Coal mine underground man-machine collaborative belt conveyor roller installation method

Abstract

The application provides a coal mine underground man-machine collaborative belt conveyor roller mounting method, adopts an auxiliary operation robot with a man-machine collaborative function; a plurality of mounting stations are divided on the frame in the conveying direction; a first row of mounting parameters is calibrated by manually dragging a six-degree-of-freedom mechanical arm, the mounting parameters of the second and third rows of to-be-mounted rollers are determined based on the first row of mounting parameters and in combination with the belt conveyor support structure size; one roller in the first row of roller supports is mounted, and the remaining seven rollers are gripped and mounted based on the mounting parameters of the first, second and third rows; the auxiliary operation robot automatically calculates the next station position according to the station path step, and completes the mounting operation of all the remaining station rollers. The method can realize the man-machine efficient collaborative operation mode, realize the efficient automatic mounting operation of the rollers, and effectively solve the problem of large automatic mounting positioning error of the belt conveyor rollers in the coal mine.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of intelligent assembly, and particularly relates to a method for installing a belt conveyor roller in a coal mine. BACKGROUND

[0002] In the daily maintenance and operation of the belt conveyor in the coal mine, the roller is a key component for supporting the conveyor belt and ensuring the stable transportation of materials, and the installation and replacement efficiency of the roller is directly related to the operation efficiency and safety of the entire coal conveying system. However, the existing technology focuses more on the replacement of the roller rather than the initial installation process. Although some technologies have realized the non-stop replacement operation of the roller, the technology used only for the installation of the roller still has the problem of low installation efficiency. At the same time, there is a lack of a special installation method for the belt conveyor roller, which makes it difficult to meet the high-intensity and fast-paced production needs in the coal mine. Therefore, in view of the urgent need for the installation of the belt conveyor roller in the coal mine, a special method that takes into account efficient installation, terrain adaptability and man-machine safety is needed to effectively ensure the safe transportation operation in the coal mine. SUMMARY

[0003] In view of the problems existing in the above-mentioned prior art, the present application provides a method for installing a belt conveyor roller in a coal mine in a man-machine cooperative manner. The method can realize efficient man-machine cooperation, can realize efficient installation of the roller, and can effectively solve the problem of difficult initial installation of the roller in the belt conveyor in the coal mine.

[0004] In order to achieve the above-mentioned application purpose, the present application provides a method for installing a belt conveyor roller in a coal mine in a man-machine cooperative manner, which adopts an auxiliary work robot with man-machine cooperation function, and the method comprises the following steps:

[0005] Step one: division of the installation station; the installation area on the rack is divided into a plurality of installation stations along the conveying direction, each installation station contains three rows of roller supports distributed continuously, and the first installation station in the conveying direction is used as the initial station;

[0006] Step two: positioning of the initial station and setting of the initial parameters; the auxiliary work robot is moved to a position aligned with the initial station to complete the positioning of the initial station; the initial parameters of the auxiliary work robot are set;

[0007] Step three: installation parameter calibration and generation of the station path step; the first row of setting installation parameters are generated by manually dragging the six-degree-of-freedom mechanical arm, the second row and the third row of setting installation parameters are generated based on the first row of setting installation parameters and combined with the structure size of the belt conveyor support, and the station path step is generated;

[0008] Step four: install the first row of supporting rollers; based on the installation parameters of the first row, the supporting rollers are grabbed and transported to the predetermined installation point one; the installation of the first supporting roller is completed by manual traction; based on the spatial position and attitude of the supporting rollers, the installation of the remaining two supporting rollers of the first row is automatically completed;

[0009] Step five: install the second row of supporting rollers; based on the installation parameters of the second row, the supporting rollers are grabbed and transported to the predetermined installation point two; based on the positional relationship between the first and second row of supporting roller brackets, the installation of the two supporting rollers of the second row is automatically completed;

[0010] Step six: install the third row of supporting rollers; based on the installation parameters of the third row, the supporting rollers are grabbed and transported to the predetermined installation point three; based on the positional relationship between the first and third row of supporting roller brackets, the installation of the three supporting rollers of the third row is automatically completed;

[0011] Step seven: install the supporting rollers of the next station; the auxiliary work robot first automatically calculates the position of the next station according to the station path step, then automatically moves to the position of the next station, and then repeats steps four to six;

[0012] Step eight: install the supporting rollers of all remaining installation stations; steps seven are repeatedly executed multiple times until the installation of the supporting rollers of all remaining installation stations is completed.

[0013] Further, in order to achieve accurate positioning of the initial station, in step two, the positioning process of the initial station is as follows: first, remotely control the auxiliary work robot to move to the initial station and ensure that the crawler chassis is parallel to the longitudinal beam of the rack; then adjust the position of the six-degree-of-freedom robot arm using a laser range finder to ensure that the center of the six-degree-of-freedom robot arm is aligned with the center line of the H-frame, and at the same time, ensure that the work coverage range of the auxiliary work robot meets the installation requirements of the three rows of supporting rollers;

[0014] The initial parameters of the auxiliary work robot include the speed and stroke range of the telescopic support table, the traction force threshold and the dragging speed of the six-degree-of-freedom robot arm, wherein the telescopic support table is slidingly installed on the crawler chassis of the auxiliary work robot, and a base is rotatably installed on the telescopic support table, the speed of the telescopic support table is set to 0.2 m / s, and the stroke range of the telescopic support table is 0.8-1.2 m; the six-degree-of-freedom robot arm is movably installed on the base, and the traction force threshold of the six-degree-of-freedom robot arm is set to 8-15 N, and the dragging speed is set to 0.3 m / s.

