the material dimensions. The larger the material height, the smaller the pressing area, and vice versa.

[0035] By adopting the above technical solution, it is ensured that materials of different heights can obtain a suitable crimping contact area. For materials with greater height, a smaller crimping area can avoid the crimping range from exceeding the top of the material, which would cause the crimping force to be dispersed; for materials with less height, a larger crimping area can provide sufficient crimping contact area to prevent unstable crimping. This improves the crimping stability of the riveting and blanking unit for materials of different heights.

[0036] Optionally, the stop sensing unit includes a stop element, a detection spear, and a sensor:

[0037] The blocking component is fixed at the end of the conveyor belt path as a physical positioning reference for the material arrival.

[0038] The detection spear is installed on one side of the blocking component and is initially in the extended state, in contact with the material;

[0039] The sensor is linked to the detection spear. When the detection spear comes into contact with the material, it sends an action signal that triggers the detection spear.

[0040] By adopting the above technical solution, the initial mechanical triggering of material arrival is achieved; the sensor and the detection spear are linked, which can convert the mechanical action of the detection spear being abutted into an action signal.

[0041] Optionally, the method further includes the following steps:

[0042] The material collection unit adjusts the material belt speed in a negative correlation with the overall size of the material. The larger the overall size of the material, the slower the material belt speed, and the smaller the overall size of the material, the faster the material belt speed.

[0043] By adopting the above technical solutions, for larger materials, a slower pulling speed can avoid the material's posture shifting during conveying or collision damage with the unidirectional limit unit and stop sensing unit due to inertia; for smaller materials, a faster pulling speed can improve the feeding efficiency while ensuring stable conveying.

[0044] Optionally, the strip collection unit includes raised toothed rollers, guides, a oscillating cylinder, strip traction components, and anti-winding components:

[0045] The conveyor belt carrying material passes through the mechanical part under the device, while the empty conveyor belt passes through the guide and hangs on the raised toothed roller.

[0046] The material belt traction component is connected to the swing cylinder. The swing cylinder pulls the material belt traction component upward along a preset path by reciprocating motion of rotating at a specific angle when the air is supplied and automatically returning to its original position when the air is cut off.

[0047] The anti-winding component is set close to the raised teeth to prevent the material belt from getting caught in the raised teeth due to tension changes during conveying.

[0048] By adopting the above technical solution, the guide component guides the empty material belt to hang on the raised tooth roller, completing the separation and guidance of the material belt and the empty material belt, and avoiding the two material belts from getting tangled; the swing cylinder provides stable power to the material belt traction component with the reciprocating motion of "air-driven rotation at a specific angle and air-cut return to position", pulling it to drive the material belt to be conveyed upward along the preset path, ensuring that the conveying rhythm is controllable; the anti-winding component is close to the raised tooth roller, which can prevent the material belt from being wound into the tooth roller due to tension fluctuations, preventing belt jamming or conveying deviation.

[0049] Secondly, this application provides a high-precision ratchet feeding control system, which adopts the following technical solution:

[0050] A high-precision ratchet feeding control system includes a processor, wherein the processor executes the steps of the high-precision ratchet feeding control method as described in any of the preceding claims.

[0051] Thirdly, this application provides a storage medium, which adopts the following technical solution:

[0052] A storage medium storing a program that, when executed by a processor, implements the steps of the high-precision ratchet feeding control method described in any one of the preceding claims.

[0053] In summary, this application includes at least one of the following beneficial technical effects: By dynamically adjusting the limiting stroke of the unidirectional limiting unit and the tension and speed of the material collection unit, the feeding system can accurately adapt to different material height and outer diameter dimensions, improving its adaptability to diverse materials; by optimizing the historical data update mechanism through image recognition and size difference analysis, and combining vibration spectrum analysis to achieve accurate early warning of material anomalies, ensuring the stability and reliability of the feeding process; by adjusting the stop structure of the stop sensing unit and the pressing force and pressing area of ​​the riveting unloading unit, accurate material positioning and stable pressing are ensured, avoiding deviation or damage; the separation guide and anti-winding design of the material collection unit effectively prevents material belt entanglement and jamming, ensuring smooth conveying. Attached Figure Description

[0054] Figure 1 This is a diagram illustrating the dragging of a nail belt.

[0055] Figure 2 This is a schematic diagram for checking rivet positioning.

[0056] Figure 3 This is a flowchart illustrating the steps of a high-precision ratchet feeding control method.

[0057] Reference numerals: 1. Swing cylinder; 2. Anti-entanglement component; 3. Raised gear hobbing; 4. Guide component; 5. Rivet; 6. Anti-retraction component; 7. Blocking component; 8. Nail-band traction component; 9. Detection spear; 10. Sensor. Detailed Implementation

[0058] The embodiments of this application are described in detail below, and examples of the embodiments are shown in the accompanying drawings.

