An actuator detection system and method

Abstract

The application discloses an actuator detection system and a detection method. The detection system comprises: a feeding mechanism for conveying the actuator to a designated position; a transfer mechanism for taking and placing the actuator and transferring the actuator between the designated position, a first work station and a second work station; a first detection mechanism for collecting the pose of the actuator at the first work station and obtaining the pose information of the actuator, wherein the pose information comprises the first axis angle of the actuator; a second detection mechanism for performing parameter testing on the actuator at the second work station; and a control unit connected with each mechanism, for controlling the second axis of the servo motor to rotate to match the first axis according to the pose information, and after obtaining the pose information, starting the transfer mechanism to translate and release the actuator to the second work station, so that the first axis is aligned with the second axis. The scheme provided by the application realizes the automatic, rapid and accurate detection of the actuator by combining the active transfer alignment of the servo motor with the passive transfer measurement in the testing link.

Description

Technical Field

[0001] This invention relates to the field of actuator testing technology, and more particularly to an actuator testing system and testing method. 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. In related technologies, actuator inspection mostly relies on manual inspection or semi-automatic inspection. Both manual and semi-automatic actuator inspection suffer from low efficiency and accuracy, and consume a lot of manpower. Summary of the Invention

[0003] To address or partially address the problems existing in related technologies, this invention provides an actuator detection system and detection method that can automate the entire process of actuator detection.

[0004] The first aspect of the present invention provides an actuator detection system, comprising: a loading mechanism for conveying an actuator to a designated position; a transfer mechanism for picking up, placing, and transferring the actuator; a first detection mechanism for acquiring the position and orientation of the actuator at a set first station and obtaining the position and orientation information of the actuator, the position and orientation information including the angle of a first axis of the actuator; a second detection mechanism including a servo motor, wherein when the actuator is at a set second station and is connected to the servo motor, the second detection mechanism is used to perform parameter testing on the actuator; and a control unit connected to the loading mechanism, the transfer mechanism, the first detection mechanism, and the second detection mechanism respectively. The mechanism is configured to: if the actuator is in the designated position, initiate the transfer mechanism to grab and move the actuator to the first workstation, and keep the actuator in the first workstation; trigger the first detection mechanism to acquire the pose of the actuator at the first workstation to obtain the pose information of the actuator; control the second axis of the servo motor to rotate to match the angle of the first axis according to the pose information; after obtaining the pose information, initiate the transfer mechanism to translate and release the actuator to the second workstation, and make the first axis and the second axis aligned and connected; drive the second detection mechanism to perform parameter testing on the actuator at the second workstation.

[0005] In conjunction with the first aspect of the present invention, in an optional embodiment, the feeding mechanism includes: a transmission component connected to the control unit for transmitting the actuator; and a photoelectric sensor connected to the control unit for monitoring the actuator and, when the actuator reaches the designated position, activating the transfer mechanism to grab the actuator via the control unit.

[0006] In conjunction with the first aspect of the invention, in an optional embodiment, the transfer mechanism includes: a first cylinder, the telescopic rod of the first cylinder moving vertically under the control of the control unit; and a gripper connected to the telescopic rod of the first cylinder and controlled by the first cylinder to grip or release the actuator.

[0007] In conjunction with the first aspect of the present invention, in an optional embodiment, the second detection mechanism further includes: a second cylinder, the telescopic rod of the second cylinder moving horizontally under the control of the control unit; and a plug-in element connected to the second cylinder and controlled by the second cylinder to approach and connect to the pin of the actuator, such that the control unit acquires an electrical signal through the plug-in element during actuator testing.

[0008] In conjunction with the first aspect of the present invention, in an optional embodiment, the second detection mechanism further includes: a coupling disposed at the end of the second shaft and used for a through-hole shaft-to-connection to the first shaft; and a torque sensor disposed on the coupling and connected to the control unit.

[0009] In conjunction with the first aspect of the invention, in an optional embodiment, it further includes: a plurality of sorting containers for receiving the corresponding actuators via the transfer mechanism after the actuator test is completed.

