An automatic alignment method and system applied to actuator detection

Abstract

This invention discloses an automatic alignment method and system for actuator detection. The automatic alignment method includes: acquiring the pose information of the actuator at a set first station, the pose information including the angle of a first axis of the actuator; determining the rotation information of the second axis based on the pose information and the initial angle of a second axis of a servo motor, and based on the angular matching relationship between the first axis and the second axis, and controlling the second axis to rotate; controlling the actuator to translate from the first station to a set second station, so that the first axis and the second axis are aligned and connected. The solution provided by this invention can achieve rapid and accurate alignment of the actuator.

Description

Technical Field

[0001] This invention relates to the field of actuator testing technology, and in particular to an automatic alignment method and system for actuator testing. Background Technology

[0002] In automobile manufacturing, the air conditioning actuator (hereinafter referred to as the actuator) is a component of the air conditioning system, and its quality can affect the operational stability and reliability of the air conditioning system. Therefore, it is necessary to conduct inspections or tests on the actuator before it leaves the factory or before it is used to ensure its reliability.

[0003] The alignment process is a crucial part of actuator detection or testing. Relying on manual alignment can be problematic, as operator skill levels and work conditions can affect the quality and efficiency, leading to fluctuations in test results. While automatic alignment is often achieved by adjusting the actuator to fit the servo motor shaft, this method struggles to guarantee precise positioning of the actuator on the test station, resulting in inaccurate test results. Summary of the Invention

[0004] To solve or partially solve the problems existing in related technologies, the present invention provides an automatic alignment method and system for actuator detection, which can realize rapid automatic alignment in actuator detection.

[0005] The first aspect of the present invention provides an automatic alignment method for actuator detection, comprising: acquiring the pose information of the actuator at a set first station, the pose information including the angle of a first axis of the actuator; determining the rotation information of the second axis based on the pose information and the initial angle of a second axis of a servo motor and based on the angle matching relationship between the first axis and the second axis, and controlling the second axis to rotate; controlling the actuator to translate from the first station to a set second station, so that the first axis and the second axis are aligned and connected.

[0006] In conjunction with the first aspect of the present invention, in an optional embodiment, obtaining the pose information of the actuator at a set first station includes: after acquiring an image of the actuator at the first station, identifying key feature points of the actuator, and solving for the pose information of the actuator, wherein the acquired image contains the first axis of the actuator.

[0007] In conjunction with the first aspect of the present invention, in an optional embodiment, identifying key feature points of the actuator and solving for the pose information of the actuator includes: performing mirror processing on the acquired image so that the coordinate system of the mirrored image is consistent with the set servo assembly coordinate system, wherein when the actuator is at the first station, the first axis is at the bottom of the actuator; identifying key feature points of the first axis on the mirrored image and determining the visual angle of the first axis in the mirrored image coordinate system.

[0008] In conjunction with the first aspect of the present invention, in an optional embodiment, determining the rotation information of the second axis based on the pose information and the initial angle of the second axis of the servo motor, and based on the angle matching relationship between the first axis and the second axis, and controlling the second axis to rotate, includes: obtaining the initial angle of the second axis in the servo assembly coordinate system; calculating the rotation information of the second axis based on the angle matching relationship between the first axis and the second axis, using the visual angle and the initial angle; and generating corresponding control commands based on the rotation information of the second axis to control the second axis of the servo motor to rotate.

[0009] In conjunction with the first aspect of the present invention, in an optional embodiment, based on the angular matching relationship between the first axis and the second axis, the rotation information of the second axis is calculated by the visual angle and the initial angle, including: taking the visual angle as the target angle of the second axis, wherein the first axis is coaxially arranged with the second axis at the second workstation and is located above the second axis; determining the optimal rotation strategy of the second axis according to the angle difference between the target angle and the initial angle, so as to generate corresponding control commands, wherein the optimal rotation strategy includes a target rotation direction and a target rotation angle.

[0010] In conjunction with the first aspect of the present invention, in an optional embodiment, determining the optimal rotation strategy for the second axis based on the angle difference between the target angle and the initial angle includes: taking the rotation angle and rotation direction corresponding to the angle difference being less than 180° as the target rotation angle and target rotation direction.

[0011] In conjunction with the first aspect of the present invention, in an optional embodiment, generating corresponding control commands based on the rotation information of the second axis to control the second axis of the servo motor to rotate includes: generating corresponding pulse signals based on the optimal rotation strategy of the second axis for sending to the servo controller of the servo motor, wherein the servo controller, in response to the pulse signals, controls the second axis to rotate the target rotation angle in the target rotation direction.

[0012] In conjunction with the first aspect of the present invention, in an optional embodiment, controlling the actuator to translate from the first workstation to a set second workstation includes: determining a planned path for the actuator based on the first workstation and the second workstation; and controlling the actuator to translate from the first workstation to the second workstation according to the planned path.

[0013] In conjunction with the first aspect of the invention, in an optional embodiment, the rotation of the second axis and the translation of the actuator are controlled simultaneously, or the rotation of the second axis and the translation of the actuator are controlled sequentially.