[0059] In the description of this specification, the references to "certain embodiments," "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples" refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0060] The high-precision ratchet feeding device in this embodiment refers to... Figure 1 and Figure 2 It is a high-precision ratchet feeding device, including a riveting and feeding unit, a material strip collecting unit, a one-way limiting unit and a stop sensing unit;

[0061] The riveting and unloading unit includes a crimping component and a crimping drive component for riveting rivets 5 to the lower conveying channel;

[0062] The material collection unit is responsible for the orderly conveying of the staples and includes raised toothed rollers 3, guides 4, swing cylinders 1, staple traction components 8, and anti-winding components 2.

[0063] The rivet belt is divided into two conveying paths: a rivet belt carrying rivets 5 and an empty rivet belt. The rivet belt carrying rivets 5 passes through the mechanical part on the lower side of the device. After the rivets 5 are riveted, the empty rivet belt passes through the guide 4 and hangs on the raised hobbing tooth 3, realizing the separation and guidance of the two rivet belts.

[0064] The swing cylinder 1 provides power for the material belt conveyor by reciprocating motion of rotating at a specific angle when the air is supplied and automatically returning to its original position when the air is cut off. This provides power for the nail belt conveyor, pulls the subsequent nail belt traction component 8, and drives the nail belt to move along a preset path.

[0065] The rivet traction component 8 is connected to the swing cylinder 1, and under the drive of the swing cylinder 1, it drives the rivet 5 carrying the rivet to move upward.

[0066] The anti-winding component 2 is set close to the raised tooth 3, which can prevent the nail tape from being rolled into the raised tooth 3 due to tension changes during conveying, thus avoiding tape jamming or conveying deviation and ensuring the stability of the nail tape path.

[0067] The one-way limiting unit includes an anti-reverse component 6, installed on the left side of the rivet conveyor path, i.e., the direction in which the rivet might retract. Through the one-way limiting structure, the rivet is only allowed to move in the upward conveying direction. Once the rivet shows a tendency to retract to the left, the anti-reverse component 6 immediately blocks it, preventing the rivet from shifting position and ensuring the continuity and accuracy of the rivet feeding process. Specifically, the anti-reverse component 6 includes a rotatably connected one-way limiting rod and an elastic reset component for resetting the one-way limiting rod. In other embodiments, the one-way limiting unit is equipped with an image sensor to acquire images of the rivets 5, thereby facilitating the identification of the rivet's height parameters.

[0068] The stop sensing unit is used to accurately determine whether the rivet 5 has reached the designated position before riveting, and includes a stopper 7, a detection spear 9, and a sensor 10.

[0069] The blocking member 7 is fixed at the end position of the rivet conveying path, serving as the physical positioning reference for the rivet 5 to be in place. In other embodiments, the blocking member 7 includes a stop bend plate, the curvature of which can be changed by a driving member to adapt to the outer diameter of the rivet 5, thereby making the rivet 5 more closely and stably positioned; or, the blocking member 7 includes at least two stop clamps. In the embodiment with two stop clamps, the clamping distance between the two stop clamps can be adjusted by a driving member to adapt to the outer diameter of the rivet 5.

[0070] The detection spear 9 is installed near the blocking part 7 and is initially in the extended state, which can contact the rivet 5.

[0071] Sensor 10 is linked with detection spear 9 to receive the action signal of detection spear 9, convert the mechanical action into an electrical signal, and realize the accurate judgment of the rivet 5 being in place.

[0072] Example 1:

[0073] A high-precision ratchet nail feeding device control method, based on the aforementioned high-precision ratchet nail feeding device, includes the following specific nail feeding steps:

[0074] Initial setup: The rivet strap carrying the rivet 5 passes through the mechanical part under the device, while the empty rivet strap passes through the guide 4 and hangs on the raised hobbing tooth 3, completing the initial installation of the rivet strap; the swing cylinder 1 is in the air-cut-off return state, the detection spear 9 is in the extended state, and the sensor 10 is in the standby detection state.

[0075] Start of rivet conveyor: Air is supplied to the swing cylinder 1, which rotates at a specific angle, pulling the rivet traction member 8 upward through the connecting structure; the rivet 5 carrying the rivet is conveyed upward synchronously. During this process, the anti-entanglement member 2 blocks the rivet 3 to prevent it from being entangled in the protruding toothed roller; at the same time, the anti-reverse member 6 restricts the rivet 3 to prevent it from retracting to the left.

[0076] Rivet 5 arrival detection: As the rivet belt continues to be conveyed upward, when the rivet 5 moves to the position where it contacts the blocking member 7, the conveying of the rivet belt is blocked and the upward movement is initially stopped; at the same time that the rivet 5 contacts the blocking member 7, it will knock back the detection spear 9 which is in the extended state; the action of knocking back the detection spear 9 triggers the sensor 10, and the sensor 10 sends an electrical signal, based on which the system accurately determines that the rivet 5 has reached the designated position.

[0077] Waiting for riveting and preparation for the next round: After the rivet 5 is in place, it remains stationary under the obstruction of the rivet 5 blocking part 7, waiting for the riveting process of the riveting feeding unit to rivet it; after the riveting is completed, the swing cylinder 1 cuts off the air and automatically returns to its original position, driving the nail belt traction part 8 to reset, preparing for the next round of nail belt conveying, and the device enters the next nail supply cycle.