[0015] Further, in order to accurately calibrate the installation parameters and ensure the accuracy of the station path step, in step three, the process of installation parameter calibration and station path step generation is as follows:

[0016] S31: Trigger the robot control module to switch from trajectory planning motion control to human-robot collaborative compliant control mode by manually pulling the six-degree-of-freedom robot arm, and use the six-axis force sensor to collect real-time force information and dynamically adjust the robot stiffness to realize the calibration of the first row installation parameters; Set the robot origin one, the robot origin two, the installation avoidance position, the predetermined installation point one and the predetermined grabbing point of the roller stacking area as the first row installation parameters in turn, and make the auxiliary working robot automatically record each position point and sequence to generate the first row installation parameters; wherein the robot origin one is the end of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table; the robot origin two is the middle section of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table; the installation avoidance position is located outside the current installation area within a range of 30-50 cm; the predetermined installation point one is located above the center area of the first row of roller supports; the predetermined grabbing point is located above the roller stack; wherein the six-axis force sensor is fixedly installed in the six-degree-of-freedom robot arm;

[0017] S32: Rotate the base counterclockwise by 90 degrees, and fine-tune the joint angles of the six-degree-of-freedom robot arm, at the same time, reuse the robot origin two, the installation avoidance position and the predetermined grabbing point in the first row installation parameters, and make the predetermined installation point two located above the center area of the second row of roller supports, and generate the second row installation parameters combined with the structure and size of the belt conveyor;

[0018] S33: Rotate the base counterclockwise by 90 degrees again, and fine-tune the joint angles of the six-degree-of-freedom robot arm, at the same time, reuse the predetermined grabbing point in the first row installation parameters, obtain the robot origin three by referring to the row distance of the roller support and the robot origin two, and make the predetermined installation point three located above the center area of the third row of roller supports, and generate the third row installation parameters combined with the structure and size of the belt conveyor; wherein the robot origin three is the first end of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table;

[0019] S34: Automatically generate the work station path step distance according to the initial work station position parameters and the H-frame standard row distance.

[0020] Further, in order to efficiently and accurately realize the installation work of the first row of rollers, in step four, the process of installing the first row of rollers is as follows:

[0021] S41: reset the six-degree-of-freedom robot arm to the robot arm origin one, control the six-degree-of-freedom robot arm to start the carrying process based on the first row setting installation parameters, drive the six-degree-of-freedom robot arm to move from the robot arm origin one to the robot arm origin two through the transverse movement of the telescopic support table, then make the six-degree-of-freedom robot arm move to the predetermined grabbing point, then identify and position the carrier roller at the predetermined grabbing point by using the 3D vision camera, automatically plan the grabbing path, and complete the grabbing operation of the carrier roller; then, the six-degree-of-freedom robot arm returns to the robot arm origin two, and then drives the six-degree-of-freedom robot arm to move from the robot arm origin two to the robot arm origin one through the telescopic support table; wherein the 3D vision camera is fixedly installed at the end of the six-degree-of-freedom robot arm; the 3D vision camera is an anti-dust industrial-grade RGB-D camera with a built-in active infrared light source;

[0022] S42: drive the six-degree-of-freedom robot arm to move to the predetermined installation point one through the telescopic action in the longitudinal direction of the telescopic support table;

[0023] S43: complete the installation operation of the first carrier roller by manually pulling the six-degree-of-freedom robot arm;

[0024] S44: based on the relative position relationship of the installation of the first row of three carrier rollers, the auxiliary work robot automatically calculates the spatial position and attitude of the remaining two carrier rollers in the first row, and automatically completes the installation operation of the remaining two carrier rollers in the first row.

[0025] Further, in order to efficiently and accurately realize the installation operation of the second row of carrier rollers, in step five, the process of installing the second row of carrier rollers is as follows:

[0026] S51: reset the six-degree-of-freedom robot arm to the robot arm origin two, control the six-degree-of-freedom robot arm to start the carrying process based on the second row setting installation parameters, the telescopic support table does not act in the transverse direction, the six-degree-of-freedom robot arm directly moves from the robot arm origin two to the predetermined grabbing point, then identifies and positions the carrier roller at the predetermined grabbing point by using the 3D vision camera, automatically plans the grabbing path, and completes the grabbing operation of the carrier roller;

[0027] S52: drive the six-degree-of-freedom robot arm to move to the predetermined installation point two through the telescopic action in the longitudinal direction of the telescopic support table;

[0028] S53: based on the relative position relationship of the installation of the first row of three carrier rollers and the second row of two carrier rollers, the auxiliary work robot automatically calculates the spatial position and attitude of the two carrier rollers in the second row, and automatically completes the installation operation of the two carrier rollers in the second row.

[0029] Further, in order to efficiently and accurately realize the installation operation of the third row of carrier rollers, in step six, the process of installing the third row of carrier rollers is as follows:

[0030] S61: reset the six-degree-of-freedom robot arm to the robot arm origin three, control the six-degree-of-freedom robot arm to start the carrying process based on the third row setting installation parameters, drive the six-degree-of-freedom robot arm to move from the robot arm origin three to the robot arm origin two through the transverse movement of the telescopic support table, then make the six-degree-of-freedom robot arm move to the predetermined grabbing point, then identify and position the roller located at the predetermined grabbing point by using the 3D vision camera, automatically plan the grabbing path, and complete the grabbing work of the roller; then, the six-degree-of-freedom robot arm returns to the robot arm origin two, and then drives the six-degree-of-freedom robot arm to move from the robot arm origin two to the robot arm origin three through the telescopic support table;

[0031] S62: the telescopic support table drives the six-degree-of-freedom robot arm to move to the predetermined installation point three through the telescopic action in the longitudinal direction;

[0032] S63: based on the relative position relationship between the first row of three rollers and the third row of three rollers, the auxiliary work robot automatically calculates the spatial position and attitude of the third row of three rollers, and automatically completes the installation work of the third row of three rollers.

[0033] Further, in order to effectively ensure that the robot arm can timely conform to the external environment when a collision occurs during movement, enhance safety and adaptability, and at the same time, better apply to artificial traction working conditions, in step three S31, when the six-degree-of-freedom robot arm is manually dragged, the compliance control module synchronously controls the stiffness of the six-degree-of-freedom robot arm, so that the six-degree-of-freedom robot arm is easy to drag; wherein the compliance control module is fixedly installed in the six-degree-of-freedom robot arm, and the compliance control module is controlled by using the mobility control method, wherein a mobility control model is established according to formula (1);

[0034] (1) ;

[0035] In the formula, M is a mass constant, ranging from ; is an acceleration deviation; B is a damping constant, ranging from ; is a speed deviation; K is a stiffness constant, ranging from ; is the actual position and target position deviation, which is used to control the displacement of the end pose of the six-degree-of-freedom robot arm; is the external force deviation, which is obtained by detecting the force of the end of the six-degree-of-freedom robot arm.