[0010] A second aspect of the present invention provides an actuator detection method, which is based on the aforementioned actuator detection system, comprising: if the actuator is at a designated position of a loading mechanism, activating a transfer mechanism to grab and move the actuator to a set first workstation, and maintaining the actuator at the first workstation; triggering a first detection mechanism to acquire the pose of the actuator at the first workstation to obtain the pose information of the actuator, the pose information including the angle of the first axis of the actuator; controlling the second axis of a servo motor to rotate to match the angle of the first axis according to the pose information; after obtaining the pose information, activating the transfer mechanism to translate and release the actuator to a set second workstation, and aligning the first axis with the second axis; and driving a second detection mechanism to perform parameter testing on the actuator at the second workstation.

[0011] In conjunction with the second aspect of the present invention, in an optional embodiment, after obtaining the pose information, the servo motor and the transfer mechanism are controlled simultaneously, or the transfer mechanism is controlled after the second axis of the servo motor is rotated to match the angle of the first axis.

[0012] In conjunction with the second aspect of the present invention, in an optional embodiment, the driving second detection mechanism performs parameter testing on the actuator at the second workstation, including: obtaining the rotation angle of the servo motor when it is used as a test load through the encoder of the servo motor of the second detection mechanism.

[0013] In conjunction with the second aspect of the present invention, in an optional embodiment, the driving second detection mechanism performs parameter testing on the actuator at the second workstation, including: acquiring the torque of the servo motor as a test load through a torque sensor.

[0014] In conjunction with the second aspect of the present invention, in an optional embodiment, the method further includes: after the second detection mechanism performs parameter testing on the actuator at the second workstation, obtaining the test result of the actuator, and controlling the transfer mechanism to grab and transfer the actuator to the corresponding sorting container based on the test result.

[0015] The technical solution provided by this invention may include the following beneficial effects: The technical solution of this invention includes a feeding mechanism, a transfer mechanism, a first detection mechanism, a second detection mechanism, and a control unit. The second detection mechanism includes a servo motor. Based on the inherent characteristics of the servo motor, during the entire detection process, the alignment stage is driven by the control unit to actively and adaptively adjust the servo motor according to the actuator's pose information obtained from the first detection mechanism. In the testing stage, the control unit controls the second detection mechanism to perform parameter testing on the actuator. In the testing stage, the servo motor passively rotates as a test load to obtain the test results. Furthermore, this invention changes the traditional method of manual alignment or adjusting the actuator to adapt to the servo motor shaft for automatic alignment, achieving accurate and rapid alignment, thereby improving detection efficiency and accuracy. Therefore, the technical solution of this invention not only automates the entire process of actuator detection but also improves detection efficiency and accuracy.

[0016] 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

[0017] 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.

[0018] Figure 1 This is a structural block diagram of the actuator detection system shown in an embodiment of the present invention; Figure 2 and Figure 3 These are perspective views of the actuator detection system (the actuator is directly above the second station) shown in an embodiment of the present invention from different angles. Figure 4 This is a perspective view of the second detection mechanism shown in an embodiment of the present invention; Figure 5 This is a perspective view of an actuator detection system (actuator at a specified position) according to an embodiment of the present invention; Figure 6 This is a perspective view of an actuator detection system (actuator at the first station) according to an embodiment of the present invention; Figure 7 This is another structural block diagram of the actuator detection system shown in an embodiment of the present invention; Figure 8 (a) Figure 8 (b) are schematic diagrams of the first axis end profile of the actuator in posture one and posture two, respectively, according to embodiments of the present invention; Figure 9 (a) Figure 9 (b) Figure 9 (c) is a schematic diagram of the shaft end profile of the coupling (the part inserted into the first shaft) provided on the second shaft in posture three, posture three' and posture four, as shown in the embodiment of the present invention; Figure 10 (a) Figure 10 (b) are schematic diagrams of the servo assembly coordinate system (top view) and the first axis end contour in the servo assembly coordinate system after image mirroring, as shown in the embodiments of the present invention. Figure 11 (a) Figure 11 (b) are schematic diagrams of the second axis 411 shaft 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. Figure 12 This is a schematic flowchart illustrating the actuator detection method according to an embodiment of the present invention; In the diagram: 1. Feeding mechanism; 11. Photoelectric sensor; 12. Drive motor; 13. Conveyor belt; 14. Stop block; 2. Transfer mechanism; 21. First cylinder; 22. Gripper; 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; 44. Torque sensor; 45. Second cylinder; 46. Connecting element; 5. Control unit; 6. Actuator; 71. Sorting container. Detailed Implementation

[0019] 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.