[0078] Example 2

[0079] A high-precision ratchet feeding control method, referring to Figure 1 Based on the aforementioned high-precision ratchet feeding device, the device includes a one-way limiting unit, a stop sensing unit, a riveting and unloading unit, and a material belt collecting unit sequentially arranged on the feeding line; the method includes the following steps:

[0080] Material parameters, including the three-dimensional dimensions of the material, are acquired through a parameter acquisition module at the front end of the feeding line, such as a laser rangefinder or a vision recognition device. The height and outer diameter of the material, which have the most significant impact on feeding positioning, are then extracted from these parameters. In this embodiment, the material is a rivet 5, and the material strip is a rivet strip.

[0081] Since rivets 5 of different heights require different limiting spaces during transportation, the limiting stroke of the unidirectional limiting unit is adjusted in a positive correlation with the rivet height. When the rivet height increases by a preset threshold, such as 2mm, the limiting stroke of the unidirectional limiting unit increases proportionally, such as 1.5mm, to ensure that rivets 5 with larger heights have sufficient space to pass through. Conversely, when the rivet height decreases, the limiting stroke is shortened accordingly to avoid the rivet 5 from shifting its posture due to excessive limiting gap, thus ensuring the stability of rivet 5 transportation from the rivet supply source.

[0082] As the power terminal for the rivet conveyor, the pulling force of the material collection unit directly affects the conveyor rhythm and the safety of the rivets 5. In this method, based on the extracted rivet height and outer diameter, a preset algorithm calculates the comprehensive rivet dimension, which comprehensively reflects the volume and conveying resistance characteristics of the rivet 5. The preset algorithm is a weighted summation formula: Comprehensive rivet dimension = α × rivet height + β × rivet outer diameter, where α and β are weighting coefficients set according to the material of the rivet 5.

[0083] The rivet belt tension is controlled by a positive correlation adjustment logic based on the overall dimensions of the rivets: when the overall dimensions of the rivets are large, it means that the volume is large and the weight is heavy, and the traction power required for the belt is greater. At this time, the tension of the rivet belt is increased to avoid the rivet belt from stalling and the rivets 5 from accumulating due to insufficient tension. When the overall dimensions of the rivets are small, if a large tension is still maintained, it is easy to cause the rivet belt to stretch and deform or the rivets 5 to shift on the rivet belt. Therefore, the tension of the rivet belt is reduced simultaneously to ensure that the rivet belt is conveyed at a stable speed, which not only avoids damage to the rivets 5, but also ensures the rivet supply efficiency.

[0084] After passing through the one-way limiting unit, the rivet 5 enters the stop sensing unit. The one-way limiting unit restricts the lateral displacement of the rivet 5 from the side, and the stop sensing unit blocks the rivet 5 from continuing to move from the conveying direction. The two form a dual positioning mechanism of lateral limiting and longitudinal stopping, which precisely limits the rivet 5 to the preset position aligned with the riveting and feeding unit, ensuring that the subsequent crimping action can accurately act on the rivet 5 and avoid crimping failure or damage to the rivet 5 due to positioning deviation.

[0085] The stop sensing unit has a built-in sensor 10, such as a contact sensor or a photoelectric sensor. After sensing the rivet 5, it generates sensing data including the position of the rivet 5 and the contact pressure. Based on this data, the system triggers the crimping action of the riveting and unloading unit, pushing the crimping component to separate the rivet 5 from the strip. Simultaneously, a differentiated crimping force adjustment strategy is adopted according to the different ranges of the rivet's overall dimensions.

[0086] If the overall dimensions of the rivet are within the preset first size range, such as 5-10mm for a standard rivet size 5. 3At this point, the rivet 5 has a moderate volume, and the outer diameter of the rivet is negatively correlated with the size of the rivet. The larger the outer diameter of the rivet 5, the larger the contact area with the crimping part, and the smaller the crimping force can achieve stable crimping, avoiding excessive crimping force that could cause deformation of the rivet 5. The smaller the outer diameter of the rivet 5, the smaller the contact area, and the greater the crimping force is required to prevent the rivet 5 from slipping off during crimping.

[0087] If the overall size of the rivet is larger than the first size range, such as an oversized rivet 5 with a diameter of 10mm... 3 In this case, the rivet 5 has a larger mass and volume, and the resistance to be overcome during crimping is stronger. Therefore, the outer diameter of the rivet is adjusted in a positive correlation with the outer diameter. The larger the outer diameter of the rivet 5, the greater the crimping force required to ensure that the rivet 5 can be effectively separated from the strip. For rivets 5 with smaller outer diameter but larger overall size, such as slender rivets 5, the crimping force also needs to be increased to cope with their greater longitudinal resistance and ensure the reliability of crimping.