[0036] Further, in order to ensure the safety of the work, in step four, the work personnel is located in the safety area, and the safety area is the area between the first row of rollers in the previous work station and the current work station.

[0037] Further, in order to efficiently and accurately identify and position the carrier roller, in step four S41, during the identification and positioning process of the 3D vision camera, the point cloud data of the carrier roller in the predetermined grabbing point is collected through multi-angle scanning, the dust outliers are removed through radius filtering, then the point cloud is segmented into independent objects through Euclidean clustering, the carrier roller pose information is identified and calculated through RANSAC cylindrical fitting, finally, the carrier roller pose is output at a frequency of 10Hz and published to the robot control module through the ROS topic, triggering the robot control module to re-plan the grabbing path; during the identification and positioning process, when the identification fails for three consecutive frames, the six-degree-of-freedom robot is reset and the audible and visual alarm is triggered, the set voice is played to remind the artificial to confirm whether the carrier roller is stacked within the predetermined grabbing point range, if not, the carrier roller is stacked within the predetermined grabbing point range, then the carrying process is restarted or switched to manual operation mode.

[0038] As a preferred, in step seven, the nth new station position is calculated according to formula (2), and then the actual distance of the H frame is measured by using the laser range finder after reaching the next station position , if , the 3D vision repositioning compensation is started, and the set installation parameters of the initial station are called, the new path is generated through the homogeneous transformation matrix, as shown in formula (3);

[0039] (2) ;

[0040] In the formula, is the standard distance of the H frame, ranging from 1.5 to 3 meters; 、 、 are the X-axis, Y-axis and Z-axis coordinates of the initial station in the reference coordinate system respectively;

[0041] (3) ;

[0042] In the formula, is the set installation parameter coordinate system transformation matrix of the initial station, is the nth new station position coordinate system transformation matrix; is the station number.

[0043] The application provides a man-machine cooperation installation method for a carrier roller in a belt conveyor, which can fully exert the advantage of a tracked chassis in adapting to various terrains to ensure the versatility of the installation method, can ensure that the robot can timely adapt to the external environment when a collision occurs during movement, and can enhance safety and adaptability, facilitate manual traction for installation parameter calibration and teaching programming, and can fully exert the advantages of a 3D vision camera in high recognition efficiency and high recognition accuracy to realize efficient and accurate grabbing of the carrier roller to be grabbed. Specifically, first, manual traction is used for installation parameter calibration of the first row of carrier rollers to be installed, so that parameter information of key nodes of the first row of carrier rollers can be obtained, thereby providing key reference point information for an auxiliary operation robot, so that only the first row of carrier rollers needs to be calibrated for installation parameters, and part of the installation parameters of the second row of carrier rollers and the third row of carrier rollers can directly use the parameter information of the first row of carrier rollers, and the other part of the installation parameters can be directly calculated based on the installation parameters calibrated by the first row and the structure size of the belt conveyor support, thereby greatly improving the calibration efficiency of the installation parameters. Then, the carrying process is started, the carrier roller is identified and grabbed by the robot combined with the 3D video module, the carrying operation is performed according to the preset installation parameter path, and the final fine adjustment installation operation is completed by manual traction, thereby realizing a man-machine efficient cooperation operation mode, improving the installation efficiency of the carrier roller, effectively reducing the labor intensity of the workers, effectively reducing the possibility of injury of the workers, and improving the safety factor in the operation process. In addition, different installation strategies are adopted for the upper and lower carrier rollers, the upper carrier roller adopts a "robot + telescopic platform horizontal movement + telescopic platform vertical movement" extended installation range, the lower carrier roller adopts a "robot + telescopic platform vertical movement" direct installation mode, and the 3D vision is combined to solve the carrier roller positioning problem under low light and dust interference in the underground mine.

[0044] The method realizes accurate grabbing and efficient carrying of the carrier roller by using a movable robot platform + visual positioning + compliant control, and finally realizes fine adjustment installation by manual operation, thereby realizing a man-machine efficient cooperation operation mode. The method can realize efficient installation of eight carrier rollers, including two rows of upper carrier rollers and one row of lower carrier rollers, in one station, and effectively solves the problem of initial installation of the carrier roller in the belt conveyor in the underground mine. BRIEF DESCRIPTION OF DRAWINGS

[0045] Figure 1 An operation process of installing a carrier roller on a rack by using an auxiliary operation robot Figure 1 ;

[0046] Figure 2 An operation process of installing a carrier roller on a rack by using an auxiliary operation robot Figure 2 ;

[0047] Figure 3 This is a flowchart of the present invention.

[0048] In the diagram: 1. Frame, 2. Auxiliary robot, 3. H-frame, 4. Longitudinal beam, 5. Roller support, 6. Tracked chassis, 7. Telescopic support platform, 8. Base, 9. Six-DOF robotic arm, 10. Roller, 11. Pre-installation point one, 12. Pre-grabbing point, 13. Pre-installation point two, 14. Pre-installation point three, 15. Robotic arm origin one, 16. Robotic arm origin two, 17. Robotic arm origin three. Detailed Implementation

[0049] The present invention will be further described below with reference to the embodiments.

[0050] like Figures 1 to 3 As shown, the present invention provides a method for installing idler rollers of a human-machine collaborative belt conveyor in underground coal mines, which uses an auxiliary operation robot with human-machine collaborative function;

[0051] The conveyor frame 1 includes multiple H-frames 3 arranged sequentially along the conveying direction, two longitudinal beams 4 fixedly installed on the upper ends of the multiple H-frames 3, and multiple rows of idler supports 5 fixedly installed between the two longitudinal beams 4 along the conveying direction. The multiple rows of idler supports 5 include multiple rows of upper idler supports and multiple rows of lower idler supports. The multiple rows of upper idler supports are at the same height, the multiple rows of lower idler supports are at the same height, and each row of lower idler supports is located below the adjacent two rows of upper idler supports. The upper idler supports are provided with three idler mounting positions, and the lower idler supports are provided with two idler mounting positions.