[0020] 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.

[0021] 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.

[0022] In related technologies, actuator inspection often relies on manual or semi-automatic inspection. Both manual and semi-automatic actuator inspection suffer from low efficiency, low accuracy, and high labor costs.

[0023] To address the aforementioned problems, embodiments of the present invention provide an actuator detection system that, by leveraging the inherent characteristics of servo motors, achieves automated, rapid, and accurate actuator detection through the organic combination of the servo motor's active alignment during the alignment phase and its passive measurement during the testing phase.

[0024] The technical solutions of the embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0025] like Figures 1-7 As shown, an embodiment of the present invention provides an actuator detection system, including a feeding mechanism 1, a transfer mechanism 2, a first detection mechanism 3, a second detection mechanism 4, and a control unit 5.

[0026] like Figure 5As shown, the feeding mechanism 1 is used to convey the actuator 6 to a designated position. In some embodiments, the feeding mechanism 1 includes a transmission component and a photoelectric sensor 11. The transmission component is connected to the control unit 5 and is used to convey the actuator 6; the photoelectric sensor 11 is connected to the control unit 5 and is used to monitor the actuator 6, and when the actuator 6 reaches the designated position, the control unit 5 activates the transfer mechanism 2 to grab the actuator 6. In at least one embodiment, the transmission component includes a drive motor 12, a conveyor belt 13, and a stop block 14; the conveyor belt 13 is connected to and controlled by the drive motor 12; the stop block 14 is located at the end of the conveyor belt 13 and is used to limit the actuator 6 to stop at the designated position on the conveyor belt 13.

[0027] In some embodiments, the transfer mechanism 2 is used to pick up, place, and transfer the actuator 6. The transfer mechanism 2 is controlled by the control unit 5, which performs the picking, placing, and transferring of the actuator 6. In at least one embodiment, the transfer mechanism 2 includes a first cylinder 21 and a gripper 22. The telescopic rod of the first cylinder 21 moves vertically under the control of the control unit 5. The gripper 22 is connected to the telescopic 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 telescopic 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 telescopic rod of the first cylinder 21 to retract, the gripper 22 releases the actuator 6, and the actuator 6 separates from the gripper 22.

[0028] In some embodiments, the first detection mechanism 3 is used to acquire the pose of the actuator 6 at a set first station and obtain the pose information of the actuator 6, including the angle of the first axis of the actuator 6. Figure 6 As shown, when actuator 6 is in the first station, the transfer mechanism 2 continues to hold actuator 6, keeping its pose in the same position. The first detection mechanism 3 can then collect the current pose of actuator 6, with the first axis of actuator 6 being the key focus of the data collection. The angle of the first axis of actuator 6 is obtained by analyzing and processing the collected pose information. This is because the first detection mechanism 3 and the servo motor 41 can work together. First, the first detection mechanism 3 determines the angle of the first axis of actuator 6, and then the second axis 411 of the servo motor 41 rotates accordingly to make the angles of the first and second axes 411 the same. Therefore, when the first axis reaches the second station, the first and second axes 411 are perfectly aligned and connected via a hole-shaft joint.

[0029] In one embodiment, the first detection mechanism 3 includes an image acquisition module 31. The image acquisition module 31 is used to acquire images of the actuator 6 at a 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 the angle of its output axis. Therefore, the acquired image should contain the first axis of the actuator 6.

[0030] Furthermore, 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 the shooting actuator 6. In this embodiment, the camera device 311 can be directly below the shooting position and facing the shooting position to accurately acquire 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.