[0088] From acquiring rivet 5 parameters to unidirectional limiting, rivet band tension adjustment, and positioning and crimping control, each step is dynamically adapted based on the actual dimensions of rivet 5. This significantly improves the system's compatibility with rivets 5 of different heights and outer diameters. The combination of a dual positioning mechanism and differentiated crimping force adjustment ensures rivet 5 positioning accuracy while preventing slippage or damage during crimping, effectively improving the material supply qualification rate.

[0089] To further improve the response accuracy and adjustment stability of the feeding system to changes in the size of rivet 5, the specific method also includes the following steps:

[0090] A high-definition image sensor is installed on the side or above the unidirectional limiting unit. This sensor maintains a fixed angle with the rivet 5 conveying path to ensure clear capture of the complete outline of the rivet 5 as it passes. When the rivet 5 is conveyed to the vicinity of the unidirectional limiting unit with the conveyor belt, the image sensor captures an image of the rivet 5 in real time. Using a preset image recognition algorithm, such as a deep learning-based object detection model and edge contour extraction algorithm, the system accurately segments the main body of the rivet 5 from the image, eliminating interfering elements such as the rivet belt background and equipment components. The system extracts the pixel region of the current rivet 5 main body, such as pixel area and pixel length / width, and calculates the difference between this and the corresponding pixel parameters of the previous rivet 5 main body to obtain a pixel difference value reflecting the difference in appearance between the two rivets 5. This pixel difference value is then compared with a preset pixel reference value to obtain a first comparison value; this value directly reflects the relative difference in appearance size between the two rivets 5. The pixel reference value is set based on the pixel fluctuation range of similar rivets 5 in history; for example, the reference value for the pixel area difference of a typical rivet 5 is 50-100 pixels. 2 .

[0091] A historical dimension database is established in the system to store the rivet height and outer diameter dimensions collected during the last rivet feeding process in real time, and this database is used as a benchmark to update the historical height and outer diameter dimensions. When the current height and outer diameter dimensions of rivet 5 are obtained, the differences between these dimensions and the corresponding historical dimensions are calculated to obtain the height difference and outer diameter difference. For example, the difference between the current height dimension of 20mm and the historical height dimension of 19.5mm is 0.5mm; the difference between the current outer diameter dimension of 8mm and the historical outer diameter dimension of 8.2mm is -0.2mm. To comprehensively reflect the overall dimensional differences of rivets 5 before and after feeding, a weighted algorithm is used to calculate a comprehensive difference, such as comprehensive difference = 0.6 × absolute value of height difference + 0.4 × absolute value of outer diameter difference, with the weights set according to the degree of influence of height and outer diameter on rivet feeding accuracy. The comprehensive difference is then proportionally calculated with a preset reference difference to obtain a second comparison value; this value quantifies the difference between rivets 5 before and after feeding from the perspective of actual physical dimensions. The preset reference difference is set according to the equipment's adjustment accuracy requirements, such as 0.3-0.5mm.

[0092] The system calculates a comprehensive comparison value by applying a preset formula to the first and second comparison values, such as comprehensive comparison value = 0.5 × first comparison value + 0.5 × second comparison value, ensuring a balanced weighting of the two dimensions. This comprehensive comparison value is then compared with a preset reference comparison value, which is set based on the system's sensitivity to size changes, such as 1.2-1.5.

[0093] If the overall comparison value is greater than the reference comparison value, it indicates that there are significant differences between the current rivet 5 and the previous rivet 5 in terms of appearance and physical dimensions. For example, if the pixel difference is much greater than the reference value or the overall difference exceeds the equipment adjustment tolerance range, the historical dimension database needs to be updated with the current rivet height and outer diameter dimensions to provide the latest dimension benchmark for the adjustment of the limit stroke, rivet tension, and pressing force of the next feeding, ensuring that subsequent adjustments can be adapted to the current rivet 5 specifications.

[0094] If the overall comparison value is less than or equal to the reference comparison value, it means that the size difference between the front and rear rivets 5 is within the allowable range, such as the size fluctuation caused by minor processing errors. There is no need to update the historical data to avoid instability of the benchmark due to frequent updates.

[0095] By supplementing the dimension of size data with pixel differences from image recognition, the difference judgment of rivet 5 becomes more comprehensive. By setting an update threshold through comprehensive comparison values, the frequent updates of historical data due to minor size fluctuations are avoided, ensuring the stability of historical size benchmarks. This improves the accuracy of subsequent adjustments such as limit stroke and tension based on historical data, and further enhances the adaptability of the feeding system to changes in the size of rivet 5 and the accuracy of rivet feeding.

[0096] To further ensure the stability of the nail supply process, the specific method also includes the following steps:

[0097] The one-way limiting unit includes a rotatably connected one-way limiting rod and an elastic reset component for resetting the one-way limiting rod. The one-way limiting rod is rotatably connected to the equipment frame via a rotating shaft and can rotate unidirectionally along the conveying direction under the push of the rivet 5, preventing the rivet 5 from retracting. The elastic reset component, such as a torsion spring or tension spring, is connected to the one-way limiting rod at one end and fixed to the frame at the other end, and can pull the one-way limiting rod back to its initial limiting position after the rivet 5 passes. This structure ensures that the rivet 5 maintains stable contact with the one-way limiting rod throughout the conveying process.