[0014] A second aspect of the present invention provides an automatic alignment system for actuator detection, comprising a control unit and a first detection mechanism, a second detection mechanism, and a transfer mechanism connected to the control unit; the first detection mechanism is used to acquire the pose information of the actuator at a set first station, the pose information including the angle of a first axis of the actuator; the second detection mechanism includes a servo motor, the second axis of the servo motor being configured to rotate under the control of the control unit for alignment with the first axis; the transfer mechanism is used to translate the actuator from the first station to a set second station; the control unit is used to determine the rotation information of the second axis based on the pose information and the initial angle of the second axis and based on the angular matching relationship between the first axis and the second axis, and control the second axis to rotate; and to drive the transfer mechanism to control the actuator to translate from the first station to the second station, so that the first axis and the second axis are aligned and connected.

[0015] The technical solution provided by this invention may include the following beneficial effects:

[0016] The technical solution of the present invention first obtains the position and pose information of the actuator at a set first station, the position and pose information including the angle of the first axis of the actuator, and then controls the second axis of the servo motor to rotate based on the determined position and pose information and the second axis of the servo motor, and controls the second axis of the servo motor to rotate based on the angle matching relationship between the first axis and the second axis; when the angles of the first axis and the second axis match, the actuator is translated from the first station to the set second station, that is, the alignment connection between the first axis and the second axis is completed.

[0017] This invention leverages the inherent characteristics of servo motors, namely, that the servo motor encoder determines the rotation angle of the servo motor shaft. It changes the traditional method of manually aligning or adjusting the actuator to adapt to the servo motor shaft for automatic alignment. Instead, the alignment process relies on first determining the position and posture information of the actuator. Based on the determined position and posture information, the servo motor is actively adjusted, and the actuator is directly moved from the first position to the second position, thus achieving precise alignment and connection between the first and second axes.

[0018] As can be seen, the present invention can realize automated and rapid alignment in actuator testing, providing the basic conditions for the whole process testing of actuators, thereby improving testing efficiency and accuracy.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the invention. Attached Figure Description

[0020] The above and other objects, features and advantages of the present invention will become more apparent from the more detailed description of exemplary embodiments of the invention in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same parts in the exemplary embodiments of the invention.

[0021] Figure 1 This is a structural block diagram of an automatic alignment system for actuator detection shown in an embodiment of the present invention;

[0022] Figure 2 and Figure 3 These are perspective views of an automatic alignment system for actuator detection (actuator at the first station) shown in an embodiment of the present invention from different angles.

[0023] Figure 4 This is another structural block diagram of an automatic alignment system for actuator detection, as shown in an embodiment of the present invention;

[0024] Figure 5 This is a perspective view of an automatic alignment system for actuator detection (the actuator is directly above the second station) as shown in an embodiment of the present invention.

[0025] Figure 6 This is a perspective view of the second detection mechanism shown in an embodiment of the present invention;

[0026] Figure 7 This is a schematic diagram of the servo assembly coordinate system (top view) as shown in an embodiment of the present invention;

[0027] Figure 8 This is a schematic diagram of the first axis end contour in the servo assembly coordinate system after image mirroring, as shown in an embodiment of the present invention.

[0028] Figure 9 (a) Figure 9 (b) are schematic diagrams of the second axis end profile in the servo assembly coordinate system at the initial angle and the target angle, as shown in the embodiments of the present invention.

[0029] Figure 10 This is a flowchart illustrating an automatic alignment method for actuator detection according to an embodiment of the present invention;

[0030] In the diagram: 1. Frame; 2. Transfer mechanism; 21. First cylinder; 22. Grab; 23. Crossbeam; 3. First detection mechanism; 31. Image acquisition module; 311. Camera equipment; 32. Image processing module; 4. Second detection mechanism; 41. Servo motor; 411. Second shaft; 42. Servo controller; 43. Coupling; 5. Control unit; 6. Actuator. Detailed Implementation

[0031] Embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the invention will be more thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0032] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The singular forms “a,” “the,” and “the” used in this invention and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0033] It should be understood that although the terms "first," "second," "third," etc., may be used in this invention to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this invention, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] The technical solutions of the embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0035] See Figures 1-5 This invention provides an automatic alignment system for actuator detection, including a control unit 5 and a transfer mechanism 2, a first detection mechanism 3, and a second detection mechanism 4 connected to the control unit 5, wherein the transfer mechanism 2, the first detection mechanism 3, and the second detection mechanism 4 are all assembled on the frame 1.