[0031] like Figure 7 As shown, the first detection mechanism 3 further includes an image processing module 32. The image processing module 32 is connected to both the image acquisition module 31 and the control unit 5. It is used to identify key feature points of the actuator 6, calculate the pose information of the actuator 6, and send it to the control unit 5. In this embodiment, after acquiring the information collected by the image acquisition module 31, the image processing module 32 analyzes the acquired image, obtains the key feature points of the actuator 6 image information based on the algorithm, locates the pose of the actuator 6, and calculates the pose information of the actuator 6 at the shooting position, such as the actual position of the actuator 6 and the angle of the first axis.

[0032] In the image processing module 32, key feature points of the actuator are identified, and the actuator's pose information is obtained. This further includes: identifying the key feature points of the actuator; and calculating the actuator's pose information at the first station based on the actuator's pose information when the preset angle is zero. The actuator's pose information at the first station includes the change in angle relative to when the preset angle is zero. Figure 8The diagram shows the contour of the first axis end of the actuator in posture one (i.e., when the actuator's preset angle is zero) and the contour of the first axis end of the actuator in posture two (i.e., when the actuator is in the first position). The angle of the first axis of the actuator in the first position can be determined based on the angle changes of the actuator in postures one and two. It should be understood that the angle is used for the alignment and positioning of the actuator 6, and when necessary, it can be combined with other information in the pose information of the actuator 6 for alignment with the servo motor 41. To better explain the angle in this embodiment of the invention, it can be understood as follows: Figure 8 As shown in (a), the first axis is defined as having an angle of zero (predefined) as posture one. Posture one is also the reference posture of the actuator. At this time, the angle is 0, which can be called the preset zero degree. Figure 8 As shown in (b), the first axis is in posture two at the first station, and the angle of the first axis is 30°. Taking the set reference line X on the end of the first axis as a reference, the angle of the first axis at the first station can be determined according to the difference in rotation angle between the reference line X of posture two and posture one, for example, 30°.

[0033] In another 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.

[0034] In some embodiments, the second detection mechanism 4 includes a servo motor 41. When the actuator 6 is in a designated second position and docked with 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 referred to as the detection position, which is used to place the actuator 6 to be tested. Figure 2 and Figure 3 As shown, this is a perspective view of the detection system as actuator 6 approaches the test position, with actuator 6 directly above the test position. Figure 4 The diagram shows a perspective view of the second detection mechanism 4 (actuator 6 is in the second station). The second detection mechanism 4 is used to test parameters such as torque, angle, voltage, and current of actuator 6 when actuator 6 is in the test position. The angle can be measured by the encoder built into the servo motor 41.

[0035] like Figure 4As shown, in at least one embodiment, the second detection mechanism 4 further includes a coupling 43 and a torque sensor 44. 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 44 is located on the coupling 43 and 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, ensuring precise synchronous transmission during rotation and minimizing transmission errors caused by loose connections or misalignment. Furthermore, a torque sensor 44 is installed at the connection point between the coupling 43 and the first shaft of the actuator 6, which 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 41 acts as the load, and its second axis 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, and second axis 411 are coaxial), the first axis can be connected to the second axis 411 via a hole-shaft type coupling. 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, achieving alignment between the first axis and coupling 43. When the first axis rotates, it naturally drives the second axis 411 to rotate.

[0036] like Figures 2-7 As shown, in at least one embodiment, the second detection mechanism 4 includes a second cylinder 45 and a connector 46. The telescopic rod of the second cylinder moves horizontally under the control of the control unit; the connector 46 is connected to the telescopic rod of the second cylinder 45 and is controlled by the second cylinder 45 to approach and connect to the pin of the actuator 6, so that the control unit 5 acquires electrical signals through the connector 46 during the testing of the actuator 6. When the second cylinder 45 pushes the connector 46 to connect the connector 46 to the actuator 6, the actuator 6 is energized and tested, thereby acquiring electrical signals such as voltage and current during the testing process.

[0037] 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 2and 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.