[0052] The auxiliary operation robot 2 includes a tracked chassis 6, a telescopic support platform 7 slidably mounted on the tracked chassis 6, a base 8 rotatably mounted on the telescopic support platform 7, a six-degree-of-freedom robotic arm 9 movably mounted on the base 8, a 3D vision camera fixedly mounted at the end of the six-degree-of-freedom robotic arm 9, and a six-dimensional force sensor and a compliant control module fixedly mounted in the six-degree-of-freedom robotic arm 9. The six-dimensional force sensor is used to collect the force data of the six-degree-of-freedom robotic arm 9. The tracked chassis, six-degree-of-freedom robotic arm, and image recognition collaborative technology architecture of the auxiliary operation robot 2 support the generation of operation paths through manual teaching and the recording of key point data.

[0053] The method includes the following steps:

[0054] Step 1: Dividing the installation workstations;

[0055] The installation area on the frame 1 is divided into multiple installation stations along the conveying direction. Each installation station contains three rows of continuously distributed idler roller brackets 5, and the first installation station in the conveying direction is used as the initial station.

[0056] Wherein, the two rows of supporting rollers 5 at the length direction of each installation station are upper supporting roller supports, and three supporting rollers 10 are needed to be installed in each row of upper supporting roller supports, and one row of supporting rollers 5 at the middle of the length direction of each installation station is a lower supporting roller support, and two supporting rollers 10 are needed to be installed in the lower supporting roller support;

[0057] Step two: positioning of the initial station and setting of initial parameters; the auxiliary work robot is moved to a position aligned with the initial station to complete the positioning of the initial station, and the initial parameters of the auxiliary work robot are set, including the speed and stroke range of the telescopic support table, the traction force threshold and the dragging speed of the six-degree-of-freedom mechanical arm;

[0058] The positioning process of the initial station is as follows: first, remotely control the auxiliary work robot 2 to move to the initial station, and ensure that the crawler chassis 6 is parallel to the longitudinal beam 4 of the rack 1; then adjust the position of the six-degree-of-freedom mechanical arm 9 using the laser range finder to ensure that the center of the six-degree-of-freedom mechanical arm 9 is aligned with the center line of the H-frame 3, and at the same time, ensure that the work coverage range of the auxiliary work robot 2 meets the installation requirements of the three rows of supporting rollers 10;

[0059] Step three: installation parameter calibration and generation of station path step distance;

[0060] The first row of set installation parameters are generated by manually dragging the six-degree-of-freedom mechanical arm 9, the second and third rows of set installation parameters are generated based on the first row of set installation parameters and combined with the structure size of the belt conveyor support, and the station path step distance is generated, and the specific process is as follows:

[0061] S31: manually pull the six-degree-of-freedom mechanical arm 9 to trigger the mechanical arm control module to switch from trajectory planning motion control to human-machine collaborative compliant control mode, use the six-dimensional force sensor to collect real-time force information and dynamically adjust the mechanical arm stiffness to realize the calibration of the first row of installation parameters; set the mechanical arm origin one 15, the mechanical arm origin two 16, the installation avoidance position, the predetermined installation point one 11 and the predetermined grabbing point 12 of the supporting roller 10 stacking area as the first row of installation parameters in turn, and make the auxiliary work robot 2 automatically record the position points and order to generate the first row of set installation parameters;

[0062] Wherein, the mechanical arm origin one 15 is the position of the telescopic support table 7 at the end of the length direction of the auxiliary work robot 2, and the base 8 is located at the center above the telescopic support table 7; the mechanical arm origin two 16 is the position of the telescopic support table 7 at the middle of the length direction of the auxiliary work robot 2, and the base 8 is located at the center above the telescopic support table 7; the installation avoidance position is located outside the current installation area within a range of 30-50 cm; the predetermined installation point one 11 is located above the center area of the first row of supporting roller supports 5; and the predetermined grabbing point 12 is located above the supporting roller stack;

[0063] In order to improve the installation efficiency of the carrier roller, and also to better save the physical strength of the workers, the mechanical arm origin 15 is located on the extension line of the length direction of the first row of carrier roller support 5, and the six-degree-of-freedom mechanical arm 9 is located 20 cm above the base 8; the mechanical arm origin 16 is located on the extension line of the length direction of the second row of carrier roller support 5, and the six-degree-of-freedom mechanical arm 9 is located 20 cm above the base 8; the predetermined installation point 11 is located 30 cm above the center area of the first row of carrier roller support 5; and the predetermined grabbing point 12 is 30 cm above the carrier roller 10 stack;

[0064] S32: The base 8 is counterclockwise rotated by 90 degrees, and the joint angle of the six-degree-of-freedom mechanical arm 9 is finely adjusted, so that the predetermined installation point two 13 is located above the center area of the second row of carrier roller support 5, and the mechanical arm origin two 16 and the predetermined grabbing point 12 in the first row of setting installation parameters are reused, and the second row of setting installation parameters is generated in combination with the structure and size of the belt conveyor;

[0065] In order to improve the installation efficiency of the carrier roller, and also to better save the physical strength of the workers, the predetermined installation point two 13 is located 30 cm above the center area of the second row of carrier roller support 5;

[0066] S33: The base 8 is counterclockwise rotated by 90 degrees again, and the joint angle of the six-degree-of-freedom mechanical arm 9 is finely adjusted, so that the predetermined installation point three 14 is located above the center area of the third row of carrier roller support 5, and the mechanical arm origin two 16 and the predetermined grabbing point 12 in the first row of setting installation parameters are reused, the mechanical arm origin three 17 is obtained by referring to the row distance of the carrier roller support 5 and the mechanical arm origin two 16, and the third row of setting installation parameters is generated in combination with the structure and size of the belt conveyor; wherein the mechanical arm origin three 17 is the first end of the telescopic support table 7 in the length direction of the auxiliary work robot 2, and the base 8 is located above the center of the telescopic support table 7;

[0067] In order to improve the installation efficiency of the carrier roller, and also to better save the physical strength of the workers, the predetermined installation point three 14 is located 30 cm above the center area of the third row of carrier roller support 5, the mechanical arm origin three 17 is located on the extension line of the length direction of the third row of carrier roller support 5, and the six-degree-of-freedom mechanical arm 9 is located 20 cm above the base 8.