[0036] In some embodiments, such as Figure 2 and Figure 3As shown, the first detection mechanism 3 is used to obtain the pose information of the actuator 6 at the set first station. The pose information includes the angle of the first axis of the actuator 6. In this embodiment, when the actuator 6 is at the first station, the transfer mechanism 2 continues to hold the actuator 6, and the pose of the actuator 6 is fixed. Then, the first detection mechanism 3 can collect the current pose of the actuator 6. The first axis of the actuator 6 is the key object of collection. By analyzing and processing the collected pose information of the actuator 6, the angle of the first axis of the actuator 6 can be obtained, including but not limited to the angle of the first axis of the actuator 6. This is because the servo motor 41 in the first detection mechanism 3 and the second detection mechanism 4 can work together. First, the first detection mechanism 3 determines the angle of the first axis of the actuator 6. Then, the second axis 411 of the servo motor 41 rotates accordingly so that the angles of the first axis and the second axis 411 are the same in the same coordinate system. Then, when the first axis reaches the second station, the first axis and the second axis 411 are exactly matched and connected by a hole-shaft connection.

[0037] like Figure 4 As shown, the first detection mechanism 3 further includes an image acquisition module 31 and an image processing module 32. The image acquisition module 31 is used to acquire images of the actuator 6 at the first station, wherein the acquired image contains the first axis of the actuator 6. In this embodiment, the first station is the shooting position. When the actuator 6 is in the shooting position, the image acquisition module 31 takes images of the actuator 6 to obtain the current pose of the actuator 6, such as its position and actuator axis angle. Therefore, the acquired image should contain the first axis of the actuator 6. Figure 2 and Figure 3 As shown, the image acquisition module 31 includes a camera device 311 positioned below the first workstation. The camera device 311 faces the first workstation and is configured as a shooting actuator 6. In this embodiment, the camera device 311 can be directly below the shooting position and facing the shooting position to accurately obtain the angle of the first axis. The camera device 311 can be a non-detachable camera or a detachable camera. When the camera device 311 is a detachable camera, it can include an industrial camera and a lens. To ensure a clearer image of the actuator 6, a light source can be provided next to the camera device 311.

[0038] like Figure 4As shown, further, the image processing module 32 is connected to both the image acquisition module 31 and the control unit 5. After acquiring an image of the actuator at the first station, it identifies key feature points of the actuator 6, calculates the pose information of the actuator 6, and sends it to the control unit 5. Specifically, the image processing module 32 performs mirroring processing on the acquired image, ensuring that the coordinate system of the mirrored image is consistent with the set servo assembly coordinate system. When the actuator is at the first station, the first axis is at the bottom of the actuator. It identifies key feature points of the first axis on the mirrored image and determines the visual angle of the first axis in the mirrored image coordinate system. Figure 7 This is a schematic diagram of the servo assembly coordinate system (top view). Figure 8 This is a schematic diagram of the first axis end contour in the servo assembly coordinate system after image mirroring. In this embodiment, after acquiring the information collected by the image acquisition module 31, the image processing module 32 first mirrors the acquired image and then analyzes it. Based on the image processing algorithm, it obtains the key feature points of the image information of the actuator 6 after mirroring, and locates the pose of the actuator 6, calculating the pose information of the actuator 6 at the shooting position, such as the visual angle of the first axis of the actuator 6 in the servo assembly coordinate system. It should be noted that in this embodiment, the image processing module 32, as a component of the first detection mechanism 3, can be a separate part from the control unit 5, or it can be integrated into the control unit 5.

[0039] In one embodiment, the first detection mechanism 3 includes a camera, a lens, and a light source. The camera, lens, and light source work together to form a visual detection system. By rationally arranging the visual detection system according to the shooting position, it can quickly acquire ideal shooting angles and lighting, providing clear image data for visual detection. Specifically, the lens is precisely connected to the camera, and the light source is installed above the camera. Through reasonable angle and brightness settings, it provides uniform and sufficient light for camera shooting, ensuring that the captured images are clear and accurate.

[0040] In some embodiments, the second detection mechanism 4 includes a servo motor 41, the second axis 411 of which is configured to rotate under the control of the control unit 5 to align with the first axis. When the second axis 411 is aligned with the first axis, the actuator 6 is in a set second position. Thereafter, the second detection mechanism 4 can be used to perform parameter testing on the actuator. During the testing process, the second axis 411 of the servo motor 41 acts as the load axis, while the first axis of the actuator 6 acts as the output axis.

[0041] like Figure 5As shown, the second detection mechanism 4 includes a servo motor 41. When the actuator 6 is in the set second position and the actuator 6 is connected to the servo motor 41, the second detection mechanism 4 is used to perform parameter testing on the actuator 6. In this embodiment, the second position is the test position of the actuator 6 to be tested, also called the detection position. This test position is used to place the actuator 6 to be tested. The second detection mechanism 4 is used to perform parameter testing on the actuator 6, such as torque, angle, voltage, and current, when the actuator 6 is in the test position. The angle can be measured by the encoder built into the servo motor 41. The second detection mechanism 4 can be any existing technology known to those skilled in the art, and how the second detection mechanism 4 performs parameter testing on the actuator 6 is not within the scope of this embodiment of the invention. Therefore, the inventor will not elaborate on it here.