[0098] After the system acquires the parameters of rivet 5 and starts the rivet supply process, a vibration sensor, such as a piezoelectric vibration sensor or an accelerometer, is installed in the middle of the one-way limit rod, in the area where the vibration signal is most stable. This sensor collects the vibration data of the one-way limit rod in real time, including dynamic parameters such as vibration acceleration and vibration frequency. Considering that the original vibration data includes equipment operating noise, such as motor vibration and rivet friction noise, a spectrum conversion algorithm, such as Fast Fourier Transform (FFT), is used to process the original vibration data. This converts the vibration signal in the time domain into spectrum data in the frequency domain. Through signal separation in the frequency dimension, low-frequency / high-frequency noise unrelated to the function of rivet 5, such as the 50Hz low-frequency noise from motor operation and the high-frequency noise from rivet friction, is filtered out. The characteristic spectrum related only to the function of rivet 5 and the one-way limit rod is then extracted.

[0099] Extract the frequency fluctuation range and the corresponding fluctuation energy value from the spectral data:

[0100] Frequency fluctuation range and frequency span: When a rivet 5 of normal specification contacts the one-way limit rod, the vibration frequency will be concentrated within the preset normal range, such as 100-200Hz, due to the stable force. The difference between the upper and lower limits of the frequency fluctuation range, i.e., the frequency span value, is small, such as ≤30Hz. If the rivet 5 has dimensional deviations (such as excessive height or irregular outer diameter) or abnormal posture (such as tilting or flipping), it will cause the contact point with the one-way limit rod and the magnitude of the force to change frequently, thereby causing the vibration frequency to fluctuate in a larger range, such as 50-250Hz, and the frequency span value exceeds the normal range, such as >30Hz.

[0101] Fluctuation energy value: Different frequency bands in the spectrum data correspond to different vibration energies. When rivet 5 is in normal operation, the vibration energy is concentrated in the normal frequency band and the energy value is stable in the preset range, such as 0.5-1.2mW. If rivet 5 is abnormal, the vibration energy in a specific frequency band will increase significantly (e.g., >1.2mW) or decrease (e.g., the vibration is weakened due to rivet 5 jamming, and the energy is <0.5mW) due to increased impact and friction with the one-way limit rod, forming an abnormal fluctuation energy value.

[0102] The system compares the extracted frequency span value with a preset reference span range, which is set based on the historical normal rivet 5 spectrum data. Simultaneously, it compares the fluctuation energy value with a preset reference fluctuation range.

[0103] If the frequency span value is outside the reference span range and the fluctuation energy value is outside the reference fluctuation range, it indicates that the working state of rivet 5 and the one-way limit rod deviates significantly from the normal situation. It can be determined that rivet 5 is abnormal, such as out-of-tolerance size or tilted posture. At this time, the system automatically eliminates the previously generated "Rivet 5 normal mark" and issues an abnormal rivet 5 warning through sound and light alarm, system pop-up window, etc. At the same time, the rivet supply process is suspended to prevent abnormal rivet 5 from entering the subsequent stop sensing and riveting material cutting stage.

[0104] If both the frequency span value and the fluctuation energy value are within the corresponding reference range, or if only a single parameter exceeds the range (such as occasional noise causing energy value fluctuation), then the rivet 5 is determined to be in normal condition, the system generates a "rivet 5 normal status indicator", and the rivet supply process continues.

[0105] Vibration spectrum analysis can comprehensively capture rivet 5 anomalies from the "operational state" dimension; whether it is the change in force caused by dimensional deviation or the change in contact mode caused by posture tilt, it will be converted into quantifiable spectrum feature differences, improving the monitoring accuracy.

[0106] To match the limiting requirements of rivets 5 with different outer diameters and further improve the positioning accuracy and conveying stability of rivets 5, the specific method also includes the following steps:

[0107] Includes two adjustment modes:

[0108] The first method: Adjusting the curvature of the stop surface of the stop plate in a negative correlation.

[0109] As a common arc-shaped limiting structure in stop sensing units, the curvature of the stop plate directly determines the contact fit with rivet 5. When the outer diameter of the rivet is different, the curvature needs to be adjusted to ensure that the stop plate fits tightly with the outer contour of rivet 5, avoiding rivet 5 shifting due to excessive gap or jamming due to excessive tightness. After obtaining the "Rivet 5 normal indicator", the system extracts the current outer diameter of rivet 5 and uses negative correlation adjustment logic to control the curvature of the stop plate.

[0110] If the outer diameter of the rivet is large (e.g., 15-20mm), the radius of curvature of the outer contour of the rivet 5 is larger, and the curvature of the stop surface needs to be reduced, that is, the stop surface is flatter. For example, a rivet 5 with an outer diameter of 20mm corresponds to a stop surface with a curvature radius of 12mm. This ensures that the stop surface can form a large area of ​​contact with the outer circle of the rivet 5. By dispersing the limiting force through multi-point contact, the rivet 5 can be prevented from being deformed by local pressure, and the lateral displacement of the rivet 5 can be stably restricted.