[0068] S34: The work station path step is automatically generated according to the initial work station position parameter and the H frame 3 standard row distance;

[0069] Step four: install the first row of carrier roller 10;

[0070] The first row of rollers 10 is grabbed based on the first row of setting installation parameters, and is transported to the predetermined installation point one; the installation of the first roller 10 is completed by manual traction; the installation of the remaining two rollers 10 in the first row is automatically completed based on the spatial position and attitude of the rollers 10, and the specific process is as follows:

[0071] S41: The six-degree-of-freedom robot arm 9 is reset to the robot arm origin one 15, the six-degree-of-freedom robot arm 9 is controlled to start the carrying process based on the first row of setting installation parameters, the six-degree-of-freedom robot arm 9 is moved from the robot arm origin one 15 to the robot arm origin two 16 through the transverse movement of the telescopic support table 7, and then the six-degree-of-freedom robot arm 9 is moved to the predetermined grabbing point 12; then, the 3D vision camera is used to identify and position the roller 10 located at the predetermined grabbing point 12, and the grabbing path is automatically planned to complete the grabbing of the roller 10; then, the six-degree-of-freedom robot arm 9 returns to the robot arm origin two 16, and then the six-degree-of-freedom robot arm 9 is moved from the robot arm origin two 16 to the robot arm origin one 15 through the telescopic support table 7;

[0072] S42: The telescopic support table 7 drives the six-degree-of-freedom robot arm 9 to move to the predetermined installation point one 11 through the telescopic action in the longitudinal direction;

[0073] S43: The installation of the first roller 10 is completed by manually pulling the six-degree-of-freedom robot arm 9;

[0074] S44: Based on the relative position relationship of the installation of the three rollers 10 in the first row, the auxiliary work robot 2 automatically calculates the spatial position and attitude of the remaining two rollers 10 in the first row, and automatically completes the installation of the remaining two rollers 10 in the first row;

[0075] Step five: install the second row of rollers 10;

[0076] The second row of rollers 10 is grabbed based on the second row of setting installation parameters, and is transported to the predetermined installation point two; based on the position relationship of the first and second rows of roller supports 5, the installation of the two rollers 10 in the second row is automatically completed, and the specific process is as follows:

[0077] S51: The six-degree-of-freedom robot arm 9 is reset to the robot arm origin two 16, the six-degree-of-freedom robot arm 9 is controlled to start the carrying process based on the second row of setting installation parameters, the telescopic support table 7 does not act in the transverse direction, and the six-degree-of-freedom robot arm 9 is directly moved from the robot arm origin two 16 to the predetermined grabbing point 12; then, the 3D vision camera is used to identify and position the roller 10 located at the predetermined grabbing point 12, and the grabbing path is automatically planned to complete the grabbing of the roller 10;

[0078] S52: The telescopic support table 7 drives the six-degree-of-freedom robot arm 9 to move to the predetermined installation point two 13 through the telescopic action in the longitudinal direction;

[0079] S53: Based on the relative position relationship between the first row of three idler rollers 10 and the second row of two idler rollers 10, the auxiliary work robot 2 automatically calculates the spatial position and attitude of the second row of two idler rollers 10 and automatically completes the installation work of the second row of two idler rollers 10;

[0080] Step six: Install the third row of idler rollers 10;

[0081] Based on the installation parameters set for the third row, the idler rollers 10 are grabbed and transported to the predetermined installation point three; based on the position relationship of the first and third rows of idler roller supports 5, the installation work of the third row of three idler rollers 10 is automatically completed, and the specific process is as follows:

[0082] S61: The six-degree-of-freedom robot arm 9 is reset to the robot arm origin three 17, and the six-degree-of-freedom robot arm 9 is controlled to start the carrying process based on the installation parameters set for the third row. The six-degree-of-freedom robot arm 9 is moved to the robot arm origin two 16 through the transverse movement of the telescopic support table 7, and then the six-degree-of-freedom robot arm 9 is moved to the predetermined grabbing point 12. Then, the 3D vision camera is used to identify and locate the idler roller 10 located at the predetermined grabbing point 12, and the grabbing path is automatically planned to complete the grabbing work of the idler roller 10. Then, the six-degree-of-freedom robot arm 9 returns to the robot arm origin two 16, and then the six-degree-of-freedom robot arm 9 is moved from the robot arm origin two 16 to the robot arm origin three 17 through the telescopic support table 7;

[0083] S62: The telescopic support table 7 drives the six-degree-of-freedom robot arm 9 to move to the predetermined installation point three 14 through the telescopic action in the longitudinal direction;

[0084] S63: Based on the relative position relationship between the first row of three idler rollers 10 and the third row of three idler rollers 10, the auxiliary work robot 2 automatically calculates the spatial position and attitude of the third row of three idler rollers 10 and automatically completes the installation work of the third row of three idler rollers 10;

[0085] Step seven: Install the idler roller 10 of the next work station;

[0086] The auxiliary work robot 2 automatically calculates the next work station position according to the work station path step distance, and then automatically moves to the next work station position. Then, steps four to six are repeatedly executed;

[0087] Step eight: Install the idler rollers 10 of all remaining installation work stations;

[0088] Step seven is repeatedly executed multiple times until the installation work of the idler rollers 10 of all remaining installation work stations is completed.

[0089] In order to effectively ensure that the robot arm can timely conform to the external environment when a collision occurs in motion, enhance safety and adaptability, and also to better apply to artificial traction working conditions, the compliance control module adopts a mobility control method for control, wherein a mobility control model is established according to formula (1);

[0090] (1);

[0091] In the formula, M is a mass constant, ranging from ; is an acceleration deviation; B is a damping constant, ranging from ; is a speed deviation; K is a rigidity constant, ranging from ; is a position deviation between the actual position and the target position, used to control the displacement of the end pose of the six-degree-of-freedom robot arm 9; is an external force deviation, obtained by detecting the force on the end of the six-degree-of-freedom robot arm 9, and the position of the six-degree-of-freedom robot arm 9 is controlled by obtaining the position deviation, thereby realizing the collision compliance of the six-degree-of-freedom robot arm 9, and having a dynamic adjustment mechanism. When the drag force is less than 10N, it does not respond; when the drag force is greater than 15N, the movement speed is reduced by 50%; when the drag force is greater than 25N, the robot arm action is paused; when the detected collision force exceeds 50N, the compliance control module triggers an emergency brake, and the brake response time is not more than 0.1s. The robot path calibration problem in the low-precision environment of the coal mine is solved by manually dragging the teaching and adding the compliance control module.