[0042] like Figure 6 As shown, it should be noted that the second detection mechanism 4 also includes a coupling 43 and a torque sensor. The coupling 43 is located at the end of the second shaft 411 and is used for a through-hole shaft connection with the first shaft; the torque sensor is located on the coupling 43 and is electrically connected to the control unit 5. Generally, the second shaft 411 cannot be directly aligned with the first shaft, therefore, the two are connected by the coupling 43. Specifically, the second shaft 411 of the servo motor 41 and the first shaft of the actuator 6 are connected by the coupling 43 to ensure precise synchronous transmission during rotation, minimizing transmission errors caused by loose connections or misalignment. Furthermore, a torque sensor (not shown in the figure) is installed in the middle of the connection between the coupling 43 and the first shaft of the actuator 6. This torque sensor 44 can measure the torque output by the actuator 6 in real time and accurately. In the actuator testing phase, the first axis refers to the output shaft of actuator 6, and the second axis 411 is the load shaft of servo motor 41. However, in the actuator alignment phase, servo motor 411 acts as the load, and its second axis 411 is no longer the load shaft but the output shaft of servo motor 41. Since the alignment connection of the first and second axes 411 is not significantly different from related technologies (i.e., the first axis, coupling 43, and second axis 411 are coaxial), the first axis can be connected to the coupling 43 via a hole-shaft adapter to achieve the connection with the second axis 411. It should be noted that the first axis of actuator 6 has a non-circular cross-section; therefore, the connection between the first and second axes 411 requires alignment. Once aligned, the first axis is plugged into the coupling 43, thus achieving the aligned connection. When the first axis rotates, it naturally drives the second axis 411 to rotate.

[0043] like Figures 2-5As shown, in some embodiments, the transfer mechanism 2 is used to translate the actuator 6 from a first workstation to a designated second workstation. The transfer mechanism 2 includes a first cylinder 21 and a gripper 22. The first cylinder 21 is connected to a control unit 5, which controls the extension rod of the first cylinder 21 to move vertically. The gripper 22 is connected to the extension rod of the first cylinder 21 and is controlled by the first cylinder 21 to grip or release the actuator 6. Specifically, when the control unit 5 controls the extension rod of the first cylinder 21 to extend, the gripper 22 grips the actuator 6, and then controls the first cylinder 21 to move the actuator 6 to the next workstation. When the control unit 5 controls the extension rod of the first cylinder 21 to retract, the gripper 22 releases the actuator 6, and the actuator 6 separates from the gripper 22. The movement trajectory of the transfer mechanism 2 is controlled by the control unit 5, which determines the planned path of the actuator 6 based on the first and second workstations and controls the actuator 6 to translate from the first workstation to the second workstation according to the planned path.

[0044] To improve transfer efficiency, the main motion trajectory of the transfer mechanism 2 can be simplified, for example, to a linear path. In at least one embodiment, the transfer mechanism 2 further includes a horizontally arranged crossbeam 23, on which a first cylinder 21 is movably mounted. The first cylinder 21 moves horizontally on the crossbeam 23, and its extension rod moves vertically. Therefore, for the first and second workstations, the straight line formed by their connection is parallel to the crossbeam 23. Figure 2 and Figure 3 As shown, Figure 2 and Figure 3 This is a perspective view from different angles showing the actuator 6 about to reach the second station, positioned directly above it. If necessary, the first cylinder 21 can be movably mounted on the crossbeam 23 via a connecting assembly configured to move vertically, thereby raising or lowering the first cylinder 21. In other words, the entire movement trajectory of the actuator 6 should be on the same vertical plane. The connecting assembly can be in the form of a guide rail slider or any other existing technology.

[0045] like Figure 1 As shown, in some embodiments, the control unit 5 is used to determine the rotation information of the second axis 411 based on the pose information and the initial angle of the second axis 411 and based on the angular matching relationship between the first axis and the second axis 411, and control the second axis 411 to rotate; and to drive the transfer mechanism to control the actuator to translate from the first station to the second station, so that the first axis and the second axis 411 are aligned and connected.

[0046] The control unit 5 can obtain the pose information of the actuator 6 at the first station, and thus know the appropriate posture of the second axis 411 of the servo motor 41 near the second station to ensure that the first axis is aligned with the second axis when it is at the second station, thereby achieving the connection between the first and second axes 411. Since the movement of the actuator 6 between the first and second stations is translation, the actual angle of the actuator 6 at the first station and the actual angle at the second station should be the same.

[0047] like Figure 7 As shown in Figure 9, in the control unit 5, based on the pose information and the initial angle of the second axis 411, and based on the angular matching relationship between the first axis and the second axis 411, the rotation information of the second axis 411 is determined, and the second axis 411 is controlled to rotate. This includes: obtaining the initial angle of the second axis 411 in the servo assembly coordinate system, such as... Figure 9 As shown in (a), after determining the visual angle of the first axis in the image coordinate system after mirroring, the visual angle and the initial angle are calculated based on the angle matching relationship between the first axis and the second axis 411 to obtain the rotation information of the second axis 411; corresponding control commands are generated according to the rotation information of the second axis 411 to control the second axis 411 of the servo motor to rotate.