[0111] If the outer diameter of the rivet is small (e.g., 5-10mm), the radius of curvature of the outer contour of the rivet 5 is smaller, and the curvature of the stop surface needs to be increased (i.e., the stop surface is steeper). For example, a rivet 5 with an outer diameter of 8mm corresponds to a stop surface with a curvature radius of 6mm, so that the stop surface can accurately wrap around the outer circle of the rivet 5, preventing the rivet 5 from "slipping" and shifting when it is in the limit position due to the stop surface being too flat, and ensuring that the rivet 5 is always aligned with the crimping center of the riveting and blanking unit.

[0112] Curvature adjustment is achieved by a servo motor driving a cam mechanism on the back of the stop plate: the motor drives the cam to rotate according to the curvature parameters corresponding to the outer diameter, which pushes the arc surface of the stop plate to undergo elastic deformation, or adjusts the curvature through a multi-segment splicing structure to match the outer diameter requirement of the current rivet 5 in real time.

[0113] The second method involves adjusting the spacing between the stop plates in a positive correlation.

[0114] For rivets 5 with regular shapes such as cylinders or squares, requiring bidirectional positioning, the stop sensing unit can adopt a stop clamping plate structure. This structure consists of two symmetrically arranged clamping plates. By adjusting the spacing between the plates, it adapts to the positioning requirements of rivets 5 with different outer diameters, avoiding the problem of "large rivets 5 getting stuck and small rivets 5 becoming loose" due to a fixed spacing. The system also assumes "normal rivet 5 indication" and uses positive correlation adjustment logic to control the clamping plate spacing based on the rivet's outer diameter.

[0115] When the outer diameter of the rivet is large (e.g., 20-25mm), the spacing between the clamping plates should be increased to 22-27mm, with a buffer gap of 0.5-2mm. For example, a cylindrical rivet 5 with an outer diameter of 25mm corresponds to a clamping plate spacing of 26mm. This ensures that the rivet 5 can smoothly enter between the clamping plates and that the elastic pads on the inner side of the clamping plates, such as rubber pads, can fit against the outer circle of the rivet 5, limiting its lateral sway.

[0116] When the outer diameter of the rivet is small (e.g., 3-8mm), the clamping plate spacing is adjusted to be smaller, such as 4-9mm. For example, a rivet 5 with an outer diameter of 5mm corresponds to a clamping plate spacing of 6mm. By reducing the gap, the activity space of the rivet 5 in the clamping plate is reduced, while avoiding the rivet 5 hitting the edge of the clamping plate under the action of conveying inertia due to excessive spacing, which would cause the posture to deviate.

[0117] The clamp spacing adjustment is driven by an electric push rod located on the outside of the clamp: the electric push rod receives the spacing parameter signal sent by the system and pushes the clamp to move laterally along the guide rail, realizing real-time and precise adjustment of the spacing. The adjustment accuracy can reach ±0.1mm, meeting the limit requirements of high-precision nail feeding.

[0118] With adaptive adjustment driven by outer diameter, the limit adaptation of rivets 5 of different specifications can be completed without manual intervention, greatly improving the versatility of the stop sensing unit.

[0119] To further improve the reliability of the riveting rivets and the rivet pass rate, the specific method also includes the following steps:

[0120] The crimping effect of the riveting blanking unit depends on the matching relationship between "crimping force - crimping area - rivet 5 height": if the crimping area is too large, and the rivet 5 height is small, the crimping component will extend beyond the top of the rivet 5 to contact the rivet band, resulting in dispersed crimping force and ineffective separation of the rivet 5 from the rivet band; if the crimping area is too small, and the rivet 5 height is large, the crimping component will only act on a local area at the top of the rivet 5, easily causing uneven force distribution and deformation damage to the rivet 5. Therefore, the crimping area needs to be adjusted in reverse according to the rivet height to ensure that the crimping energy can be accurately applied to the rivet 5 body.

[0121] Dynamic adjustment process of crimping area

[0122] Parameter linkage trigger: When the system obtains the "Rivet 5 normal status" (i.e., the vibration monitoring in the early stage determines that rivet 5 has no dimensional deviation or abnormal posture), it automatically extracts the current height dimension of rivet 5 and transmits it to the control module of the riveting and cutting unit to trigger the pressing area adjustment command.

[0123] Crimping component structure and adjustment mechanism: The crimping component of the riveting blanking unit adopts a combination structure of "main crimping head + retractable secondary crimping head"; the main crimping head is a fixed core area, and the retractable secondary crimping head is set around the main crimping head. The extension / retraction of the secondary crimping head is controlled by the built-in micro cylinder, thereby changing the overall crimping area. When it extends, the crimping area increases, and when it retracts, the crimping area decreases.