[0092] In order to efficiently and accurately identify and position the rollers, the 3D vision camera is an anti-dust industrial-grade RGB-D camera with a built-in active infrared light source, which can effectively penetrate the low-illumination environment and dust interference in the underground mine. During the identification and positioning process of the 3D vision camera, the point cloud data (XYZRGB point cloud) of the rollers 10 in the predetermined grabbing point 12 is first collected through multi-angle scanning, then the dust outliers are removed through radius filtering, then the point cloud is segmented into independent objects through Euclidean clustering, then the roller 10 pose information is identified and calculated through RANSAC cylindrical fitting, and finally the roller 10 pose is output at a frequency of 10Hz and published to the robot arm control module through the ROS topic, triggering the robot arm control module to re-plan the grabbing path. During the identification process, when the identification fails for 3 consecutive frames, the six-degree-of-freedom robot arm 9 is reset and an audible and visual alarm is triggered. The set voice is played to remind the artificial to confirm whether the rollers 10 are stacked within the predetermined grabbing point 12 range. If not, the rollers 10 are stacked within the predetermined grabbing point 12 range, and then the carrying process is restarted or switched to a manual operation mode.

[0093] As a preferred, in step two, the speed of the telescopic support table 7 is set to 0.2 m / s, and the stroke range of the telescopic support table 7 is 0.8-1.2 m. As a preferred, in step two, the traction force threshold of the six-degree-of-freedom robot arm 9 is set to 8-15 N, so that the six-degree-of-freedom robot arm 9 is not responsive below 8 N, triggers overload protection above 15 N, and slows down by 50% when exceeding 15 N, and pauses the action of the six-degree-of-freedom robot arm 9 when exceeding 25 N. In addition, the dragging speed is set to 0.3 m / s. In this way, the safety factor in the human-robot collaboration process can be effectively ensured. In order to effectively save the physical strength of the operating personnel, in S31 of step three, when manually dragging the six-degree-of-freedom robot arm 9, the compliance control module synchronously controls the stiffness of the six-degree-of-freedom robot arm 9, so that the six-degree-of-freedom robot arm is easy to drag. In order to enable the operating personnel to pull the six-degree-of-freedom robot arm and perform the installation operation of the carrier roller in the corresponding safety area according to different installation conditions, so as to ensure the safety factor of himself, in step four, the operating personnel is located in the safety area, and the safety area is the area between the first row of carrier rollers in the previous station and the current station.

[0094] In order to comprehensively obtain the point cloud data of the carrier roller, in steps four to six, the 3D vision camera scans at a variable angle.

[0095] In order to accurately and efficiently obtain the position parameters of the new station, in step seven, the nth new station position is first calculated according to formula (2), and then when reaching the next station position, the actual travel distance of the H frame 3 is measured by using the laser range finder , if , the 3D vision repositioning compensation is started, and at the same time, the set installation parameters of the initial station are called, and a new path is generated through the homogeneous transformation matrix, as shown in formula (3);

[0096] (2);

[0097] In the formula, is the standard travel distance of the H frame 3, ranging from 1.5 to 3 meters; , , are the X-axis, Y-axis, and Z-axis coordinates of the initial station in the reference coordinate system, respectively;

[0098] (3);

[0099] In the formula, is the set installation parameter coordinate system transformation matrix of the initial station, is the nth new station position coordinate system transformation matrix; is the station number.

[0100] ​The application adopts a tracked chassis, combines a compliant control mechanical arm scheme, fuses a 3D vision camera to solve the identification and positioning of the carrier roller, and proposes a human-machine cooperation installation method for the carrier roller in the belt conveyor. On the one hand, the tracked chassis can fully exert the advantage of adapting to various terrains to ensure the universality of the installation method. On the other hand, the mechanical arm can timely adapt to the external environment when a collision occurs during movement, thereby enhancing safety and adaptability. Meanwhile, it is convenient for manual traction to calibrate installation parameters and teach programming. In addition, the 3D vision camera can fully exert the advantages of high identification efficiency and high identification precision to realize efficient and accurate grabbing of the carrier roller. Specifically, first, manual traction is used to calibrate the installation parameters of the first row of carrier rollers to obtain the parameter information of each key node of the first row of carrier rollers. Thus, the key reference point information can be provided for the auxiliary operation robot. In this way, only the first row of carrier rollers needs to be calibrated for installation parameters. Part of the installation parameters of the second row of carrier rollers and the third row of carrier rollers can directly use the parameter information of the first row of carrier rollers, and the other part of the installation parameters can be directly calculated based on the installation parameters of the first row of carrier rollers and the structure size of the belt conveyor support, thereby greatly improving the calibration efficiency of the installation parameters. Next, the carrying process is started, the mechanical arm combined with the 3D video module completes the carrier roller identification and grabbing operation, and then the carrying operation is performed according to the preset installation parameter path. Finally, the manual traction completes the final fine-tuning installation operation, realizes the efficient human-machine cooperation operation mode, improves the installation efficiency of the carrier roller, effectively reduces the labor intensity of the workers, and effectively reduces the possibility of worker injury, thereby improving the safety factor during the operation process. In addition, different installation strategies are adopted for the upper and lower carrier rollers. The upper carrier roller adopts the “mechanical arm + telescopic platform horizontal movement + telescopic platform vertical movement” extended installation range, and the lower carrier roller adopts the “mechanical arm + telescopic platform vertical movement” direct installation method. Meanwhile, the 3D vision solves the positioning problem of the carrier roller under low light and dust interference in the underground mine.

[0101] The method realizes accurate grabbing and efficient carrying operation of the carrier roller through the movable robot platform + visual positioning + compliant control, and finally realizes the fine-tuning installation by manual operation, thereby realizing the efficient human-machine cooperation operation mode. The method can realize efficient installation of eight carrier rollers, i.e., two rows of upper carrier rollers (first row and third row, each row has three carrier roller installation positions) and one row of lower carrier rollers (second row, the second row has two carrier roller installation positions), thereby effectively solving the initial installation difficulty of the carrier roller in the belt conveyor in the underground coal mine.