[0048] Among them, such as Figure 7 As shown, in the servo assembly coordinate system, the right-center position of the rotation circle is set as angle 0. Through software processing, the counter-clockwise direction is set as the angle increasing direction, and the rotation automatically returns to zero after completing one 360° revolution. Figure 9 As shown, take the axis center N of the second axis 411 and the feature point M on the second axis 411. The axis center N coincides with the point of the rotation circle of the servo assembly coordinate system. The angle pointed to by the ray NM in the servo assembly coordinate system is the angle of the second axis. Similarly, as... Figure 8 As shown, take the axis center N′ of the first axis and the feature point M′ on the first axis. The feature point M′ corresponds to the feature point M. Then, the angle pointed to by the ray N′M′ in the servo assembly coordinate system is the angle of the first axis.

[0049] In at least one embodiment, based on the angular matching relationship between the first axis and the second axis 411, the rotation information of the second axis 411 is calculated by considering the visual angle and the initial angle. This can be achieved by using the visual angle as the target angle of the second axis 411, where the first axis is coaxially positioned with and above the second axis 411 at the second workstation. Based on the angle difference between the target angle and the initial angle, the optimal rotation strategy for the second axis 411 is determined to generate corresponding control commands. The optimal rotation strategy includes a target rotation direction and a target rotation angle. Further, determining the optimal rotation strategy for the second axis 411 based on the angle difference between the target angle and the initial angle can include using the rotation angle and rotation direction corresponding to an angle difference of less than 180° as the target rotation angle and target rotation direction.

[0050] In at least one embodiment, generating corresponding control commands based on the rotation information of the second axis 411 to control the rotation of the second axis 411 of the servo motor may include: generating corresponding pulse signals based on the optimal rotation strategy of the second axis 411, for sending to the servo controller of the servo motor; the servo controller responding to the pulse signals controls the second axis 411 to rotate by a target rotation angle in the target rotation direction, such as... Figure 9 As shown in (b).

[0051] It should be noted that the control unit 5 in the embodiments of the present invention can be a controller integrated on various mechanisms, with the controllers interconnected, or it can be an independent controller to communicate data with various mechanisms.

[0052] In at least one embodiment, the control unit 5 can be a host computer, which is interconnected with various mechanisms via wired or wireless communication. The host computer communicates data via the TCP / IP protocol and analyzes the collected operational data.

[0053] In one embodiment, the control unit 5, after acquiring the pose information, sequentially controls the servo motor 41 and the transfer mechanism 2. During operation, the servo motor 41 rotates by a fixed angle for each pulse received. This fixed angle is determined by the internal structure and microstepping settings of the servo motor 41. For example, in a specific microstepping mode, a common servo motor 41 might rotate 0.001° for each pulse received. Therefore, the second axis 411 of the servo motor 41 rotates very quickly to match the first axis. After the second axis 411 is in position, controlling the transfer mechanism 2 to move the actuator 6 to the second station achieves accurate alignment of the first axis and the second axis.

[0054] In another embodiment, the control unit 5 is used to simultaneously control the servo motor 41 and the transfer mechanism 2 after acquiring the pose information. The servo motor 41 and the transfer mechanism 2 are two relatively independent devices, and the time it takes for the servo motor 41 to reach its position is significantly shorter than that of the transfer mechanism 2 in practice. Therefore, after acquiring the pose information, the servo motor 41 and the transfer mechanism 2 can operate simultaneously, effectively saving the waiting time between different processes, shortening the alignment cycle, and thus improving the detection efficiency of the actuator 6.

[0055] Generally, after acquiring the pose information, before the actuator 6 reaches the second station, the rotation time of the first axis of the servo motor 41 is less than the translation time of the actuator 6. Therefore, it is sufficient to satisfy the condition that the second axis 411 of the servo motor 41 rotates into position before the actuator 6 reaches the second station. Rotating into position means that the angle of the second axis 411 is the same as that of the first axis.

[0056] In at least one embodiment, the second detection mechanism 4 further includes a servo controller 42. The servo controller 42 is connected to the control unit 5; wherein the control unit 5 generates corresponding control commands based on the pose information and sends them to the servo controller 42, causing the servo controller 42 to drive the servo motor 41 to rotate to match the angle of the first axis. In this embodiment, the control unit 5 sends the pose information to the servo controller 42, and the servo controller 42 controls the servo motor 41 to rotate into position, i.e., the angle of the second axis 411 is the same as that of the first axis, to achieve automated alignment of the first and second axes 411. The rotation angle of the servo motor 41 can be determined by the servo motor 41 encoder.