[0124] Negative correlation adjustment execution:

[0125] If the rivet height is large (e.g., 15-20mm): the top area of ​​rivet 5 is sufficient to support the crimping force. The control module sends a command to retract the retractable secondary pressure head, leaving only a small crimping area of ​​the main pressure head, such as 10mm×10mm. This prevents the secondary pressure head from extending beyond the top of rivet 5 to contact the rivet band, ensuring that the crimping force is concentrated on the center of rivet 5 and preventing crimping failure due to force dispersion.

[0126] If the rivet height is small (e.g., 5-10mm): The top area of ​​rivet 5 is limited. The control module drives the retractable secondary pressure head to extend, expanding the pressing area, such as 15mm×15mm. By increasing the contact area, the pressing stability is improved, avoiding deformation of rivet 5 due to excessive local force, and preventing rivet 5 from sliding off the pressing component during pressing.

[0127] During the adjustment process, the system monitors the expansion and contraction of the auxiliary pressure head in real time through a displacement sensor to ensure the matching accuracy between the pressing area and the rivet height.

[0128] Through dynamic adjustment, the pressing area is always adapted to the height of the rivet 5: the rivet 5 with a large height is stressed only in the core area, avoiding edge deformation; the rivet 5 with a small height is stressed evenly, preventing local crushing.

[0129] To further optimize the material feeding process, the strip speed is dynamically adjusted based on the overall dimensions of the rivets. This includes the following steps:

[0130] The material collection unit adjusts the rivet tape pulling speed in a negative correlation with the overall size of the rivet. The larger the overall size of the rivet, the slower the rivet tape pulling speed, and the smaller the overall size of the rivet, the faster the rivet tape pulling speed.

[0131] When the overall size of the rivet is large, such as large volume and heavy weight, its inertia is stronger. If the pulling speed is too fast, it is easy to cause posture deviation due to inertial impact when passing through the one-way limit unit, such as tilting or flipping. When entering the stop sensing unit, the rivet 5 may be damaged or the blocking part 7 may be worn due to excessive impact force.

[0132] When the overall dimensions of the rivets are small, such as small size, light weight, and weak inertia, they can maintain a stable posture even if the pulling speed is increased. If a slow pulling speed is still used, the number of rivets supplied per unit time will be reduced, thus reducing the overall production efficiency.

[0133] Therefore, the pulling speed needs to be adjusted in reverse according to the overall size of the rivet to achieve a stable feeding of large-sized rivets and a high-efficiency adaptation effect for small-sized rivets.

[0134] Based on the previously obtained rivet height and outer diameter dimensions, a preset algorithm is used, such as: Overall dimension = γ × Height dimension + δ × Outer diameter dimension, where γ and δ are weighting coefficients. According to the rivet density setting, the overall rivet dimension is calculated. Then, a pre-stored overall dimension-pulling speed correspondence table is called, such as an overall dimension of 5-10mm. 3 Corresponding to a pulling speed of 80mm / s, 10-15mm 3 Corresponding to a pulling speed of 60mm / s, 15-20mm 3 Given a pulling speed of 40 mm / s, determine the target pulling speed for rivet 5.

[0135] The tension speed of the material collection unit is adjusted by driving the nail belt traction component 8 and the swing cylinder 1. The swing cylinder 1 is connected to the nail belt traction component 8. After receiving the target tension speed signal sent by the system, the air pressure of the swing cylinder 1 is adjusted, thereby changing the tension speed of the nail belt. During the adjustment process, the encoder installed next to the traction roller collects the actual tension speed of the nail belt in real time and feeds it back to the system to form a closed-loop control.

[0136] When switching between rivets of different overall sizes, the system employs a "stepped speed increase / decrease" strategy, such as adjusting the speed by 10mm / s every 0.5 seconds, to avoid sudden changes in tension caused by abrupt changes in the pulling speed. For example, when switching from an overall size of 20mm... 3(Pulling speed 40mm / s) Switch to 5mm 3 When the tension is 80 mm / s, gradually increase the tension in 4 stages to prevent the nail strip from breaking due to excessive tension or the nail strip from becoming loose and accumulating due to insufficient tension.

[0137] This application also discloses a high-precision ratchet feeding control system, including a processor, wherein the processor executes the steps of the high-precision ratchet feeding control method as described in any of the above embodiments.

[0138] This application also discloses a storage medium storing a program, which, when executed by a processor, implements the steps of the high-precision ratchet feeding control method described in any of the above embodiments.