Claims

1. A coal mine underground man-machine collaborative belt conveyor roller installation method, an auxiliary work robot with man-machine collaboration function is used, the frame of the conveyor comprises a plurality of H frames distributed in sequence along the conveying direction, two longitudinal beams fixedly installed on the upper ends of the plurality of H frames, and a plurality of rows of roller supports fixedly installed in sequence along the conveying direction between the two longitudinal beams; the plurality of rows of roller supports comprise a plurality of rows of upper roller supports and a plurality of rows of lower roller supports; the heights of the plurality of rows of upper roller supports are the same, the heights of the plurality of rows of lower roller supports are the same, and each row of lower roller supports is located below the adjacent two rows of upper roller supports; three roller installation positions are arranged on the upper roller support, and two roller installation positions are arranged on the lower roller support; the auxiliary work robot comprises a tracked chassis, a telescopic support platform slidably installed on the tracked chassis, a base rotatably installed on the telescopic support platform, a six-degree-of-freedom mechanical arm movably installed on the base, a 3D vision camera fixedly installed at the end of the six-degree-of-freedom mechanical arm, and a six-dimensional force sensor and a compliant control module fixedly installed in the six-degree-of-freedom mechanical arm, the six-dimensional force sensor is used to collect force data of the six-degree-of-freedom mechanical arm; characterized in that, The installation method comprises the following steps: Step one: division of installation stations; the installation area on the rack is divided into multiple installation stations along the conveying direction, each installation station comprising three rows of supporting frames of supporting rollers which are distributed continuously, and the first installation station in the conveying direction is used as an initial station; Step two: positioning of the initial station and setting of initial parameters; the auxiliary work robot is moved to a position aligned with the initial station to complete positioning of the initial station; initial parameters of the auxiliary work robot are set; Step three: installation parameter calibration and generation of station path step distance; the first row of installation parameters is generated by manually dragging the six-degree-of-freedom robot arm, the second and third rows of installation parameters are generated based on the first row of installation parameters and in combination with the structure size of the belt conveyor support frame, and the station path step distance is generated; Step four: installation of the first row of supporting rollers; the supporting rollers are grabbed based on the first row of installation parameters and are conveyed to a predetermined installation point one; the installation of the first supporting roller is completed by manual traction; the installation of the remaining two supporting rollers in the first row is automatically completed based on the spatial position and attitude of the supporting rollers; Step five: installation of the second row of supporting rollers; the supporting rollers are grabbed based on the second row of installation parameters and are conveyed to a predetermined installation point two; the installation of the two supporting rollers in the second row is automatically completed based on the positional relationship between the supporting roller supports in the first and second rows; Step six: installation of the third row of supporting rollers; the supporting rollers are grabbed based on the third row of installation parameters and are conveyed to a predetermined installation point three; the installation of the three supporting rollers in the third row is automatically completed based on the positional relationship between the supporting roller supports in the first and third rows; Step seven: installation of the supporting rollers of the next station; the auxiliary work robot automatically calculates the position of the next station according to the station path step distance, automatically moves to the position of the next station, and then repeats steps four to six; Step eight: installation of the supporting rollers of all remaining installation stations; steps seven are repeatedly executed multiple times until the installation of the supporting rollers of all remaining installation stations is completed.

2. The method according to claim 1, characterized in that, In step two, the positioning process of the initial station is as follows: the auxiliary work robot is first remotely moved to the initial station and is ensured to be parallel to the longitudinal beams of the rack; then the position of the six-degree-of-freedom robot arm is adjusted by using a laser range finder to ensure that the center of the six-degree-of-freedom robot arm is aligned with the center line of the H frame, and at the same time, the work coverage range of the auxiliary work robot is ensured to meet the installation requirements of the three rows of supporting rollers; The initial parameters of the auxiliary work robot include the speed and stroke range of the telescopic support table, the traction force threshold and dragging speed of the six-degree-of-freedom robot arm, wherein the speed of the telescopic support table is set to 0.2 m / s, the stroke range of the telescopic support table is 0.8-1.2 m, the traction force threshold of the six-degree-of-freedom robot arm is set to 8-15 N, and the dragging speed is set to 0.3 m / s.

3. The method according to claim 2, characterized in that, In step three, the process of installation parameter calibration and generation of station path step distance is as follows: S31: by manual traction six degrees of freedom mechanical arm, trigger the mechanical arm control module is switched from trajectory planning motion control to human-robot collaborative compliant control mode, real-time acquisition of force information by six-axis force sensor and dynamic adjustment of mechanical arm stiffness, realize the first row of installation parameter calibration; sequentially set the mechanical arm origin one, the mechanical arm origin two, the installation avoidance position, the predetermined installation point one and the predetermined grabbing point of the roller stacking area as the first row of installation parameters, and make the auxiliary working robot automatically record each position point and sequence, generate the first row of setting installation parameters; wherein, the mechanical arm origin one is the end of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table; the mechanical arm origin two is the middle section of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table; the installation avoidance position is located outside the current installation area 30~50cm; the predetermined installation point one is located above the center area of the first row of roller support; the predetermined grabbing point is located above the roller stack; wherein, the six-axis force sensor is fixedly installed in the six degrees of freedom mechanical arm; S32: rotate the base counterclockwise by 90 degrees, and fine-tune the joint angle of the six degrees of freedom mechanical arm, at the same time, reuse the mechanical arm origin two, the installation avoidance position and the predetermined grabbing point in the first row of setting installation parameters, and make the predetermined installation point two located above the center area of the second row of roller support, and generate the second row of setting installation parameters combined with the structure and size of the belt conveyor; S33: rotate the base counterclockwise by 90 degrees again, and fine-tune the joint angle of the six degrees of freedom mechanical arm, at the same time, reuse the predetermined grabbing point in the first row of setting installation parameters, obtain the mechanical arm origin three by referring to the row distance of the roller support and the mechanical arm origin two, and make the predetermined installation point three located above the center area of the third row of roller support, generate the third row of setting installation parameters combined with the structure and size of the belt conveyor; wherein, the mechanical arm origin three is the first end of the telescopic support table in the length direction of the auxiliary working robot, and the position when the base is located above the center of the telescopic support table; S34: automatically generate the work station path step according to the initial work station position parameters and the H frame standard row distance.