[0038] In some embodiments, the control unit 5 is connected to the feeding mechanism 1, the transfer mechanism 2, the first detection mechanism 3, and the second detection mechanism 4, respectively, and is used for: if the actuator 6 is in a designated position, starting the transfer mechanism 2 to grab and move the actuator 6 to the first station and keeping the actuator 6 in the first station; triggering the first detection mechanism 3 to perform pose acquisition on the actuator 6 at the first station to obtain the pose information of the actuator 6; controlling the second axis 411 of the servo motor 41 to rotate to match the angle with the first axis according to the pose information; after obtaining the pose information of the actuator 6, starting the transfer mechanism 2 to translate and release the actuator 6 to the second station, so that the first axis and the second axis 411 are aligned and connected; and driving the second detection mechanism 4 to perform parameter testing on the actuator 6 at the second station. In this embodiment, the actuator 6 changes its position through the feeding mechanism 1 and the transfer mechanism 2, wherein the control unit 5 controls the feeding mechanism 1 to transfer the actuator 6 to the designated position, and then controls the transfer mechanism 2 to change the position of the actuator 6 by setting a key station.

[0039] In some embodiments, in the control unit 5, controlling the second axis 411 of the servo motor 41 to rotate to match the angle with the first axis according to the pose information further includes: calculating the pose information and the initial angle of the second axis based on the angle matching relationship between the first axis at the first station and the rotated second axis 411 to obtain the rotation angle of the second axis; generating a corresponding control command according to the rotation angle of the second axis; and controlling the second axis of the servo motor to rotate in response to the control command.

[0040] The angle matching relationship between the first axis at the first station and the rotated second axis 411 is that the angle of the rotated second axis 411 is the same as the angle of the first axis at the first station, and the first axis and the second axis 411 can be aligned and connected.

[0041] In this embodiment of the invention, the initial angle of the second axis is the angle relative to the first axis when the angle is zero. For example... Figure 9 As shown in (a), this is the profile of the second axis end when the second axis is in attitude three (initial angle is zero); Figure 9 As shown in (b), this is the profile of the second axis end when the second axis is in attitude three' (initial angle is not zero); Figure 9 As shown in (c), the second axis is in posture four (angle after rotation), which is the profile of the second axis end, i.e. the angle of the second axis. The angles of the first axis and the second axis are both from the top or bottom view.

[0042] To explain, such as Figure 8 and Figure 9 As shown, assuming the initial angle of the second axis before rotation is a preset zero degree, the end face profile of its axis is shown in the figure. Figure 9 In attitude three, if the angle of the first axis at the first station is 30°, then to match the second axis with the first axis, the second axis should be rotated 30°. At this point, the angle of the rotated second axis will be the same as the angle of the first axis at the first station. (See [reference]). Figure 9 The posture of the four and Figure 8 The second posture.

[0043] like Figure 8 and Figure 9 As shown, assuming the initial angle of the second axis before rotation is not the preset zero degree, its end face profile is shown in the figure. Figure 9 In attitude 3′, the initial angle of the second axis before rotation is 15° relative to the preset zero degree. Therefore, when the angle of the first axis in the first station is 30°, in order to match the second axis with the first axis, the second axis should be rotated by another 15° on the current basis, so that the angle of the second axis after rotation is 30°. At this time, the angle of the first axis (attitude 2) in the first station is the same as the angle of the second axis after rotation (attitude 4).

[0044] 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 these controllers interconnected, or it can be an independent controller for data communication with various mechanisms. 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.

[0045] In some embodiments, the detection system further includes a plurality of sorting containers 71, which are used to receive the corresponding actuators 6 via the transfer mechanism 2 after the actuator 6 has been tested. For example, the detection system includes two sorting containers 71, one for placing actuators 6 that have passed the test and the other for placing actuators 6 that have failed the test. The specific position of the sorting containers 71 can be set according to the movement trajectory of the actuators 6.

[0046] The entire testing process can be roughly divided into four stages: loading, alignment, testing, and sorting. The loading stage is controlled by the control unit 5, which controls the loading mechanism 1. The other three stages are controlled by the control unit 5, which controls the transfer mechanism 2 to move the actuator 6 between different workstations. The control unit 5 can connect all stages to achieve full automation of the actuator 6 testing process. In the alignment stage, the control unit 5 drives the servo motor 41 of the second detection mechanism 4 to actively and adaptively adjust based on the positional information of the actuator 6 obtained from the first detection mechanism 3. Then, it controls the transfer mechanism 2 to move the actuator 6 from the first workstation to the second workstation for subsequent testing. In the testing stage, the control unit 5 controls the second detection mechanism 4 to perform parameter testing on the actuator 6. During testing, the servo motor 41 passively rotates as a test load to obtain test results. In the sorting stage, the control unit 5 controls the transfer mechanism 2 to place the actuator 6 into the corresponding sorting container 71 based on the test results.