[0057] In at least one embodiment, the servo assembly coordinate system is first established, such as... Figure 7As shown, the right-center position of the rotation circle is set as the angle 0 point. Through software processing, the counterclockwise direction is set as the angle increasing direction, and it automatically returns to zero after one 360° rotation. First, determine the coordinate angle of the servo motor in the servo assembly coordinate system, for example, 225°. When the actuator is in the shooting position, the camera is placed below the shooting position, shooting the first axis in the actuator from below. Therefore, the coordinate system of the image captured by the camera can be mirrored to ensure that it is consistent with the coordinate system of the servo assembly. The angle of the first axis captured by the image is identified as 345.8° through the image processing algorithm. Therefore, in this embodiment, the visual angle of 345.8° can be obtained first, and a command with a specific protocol is sent to the main control board through the network: "RUN_TO_CCD=***345.8°*". After receiving the "RUN_TO_CCD=***345.8°*" command, the main control board sets "***345.8°*" as the target angle, calculates the difference between the target angle and the initial angle of the current servo assembly, and takes the closest distance. To ensure accurate alignment of the first and second axes 411, the second axis 411 of the servo motor must rotate from 225° to 345.8°. There are two methods: the servo motor can rotate counter-clockwise by 345.8° - 225° = 119.2°, or it can rotate clockwise by 225° + 360° - 345.8° = 239.2°. Of these two rotation strategies, 119.2° is less than 180°; therefore, the optimal rotation strategy is a counter-clockwise rotation of 119.2°. Given that the servo controller generates 7200 pulses per revolution, multiplying the required target rotation angle by 20 yields the number of pulses needed to reach the target angle. Combining this with the counter-clockwise rotation of the servo controller ensures that the second axis 411 of the servo motor quickly reaches the target angle, laying the foundation for successful alignment.

[0058] Obviously, this embodiment of the invention utilizes the inherent characteristics of the servo motor 41, namely, the encoder of the servo motor 41 determines the rotation angle of the servo motor 41 axis. This changes the traditional method of manually aligning or adjusting the actuator 6 to adapt to the servo motor 41 axis for automatic alignment. Instead, the alignment process relies on first determining the angle of the first axis of the actuator 6, and then actively adjusting the angle of the second axis 411 of the servo motor 41 based on the determined angle of the first axis. Subsequently, the actuator 6 is directly moved from the first station to the second station through the transfer mechanism 2, thus achieving precise alignment and connection of the first axis and the second axis 411.

[0059] In this embodiment of the invention, the motion trajectory of the actuator 6 is on the same vertical plane. The transfer mechanism 2 mainly controls the actuator 6 to move horizontally and vertically, without movement or rotation in other directions. This simplifies the control of the actuator 6 itself during the alignment process, thereby improving alignment efficiency. Furthermore, considering that the alignment process is achieved through the active alignment of the servo motor 41, and that the rotational accuracy of the servo motor 41 can be autonomously selected, the alignment accuracy can be improved by enhancing the accuracy of the servo motor 41.

[0060] As can be seen, the automatic alignment system for actuator detection provided in this embodiment of the invention can automate the alignment process of actuator 6 throughout the entire detection process, providing the necessary foundation for full-process automation. This embodiment of the invention achieves precise alignment of actuator 6 through the joint cooperation of the first detection mechanism 3 and the second detection mechanism 4, without requiring excessive control of actuator 6 itself. Instead, it uses the position and pose information of actuator 6 to control the servo motor 41 adapted to actuator 6, and the control of the servo motor 41 is simple and easy to operate.

[0061] like Figure 10 As shown, this embodiment of the invention also provides an automatic alignment method for actuator detection, which can be based on the aforementioned automatic alignment system for actuator detection, or on the control unit within that automatic alignment system, depending on the actual situation. The automatic alignment method mainly includes steps S1001 to S1003.

[0062] Step S1001: Obtain the pose information of the actuator at the set first station. The pose information includes the angle of the first axis of the actuator.

[0063] In step S1001, the pose information of the actuator 6 at the designated first station can be obtained through the first detection mechanism 3. The first detection mechanism 3 includes an image acquisition module 31 and an image processing module 32. The image processing module 32 can be integrated into the control unit 5 or exist independently of the control unit 5. In the first detection mechanism 3, the image acquisition module 31 acquires images of the actuator 6 at the first station, and the acquired images contain the first axis of the actuator 6. The image processing module 32 identifies the key feature points of the actuator 6 and solves for the pose information of the actuator 6.

[0064] In at least one embodiment, step S1001 may include: after acquiring an image of the actuator at the first station, identifying key feature points of the actuator and solving for the actuator's pose information, wherein the acquired image contains the actuator's first axis. Further, in this embodiment, the acquired image is mirrored so that the coordinate system of the mirrored image is consistent with the set servo assembly coordinate system, wherein when the actuator is at the first station, the first axis is at the bottom of the actuator; key feature points of the first axis on the mirrored image are identified, and the visual angle of the first axis in the mirrored image coordinate system is determined, such as... Figure 8 As shown. In this embodiment, the image acquisition module 31 can be a camera, positioned directly below the shooting position to capture an upward-facing image of the first axis of the actuator 6. Therefore, the initial image coordinate system containing the angle of the directly obtained image is a mirror image of the servo assembly coordinate system. Thus, in this embodiment, the image can be mirrored first, and then image recognition analysis can be performed on the mirrored image. Image mirroring ensures that the coordinate system of the image captured by the camera is consistent with the servo assembly coordinate system. After acquiring the information from the image acquisition module 31, the image processing module 32 mirrors the acquired image and then analyzes it. Based on the image processing algorithm, it obtains the key feature points of the mirrored image of the actuator 6, locates the pose of the actuator 6, and calculates the pose information of the actuator 6 at the shooting position, such as the visual angle of the first axis of the actuator 6 in the servo assembly coordinate system.