[0139] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A high-precision ratchet feed control method, characterized by, The method comprises the following steps: Obtaining material parameters, extracting material height size and material outer diameter size according to the material parameters, and positively correlating the material height size to adjust the limiting stroke of the one-way limiting unit, the larger the material height size, the longer the limiting stroke, and the smaller the material height size, the shorter the limiting stroke; The material belt collecting unit pulls the material belt, calculates the material comprehensive size according to the material height size and the material outer diameter size, and positively correlates the material comprehensive size to adjust the material belt pulling force, the larger the material comprehensive size, the greater the material belt pulling force, and the smaller the material comprehensive size, the smaller the material belt pulling force; The material passes through the one-way limiting unit and enters the stop sensing unit, and is limited by the one-way limiting unit and the stop sensing unit at the position aligned with the riveting and discharging unit; The stop sensing unit generates sensing data after sensing the material, and controls the riveting and discharging unit to press and separate the material from the material belt according to the sensing data, and if the material comprehensive size is within a preset first size range, then negatively correlates the material outer diameter size to adjust the riveting and discharging unit pressing force; if the material comprehensive size is greater than the value within the first size range, then positively correlates the material outer diameter size to adjust the riveting and discharging unit pressing force; The material belt collecting unit comprises a convex gear (3), a guide (4), a swing cylinder (1), a material belt traction component, and an anti-winding component (2): The material belt carrying the material passes through the lower mechanical part of the device, and the empty material belt passes through the guide (4) and is hung on the convex gear (3); The material belt traction component is connected with the swing cylinder (1), the swing cylinder (1) rotates a specific angle through air supply, automatically returns to the original position through air cut-off, and reciprocates to pull the material belt traction component to move upward by a preset path; The anti-winding component (2) is arranged close to the convex gear (3) to prevent the material belt from winding into the convex gear (3) due to tension change during conveying.

2. The high precision ratchet feed control method of claim 1, wherein, The method further comprises the following steps: Based on the image sensor arranged on the one-way limiting unit, an image of the material is obtained, the main body of the material is identified from the image of the material, the pixel difference value between the current material main body and the last material main body is calculated, and the first comparison value is calculated according to the pixel difference value and a preset pixel reference value; The last material height size is used to update the historical height size, and the last material outer diameter size is used to update the historical outer diameter size; The difference between the current material height size and the historical height size is calculated as a height difference value, and the difference between the current material outer diameter size and the historical outer diameter size is calculated as an outer diameter difference value; The comprehensive difference value is calculated according to the height difference value and the outer diameter difference value; The second comparison value is calculated according to the comprehensive difference value and a preset reference difference value; The comprehensive comparison value is calculated according to the first comparison value and the second comparison value, if the comprehensive comparison value is greater than a preset reference comparison value, then the current material height size is used to update the historical height size, and the current material outer diameter size is used to update the historical outer diameter size.

3. The high precision ratchet feed control method of claim 2, wherein, The method further comprises the following steps: The one-way limiting unit comprises a one-way limiting rod connected in rotation and an elastic reset component for resetting the one-way limiting rod; Based on the obtained material parameters, vibration data is obtained through the vibration sensor arranged on the one-way limiting rod; The frequency spectrum data is calculated according to the vibration data using a frequency spectrum conversion algorithm; The frequency fluctuation range and the fluctuation energy value corresponding to the frequency fluctuation range in the frequency spectrum data are extracted; The frequency span value of the frequency fluctuation range is calculated; If the frequency span of the frequency fluctuation range is outside the preset reference span range and the fluctuation energy value is outside the preset reference fluctuation range, the material normal identification is eliminated and a material abnormality early warning prompt is issued, otherwise, the material normal identification is generated.

4. The high-precision ratchet feed control method according to claim 3, wherein The method further comprises the following steps: Based on the material normal identification, the curvature of the stop face of the stop sensing unit is adjusted according to the negative correlation of the material outer diameter size, that is, the larger the material outer diameter size, the smaller the curvature, and the smaller the material outer diameter size, the larger the curvature. Alternatively, the clamping plate spacing of the stop sensing unit is adjusted according to the positive correlation of the material outer diameter size, that is, the larger the material outer diameter size, the larger the clamping plate spacing, and the smaller the material outer diameter size, the smaller the clamping plate spacing.

5. The high-precision ratchet feed control method according to claim 4, wherein The method further comprises the following steps: Based on the material normal identification, the pressure contact area of the riveting material cutting unit is adjusted according to the negative correlation of the material height size, that is, the larger the material height size, the smaller the pressure contact area, and the smaller the material height size, the larger the pressure contact area.

6. The high-precision ratchet feed control method of claim 1, wherein, The stop sensing unit comprises a blocking piece (7), a detection lance (9) and a sensor (10): The blocking piece (7) is fixed at the end position of the material belt conveying path as a physical positioning reference for the material to be in place; The detection lance (9) is installed on one side of the blocking piece (7) and is in an extended state in the initial state and in contact with the material; The sensor (10) is linked with the detection lance (9) and sends an action signal triggered by the detection lance (9) when the detection lance (9) abuts against the material.

7. The high-precision ratchet feed control method according to claim 6, wherein The method further comprises the following steps: The material belt collecting unit adjusts the material belt pulling speed according to the negative correlation of the material comprehensive size, that is, the larger the material comprehensive size, the slower the material belt pulling speed, and the smaller the material comprehensive size, the faster the material belt pulling speed.

8. A high precision ratchet feed control system characterized by, The processor executes the steps of the high-precision ratchet feeding control method according to any one of claims 1-7.

9. A storage medium, characterized by The storage medium stores a program, and the program is executed by the processor to realize the steps of the high-precision ratchet feeding control method according to any one of claims 1-7.

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