[0047] Clearly, the movement trajectory of the transfer mechanism 2 involves the termination position of the actuator 6 in the feeding stage, the alignment stage, the testing stage, and the sorting stage. In order to improve the efficiency of the entire inspection process, the movement trajectory of the actuator 6 can be made to be on the same vertical plane. The transfer mechanism 2 mainly controls the actuator 6 to move in the horizontal and vertical directions, without movement or rotation in other directions. This simplifies the trajectory of the actuator 6 itself in the alignment stage or between adjacent stages, thereby improving the inspection efficiency.

[0048] 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 selected autonomously, the alignment accuracy can be improved by improving the accuracy of the servo motor 41.

[0049] For the alignment process, common automatic alignment methods often involve keeping the angle of the first axis of the servo motor 41 fixed, and adjusting the angle of the actuator 6 to achieve alignment. In this embodiment of the invention, 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, thus achieving automatic alignment of the first and second axes 411. Simply put, the control unit 5 can obtain the pose information of the actuator 6 at the first station, and then know what posture the second axis 411 of the servo motor 41 near the second station should be in to ensure that when the first axis is at the second station, it is aligned with the first axis, thereby achieving the connection of the first and second axes 411. The movement of actuator 6 between the first station and the second station is a translation. Therefore, the angle of actuator 6 at the first station and the angle at the second station are naturally the same. Thus, the angle of the second axis 411 of servo motor 41 matches that of the first axis, including: the angle of the second axis 411 is the same as that of the first axis.

[0050] In a preferred embodiment, the image processing module 32 is used to mirror the acquired image so that the coordinate system of the mirrored image is consistent with the set servo assembly coordinate system. When the actuator 6 is in the first station, the first axis is at the bottom of the actuator. The key feature points of the first axis on the mirrored image are identified to determine the visual angle of the first axis in the mirrored image coordinate system. Figure 10 (a) is a schematic diagram of the servo assembly coordinate system (top view); Figure 10 (b) is a schematic diagram of the first axis end profile in the servo assembly coordinate system after image mirroring. Control unit 5 is used to obtain the initial angle of the second axis 411 in the servo assembly coordinate system, such as... Figure 11 As shown in (a); the visual angle is used as the target angle of the second axis 411, wherein the first axis is coaxially set with the second axis 411 at the second station and is located above the second axis 411; based on the angle difference between the target angle and the initial angle, the optimal rotation strategy of the second axis 411 is determined to generate corresponding control commands. The optimal rotation strategy includes the target rotation direction and the target rotation angle, and the rotation angle and rotation direction corresponding to the angle difference being less than 180° are taken as the target rotation angle and the target rotation direction; a corresponding pulse signal is generated based on the optimal rotation strategy of the second axis 411 to be sent to the servo controller 42 of the servo motor 41. The servo controller 42 responds to the pulse signal and controls the second axis 411 to rotate in the target rotation direction by the target rotation angle. The shaft end profile of the rotated second axis 411 in the servo assembly coordinate system is as follows. Figure 11 As shown in (b).

[0051] Among them, such as Figure 10 As shown in (a), in the servo assembly coordinate system, the right center position of the rotation circle range 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 completing one 360° rotation. Figure 10 As shown in (b), the axis center N′ of the first axis and the feature point M′ on the first axis are taken. 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 N′M′ in the servo assembly coordinate system is the angle of the first axis. Similarly, as Figure 11 As shown, take the axis center N of the second axis 411 and the feature point M on the second axis 411. Feature point M corresponds to feature point M′. Then, the angle pointed to by ray NM in the servo assembly coordinate system is the angle of the second axis.

[0052] For example, first set the servo assembly coordinate system, such as... Figure 10 As shown in (a), 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 of a specific protocol can be 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.