[0065] Step S1002: Based on the pose information and the initial angle of the second axis 411 of the servo motor, and based on the angle matching relationship between the first axis and the second axis 411, determine the rotation information of the second axis 411, and control the second axis 411 to rotate.

[0066] In some embodiments, step S1002 may include: obtaining the initial angle of the second axis 411 in the servo assembly coordinate system; calculating the visual angle and the initial angle based on the angle matching relationship between the first axis and the second axis 411 to obtain the rotation information of the second axis 411; generating corresponding control commands according to the rotation information of the second axis 411 to control the second axis 411 of the servo motor to rotate.

[0067] Furthermore, based on the angular matching relationship between the first axis and the second axis 411, the visual angle and the initial angle are calculated to obtain the rotation information of the second axis 411. This can include: using the visual angle as the target angle of the second axis 411, wherein the first axis is coaxially set with the second axis 411 at the second workstation and located above the second axis 411; determining the optimal rotation strategy of the second axis 411 based on the angle difference between the target angle and the initial angle to generate corresponding control commands, wherein the optimal rotation strategy includes the target rotation direction and the target rotation angle. Specifically, determining the optimal rotation strategy of the second axis 411 based on the angle difference between the target angle and the initial angle can be achieved by using the rotation angle and rotation direction corresponding to an angle difference of less than 180° as the target rotation angle and target rotation direction.

[0068] Furthermore, based on the rotation information of the second axis 411, corresponding control commands are generated to control the second axis 411 of the servo motor to rotate. This includes: generating corresponding pulse signals based on the optimal rotation strategy of the second axis 411, which are then sent to the servo controller of the servo motor. In response to the pulse signals, the servo controller controls the second axis 411 to rotate by a target rotation angle in the target rotation direction.

[0069] In this embodiment, the control unit 5 can obtain the visual angle of the first axis of the actuator 6 at the first workstation through the image processing module 32, and then determine the angle at which the second axis 411 of the servo motor 41 near the second workstation should be so that the second axis 411 and the first axis are at the same angle when the actuator 6 is at the second workstation. Based on this, the control unit 5 can control the servo motor 41 to rotate into position so that the second axis 411 of the servo motor 41 rotates to the same angle as the first axis, providing a prerequisite for the subsequent automated alignment of the first axis and the second axis 411.

[0070] Step S1003: Control the actuator to move from the first station to the set second station, and make the first axis and the second axis 411 aligned and connected. The second station can be the position when the actuator is tested for parameters.

[0071] In step S1003, the planned path of actuator 6 is determined based on the first and second workstations; actuator 6 is then controlled to move from the first workstation to the second workstation according to the planned path. Specifically, control unit 5 plans the path for the actuator based on the first and second workstations, and controls the transfer mechanism 2 to move actuator 6 from the first workstation to the second workstation according to the planned path. When actuator 6 is at the second workstation, its first axis is aligned with servo motor 41, so that the actuator can drive the second axis 411 of servo motor 41 to rotate during subsequent parameter testing.

[0072] Furthermore, step S1003 can be performed after step S1002 or simultaneously with step S1002, that is, simultaneously controlling the rotation of the second axis 411 and the translation of the actuator, or controlling the rotation of the second axis 411 and the translation of the actuator sequentially. When step S1003 is performed simultaneously with step S1002, the time required for alignment can be effectively shortened, eliminating the need to wait for the servo motor 41 to rotate into position before controlling the actuator 6 to translate from the first station to the second station.

[0073] In at least one embodiment, after acquiring the pose information, the servo motor 41 and the transfer mechanism 2 are controlled simultaneously. The servo motor 41 and the transfer mechanism 2 are two relatively independent devices, and the time for the servo motor 41 to reach its position is significantly shorter than that for the transfer mechanism 2 in practice. Therefore, after acquiring the pose information, the servo motor 41 and the transfer mechanism 2 can operate simultaneously, which can effectively save the waiting time between different processes, shorten the alignment cycle, and thus improve the detection efficiency of the actuator 6.