4. The method according to claim 3, characterized in that, In step four, the process of installing the first row of rollers is as follows: S41: make the six degrees of freedom mechanical arm reset to the mechanical arm origin one, control the six degrees of freedom mechanical arm to start the carrying process based on the first row of setting installation parameters, drive the six degrees of freedom mechanical arm to move from the mechanical arm origin one to the mechanical arm origin two through the transverse movement of the telescopic support table, then make the six degrees of freedom mechanical arm move to the predetermined grabbing point, then use the 3D vision camera to identify and locate the roller at the predetermined grabbing point, and automatically plan the grabbing path to complete the grabbing work of the roller; then, the six degrees of freedom mechanical arm returns to the mechanical arm origin two, and then drives the six degrees of freedom mechanical arm to move from the mechanical arm origin two to the mechanical arm origin one through the telescopic support table; wherein, the 3D vision camera is fixedly installed at the end of the six degrees of freedom mechanical arm; the 3D vision camera is an anti-dust industrial grade RGB-D camera with built-in active infrared light source; S42: The telescopic support table drives the six-degree-of-freedom robot to move to a predetermined installation point one through telescopic action in the longitudinal direction; S43: The installation of the first idler is completed by manually dragging the six-degree-of-freedom robot; S44: Based on the relative position relationship of the installation of the first three idlers, the auxiliary work robot automatically calculates the spatial position and attitude of the remaining two idlers in the first row and automatically completes the installation of the remaining two idlers in the first row.

5. The method of installing a belt conveyor idler for use in underground coal mining according to claim 4, wherein, In step five, the process of installing the second row of idlers is as follows: S51: The six-degree-of-freedom robot is reset to the robot origin two, and the six-degree-of-freedom robot is controlled to start the carrying process based on the second row of installation parameters. The telescopic support table does not move in the transverse direction, and the six-degree-of-freedom robot directly moves from the robot origin two to the predetermined grabbing point. Then, the 3D vision camera is used to identify and locate the idler at the predetermined grabbing point, and the grabbing path is automatically planned to complete the grabbing of the idler; S52: The telescopic support table drives the six-degree-of-freedom robot to move to a predetermined installation point two through telescopic action in the longitudinal direction; S53: Based on the relative position relationship of the installation of the first three idlers and the second two idlers, the auxiliary work robot automatically calculates the spatial position and attitude of the second two idlers and automatically completes the installation of the second two idlers.

6. The method of installing a belt conveyor idler for an underground coal mine according to claim 5, characterised in that, In step six, the process of installing the third row of idlers is as follows: S61: The six-degree-of-freedom robot is reset to the robot origin three, and the six-degree-of-freedom robot is controlled to start the carrying process based on the third row of installation parameters. The six-degree-of-freedom robot is moved from the robot origin three to the robot origin two through the transverse movement of the telescopic support table, and then the six-degree-of-freedom robot is moved to the predetermined grabbing point. Then, the 3D vision camera is used to identify and locate the idler at the predetermined grabbing point, and the grabbing path is automatically planned to complete the grabbing of the idler. Then, the six-degree-of-freedom robot returns to the robot origin two, and then the six-degree-of-freedom robot is moved from the robot origin two to the robot origin three through the telescopic support table; S62: The telescopic support table drives the six-degree-of-freedom robot to move to a predetermined installation point three through telescopic action in the longitudinal direction; S63: Based on the relative position relationship of the installation of the first three idlers and the third three idlers, the auxiliary work robot automatically calculates the spatial position and attitude of the third three idlers and automatically completes the installation of the third three idlers.

7. The method of installing a belt conveyor idler for an underground coal mine according to claim 6, characterised in that, In S31 of step three, when the six-degree-of-freedom robot is manually dragged, the compliance control module synchronously controls the stiffness of the six-degree-of-freedom robot, so that the six-degree-of-freedom robot is easy to drag. The compliance control module is fixedly installed in the six-degree-of-freedom robot, and the compliance control module is controlled by using a mobility control method. According to formula (1), a mobility control model is established; （1）； In the formula, M is a mass constant, ranging from ; is an acceleration deviation; B is a damping constant, ranging from ; is a speed deviation; K is a rigidity constant, ranging from ; is a deviation between the actual position and the target position, used to control the offset of the end pose of the six-degree-of-freedom manipulator; is an external force deviation, obtained by detecting the force on the end of the six-degree-of-freedom manipulator.

8. The method of installing a belt conveyor idler for an underground coal mine according to claim 7, characterised in that, In step four, the work personnel is located in a safety area, and the safety area is the area between the first row of idlers in the previous station and the current station.

9. The method of installing a belt conveyor idler for an underground coal mine according to claim 8, characterised in that, In S41 of step four, in the recognition and positioning process of the 3D vision camera, the point cloud data of the idler in the predetermined grabbing point is collected through multi-angle scanning, then the dust outliers are removed through radius filtering, then the point cloud is segmented into independent objects through Euclidean clustering, then the idler pose information is recognized and solved through RANSAC cylindrical fitting, finally, the idler pose is output at a frequency of 10 Hz, and is published to the robot arm control module through the ROS topic, triggering the robot arm control module to re-plan the grabbing path; in the recognition and positioning process, when the recognition fails for 3 consecutive frames, the six-degree-of-freedom robot arm is reset and an audible and visual alarm is triggered, a set voice is played to remind the artificial to confirm whether the idler is stacked within the predetermined grabbing point range, if not, the idler is stacked within the predetermined grabbing point range, and then the carrying process is restarted or switched to a manual operation mode.

10. The method of installing a belt conveyor idler for an underground coal mine according to claim 8, characterised in that, In step seven, the position of the nth new station is calculated according to formula (2), and then the actual distance of the H frame is measured by using a laser range finder when reaching the next station position , if , the 3D vision camera is started to compensate for the repositioning, and at the same time, the setting installation parameters of the initial station are called to generate a new path through a homogeneous transformation matrix, as shown in formula (3); （2）； In the formula, H is the standard row spacing, ranging from 1.5 to 3 meters; , , X, Y, and Z are the coordinates of the initial station in the reference coordinate system, respectively. （3）； In the formula, is the set installation parameter coordinate system transformation matrix of the initial station, is the nth new station position coordinate system transformation matrix; is the station number.

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