[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 eliminating 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 the testing phase, the servo motor 41 serves as the test load. Driven by the actuator 6, the second axis 411 of the servo motor 41 rotates. At this time, the first axis of the actuator 6 can be regarded as the output axis.

[0057] Therefore, by taking advantage of the characteristics of the servo motor itself, the present invention cleverly achieves automated, fast and accurate detection of the actuator 6 by organically combining the active operation of the servo motor 41 in the alignment stage and the passive operation in the testing stage.

[0058] like Figure 12 as well as Figures 1 to 7 As shown, this embodiment of the invention also provides an actuator detection method, which is based on the above-described actuator detection system and includes: Step S1201: If the actuator 6 is in the designated position of the feeding mechanism 1, start the transfer mechanism 2 to grab and move the actuator 6 to the set first station, and keep the actuator 6 in the first station; Step S1202: Trigger the first detection mechanism 3 to perform pose acquisition on the actuator 6 at the first station to obtain the pose information of the actuator 6, including the angle of the first axis of the actuator 6; Step S1203: Control the second axis 411 of the servo motor 41 to rotate to match the angle of the first axis according to the pose information; Step S1204: After obtaining the pose information, start the transfer mechanism 2 to translate and release the actuator 6 to the set second station, so that the first axis and the second axis 411 are aligned and connected; drive the second detection mechanism 4 to perform parameter testing on the actuator 6 at the second station.

[0059] Based on the inherent characteristics of servo motors, this invention provides an actuator 6 detection method. In the alignment stage, the control unit 5 drives the servo motor 41 to actively and adaptively adjust according to the position and pose information of the actuator 6 obtained from the first detection mechanism 3. Specifically, the second axis of the servo motor is rotated until its angle matches the angle of the first axis at the first station. In the testing stage, the control unit 5 controls the second detection mechanism 4 to perform parameter testing on the actuator 6. During testing, the servo motor 41 passively rotates as a test load to obtain the test results. This invention also changes the traditional method of manually aligning or adjusting the actuator 6 to adapt to the servo motor 41 axis for automatic alignment, achieving accurate and rapid alignment, thereby improving detection efficiency and accuracy. Therefore, this invention achieves full automation of the actuator 6 detection process while also improving detection efficiency and accuracy.

[0060] In some embodiments, after obtaining the pose information, the servo motor 41 and the transfer mechanism 2 are controlled simultaneously, or the transfer mechanism 2 is controlled after the second axis 411 of the servo motor 41 is rotated to match the angle of the first axis.

[0061] In some embodiments, driving the second detection mechanism 4 to perform parameter testing on the actuator 6 at the second station includes: obtaining the rotation angle of the servo motor 41 when it is used as a test load through the encoder of the servo motor 41.

[0062] In some embodiments, driving the second detection mechanism 4 to perform parameter testing on the actuator 6 at the second station includes: obtaining the torque of the servo motor 41 when it is used as a test load through the torque sensor 44 between the first axis and the second axis 411.

[0063] In some embodiments, the method further includes: after driving the second detection mechanism 4 to perform parameter testing on the actuator 6 at the second work station, obtaining the test results of the actuator 6, and controlling the transfer mechanism 2 to grab and transfer the actuator 6 to the corresponding sorting container 71 based on the test results.

[0064] Regarding the methods in the above embodiments, the specific implementation of each embodiment has been described in detail in the embodiments related to the system, and will not be elaborated further here.