[0074] In this embodiment, the automatic alignment method, as a crucial link in the entire detection process of actuator 6, utilizes the characteristics and functions of the first detection mechanism 3 and the second detection mechanism 4. Through a sophisticated alignment design, it shortens the alignment cycle, improves alignment efficiency, and simplifies the control of actuator 6 itself. Furthermore, by selecting a high-precision servo motor 41, alignment accuracy can be improved, thereby enhancing detection accuracy. As described in the alignment system embodiment, the movement trajectory of actuator 6 lies on the same vertical plane. The transfer mechanism 2 primarily controls actuator 6 to move horizontally and vertically, without movement or rotation in other directions. This simplifies the control of actuator 6 itself in the alignment method, thereby improving alignment efficiency. Moreover, considering that the alignment process is achieved through the active alignment of the servo motor 41, and that the rotational accuracy of the servo motor 41 can be autonomously selected, the alignment accuracy can be improved by enhancing the accuracy of the servo motor 41.

[0075] Regarding the automatic alignment method in the above embodiments, the mechanisms required for the specific execution of each operation have been described in detail in the embodiments of the automatic alignment system, and will not be elaborated further here.

[0076] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. An automatic alignment system for actuator detection, characterized in that: It includes a control unit and a first detection mechanism, a second detection mechanism, and a transfer mechanism connected to the control unit; The first detection mechanism is used to acquire the position and orientation information of the actuator at a set first station, the position and orientation information including the angle of the first axis of the actuator; The first detection mechanism further includes an image acquisition module and an image processing module. The image acquisition module is used to acquire images of the actuator at the first station, and the acquired images contain the first axis of the actuator. The image acquisition module includes a camera device located directly below the first station, facing the first station and configured to capture images of the actuator. The image processing module is used to identify the key feature points of the actuator after acquiring images of the actuator at the first station, solve for the pose information of the actuator, and send it to the control unit. The second detection mechanism includes a servo motor, the second axis of which is configured to rotate under the control of the control unit so as to align the second axis with the first axis; The transfer mechanism is used to move the actuator from the first station to a designated second station; wherein the second station is configured such that the actuator is in the second station when the second axis is aligned and connected with the first axis; The transfer mechanism includes a horizontally arranged crossbeam, a first cylinder, and a gripper. The first cylinder is movably mounted on the crossbeam and moves horizontally on the crossbeam. The extension rod of the first cylinder moves vertically. The first cylinder is connected to a control unit, which controls the vertical movement of the extension rod of the first cylinder. The gripper is connected to the extension rod of the first cylinder and is controlled by the first cylinder to grip or release the actuator. The straight line formed by the connection between the first station and the second station is parallel to the crossbeam. The control unit is used to determine the rotation information of the second axis based on the pose information and the initial angle of the second axis and based on the angle matching relationship between the first axis and the second axis, and control the second axis to rotate; and to drive the transfer mechanism to control the actuator to translate from the first station to the second station, so that the first axis and the second axis are aligned and connected.

2. The automatic alignment system according to claim 1, characterized in that: Identify the key feature points of the actuator and solve for the actuator's pose information, including: The acquired image is mirrored so that the coordinate system of the mirrored image is consistent with the set coordinate system of the servo assembly. When the actuator is at the first station, the first axis is at the bottom of the actuator. Identify key feature points of the first axis on the mirrored image and determine the visual angle of the first axis in the coordinate system of the mirrored image.

3. The automatic alignment system according to claim 2, characterized in that: Based on the pose information and the initial angle of the second axis, and based on the angle matching relationship between the first axis and the second axis, the rotation information of the second axis is determined, and the second axis is controlled to rotate, including: Obtain the initial angle of the second axis in the servo assembly coordinate system; Based on the angle matching relationship between the first axis and the second axis, the visual angle and the initial angle are calculated to obtain the rotation information of the second axis; Based on the rotation information of the second axis, corresponding control commands are generated to control the second axis of the servo motor to rotate.

4. The automatic alignment system according to claim 3, characterized in that: The calculation of the rotation information of the second axis based on the angle matching relationship between the first axis and the second axis, using the visual angle and the initial angle, includes: The visual angle is used as the target angle of the second axis, wherein the first axis is coaxially arranged with the second axis at the second workstation and is located above the second axis; Based on the angle difference between the target angle and the initial angle, the optimal rotation strategy for the second axis is determined to generate corresponding control commands. The optimal rotation strategy includes the target rotation direction and the target rotation angle.

5. The automatic alignment system according to claim 4, characterized in that: Based on the angle difference between the target angle and the initial angle, the optimal rotation strategy for the second axis is determined, including: The rotation angle and rotation direction corresponding to the angle difference being less than 180° are taken as the target rotation angle and target rotation direction.

6. The automatic alignment system according to claim 5, characterized in that: Based on the rotation information of the second axis, corresponding control commands are generated to control the second axis of the servo motor to rotate, including: A corresponding pulse signal is generated according to the optimal rotation strategy of the second axis, and sent to the servo controller of the servo motor. The servo controller responds to the pulse signal and controls the second axis to rotate the target rotation angle in the target rotation direction.

7. The automatic alignment system according to claim 1, characterized in that: The control unit simultaneously controls the rotation of the second axis and the translation of the actuator, or controls the rotation of the second axis and the translation of the actuator in sequence.

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