[0065] 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 actuator detection system, characterized in that, include: The feeding mechanism is used to transport the actuator to the designated position; The transfer mechanism is used to pick up, place, and transfer the actuator. The first detection mechanism is used to collect the pose of the actuator at a set first station and obtain the pose information of the actuator, the pose information including the angle of the first axis of the actuator, the first axis being the output axis of the actuator; The second testing mechanism includes a servo motor. When the actuator is in the set second position and connected to the servo motor, the second testing mechanism is used to perform parameter testing on the actuator. The control unit, connected to the feeding mechanism, the transfer mechanism, the first detection mechanism, and the second detection mechanism respectively, is used for: If the actuator is in the designated position, the transfer mechanism is activated to grab and move the actuator to the first workstation, and the actuator is kept in the first workstation. The first detection mechanism is triggered to collect the pose of the actuator at the first workstation to obtain the pose information of the actuator. Based on the pose information, the second axis of the servo motor is controlled to rotate to match the angle of the first axis, and the second axis is the output axis of the servo motor; After obtaining the pose information, the transfer mechanism is activated to translate and release the actuator to the second workstation, so that the first axis and the second axis are aligned and connected. The second detection mechanism is driven to perform parameter testing on the actuator at the second workstation. The first detection mechanism 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 workstation, wherein the acquired image contains the first axis; The image processing module is used to mirror the acquired image so 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, and the first station is the shooting position. The module identifies the 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. Furthermore, in the control unit, the visual angle is used as the target angle of the second axis; the initial angle of the second axis in the servo assembly coordinate system is obtained; based on the angle difference between the target angle and the initial angle, the optimal rotation strategy of the second axis is determined to generate corresponding control commands. The optimal rotation strategy includes a target rotation direction and a target rotation angle, and the rotation angle and rotation direction corresponding to an angle difference of less than 180° are taken as the target rotation angle and the target rotation direction; a corresponding pulse signal is generated based on the optimal rotation strategy of the second axis to be 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.

2. The actuator detection system according to claim 1, characterized in that: The feeding mechanism includes: A transmission component, connected to the control unit, is used to transmit the actuator; A photoelectric sensor, connected to the control unit, is used to monitor the actuator and, when the actuator reaches the designated position, to activate the transfer mechanism to grab the actuator.

3. The actuator detection system according to claim 1, characterized in that: The transfer mechanism includes: The first cylinder, the telescopic rod of the first cylinder moves vertically under the control of the control unit; The gripper is connected to the telescopic rod of the first cylinder and is controlled by the first cylinder to grip or release the actuator.

4. The actuator detection system according to claim 1, characterized in that: The second testing institution also includes: The second cylinder, whose telescopic rod moves horizontally under the control of the control unit; A plug-in element is connected to the second cylinder and controlled by the second cylinder to approach and connect to the pins of the actuator, such that the control unit receives an electrical signal through the plug-in element during actuator testing.

5. The actuator detection system according to claim 1, characterized in that: The second testing institution also includes: A coupling is provided at the end of the second shaft and is used to be adapted to connect with the first shaft through a hole shaft. A torque sensor is mounted on the coupling and connected to the control unit.

6. The actuator detection system according to claim 1, characterized in that: It also includes multiple sorting containers, which are used to receive the corresponding actuators via the transfer mechanism after the actuator test is completed.

7. An actuator detection method, based on the actuator detection system according to any one of claims 1 to 6, characterized in that, include: If the actuator is in the designated position of the feeding mechanism, the transfer mechanism is activated to grab and move the actuator to the set first station, and the actuator is kept in the first station; The first detection mechanism is triggered to perform pose acquisition on the actuator at the first workstation to obtain the pose information of the actuator, the pose information including the angle of the first axis of the actuator; Based on the pose information, control the second axis of the servo motor to rotate to match the angle of the first axis; After obtaining the pose information, the transfer mechanism is activated to translate and the actuator is released to the set second work station, so that the first axis and the second axis are aligned and connected. The second testing mechanism is driven to perform parameter testing on the actuator at the second workstation.

8. The actuator detection method according to claim 7, characterized in that: The second detection mechanism drives the actuator to perform parameter testing at the second workstation, including: The rotation angle of the servo motor when it is used as a test load is obtained by the encoder of the servo motor of the second detection mechanism.

9. The actuator detection method according to claim 7, characterized in that: The second detection mechanism drives the actuator to perform parameter testing at the second workstation, including: The torque of the servo motor when used as a test load is obtained using a torque sensor.

10. The actuator detection method according to claim 7, characterized in that, Also includes: After the second detection mechanism performs parameter testing on the actuator at the second workstation, the test results of the actuator are obtained, and the transfer mechanism is controlled to grab and transfer the actuator to the corresponding sorting container based on the test results.

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