Case feeding method and system

Abstract

The invention discloses a case feeding method and system. The method comprises the steps that a skip car of a current feeding station and the state of a case on the skip car are obtained; when it is detected that a case exists on the skip car, the robot is controlled to execute recognition operation or grabbing operation, and the recognition operation comprises the steps that a visual system recognizes the type of the case and recognizes the layer number and the thickness of the case in combination with a distance measuring system; the grabbing operation comprises the steps that clamping jaw parameters are called according to the recognition result of the recognition operation, and the robot is controlled to grab the case to the line body in sequence; when it is detected that the skip car exists but no case exists, the carrying system is controlled to carry the skip car to a sorting area for case loading, and a full load signal is generated after full load; and when the skip car is not detected and a full-load signal is obtained, the carrying system is controlled to carry the full-load skip car to a feeding station. A series of problems of high labor cost, low feeding efficiency, high labor intensity and the like are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic feeding, in particular to a machine case feeding method and system. BACKGROUND

[0002] With the continuous improvement of scientific and technological level, automation production becomes more and more popular. Computers and servers have different types of machine cases, and the size gap of machine cases is large. The current distribution method needs manual cooperation. The sorting operator sorts the machine cases to the trolley, manually pushes the machine cases to the machine case online station, and places the machine cases on the load plate after the empty load plate is in place. The production efficiency is low, and the labor is occupied, which increases the cost of enterprises.

[0003] Therefore, how to improve the efficiency of automatic feeding of machine cases is a problem to be solved by those skilled in the art. SUMMARY

[0004] The purpose of the embodiment of the present application is to provide a machine case feeding method and system, which can solve a series of problems such as high labor cost, low feeding efficiency and high labor intensity.

[0005] To solve the above technical problems, the embodiment of the present application provides a machine case feeding method, which comprises:

[0006] Obtaining the state of the trolley and the machine case on the trolley of the current feeding station;

[0007] When it is detected that there is a machine case on the trolley, controlling the robot to perform an identification operation or a grabbing operation. The identification operation comprises a visual system identifying the type of the machine case, and combining a ranging system to identify the number of layers and the thickness of the machine case. The grabbing operation comprises calling a gripper parameter according to the identification result of the identification operation, and controlling the robot to grab the machine cases to the line body in sequence;

[0008] When it is detected that there is a trolley but no machine case, controlling the handling system to handle the trolley to the sorting area for machine case loading, and generating a full load signal after full loading;

[0009] When no trolley is detected and the full load signal is obtained, controlling the handling system to handle the full load trolley to the feeding station.

[0010] In some embodiments, the step of obtaining the state of the trolley and the machine case on the trolley of the current feeding station comprises:

[0011] Controlling a first level sensor to detect whether there is a trolley in the feeding station, and controlling a second level sensor to detect whether there is a machine case.

[0012] In some embodiments, the step of obtaining the full load signal comprises:

[0013] When the number of cases loaded on the sorting area trolley reaches the preset target number, the scanning terminal triggers data collection of the trolley identity code;

[0014] The collected identity code is verified by the coding recognition system to match the target trolley, a full load status confirmation signal is generated and fed back to the control system.

[0015] In some embodiments, the step of controlling the handling system to handle the full load trolley to the feeding station includes:

[0016] The handling system moves to a preset point of the sorting area;

[0017] The trolley of the sorting area is lifted to the transportation height by the jacking;

[0018] The trolley is handled along a preset transportation channel to the feeding station.

[0019] In some embodiments, the step of handling the trolley along the preset transportation channel to the feeding station includes:

[0020] The handling system handles the trolley to a previous station of the feeding station, and sends a reaching signal to the host computer of the control system through a preset communication interface;

[0021] The host computer responds to the reaching signal: if a confirmation signal is returned, the next step is executed; if a negative signal or no response is returned, an alarm device is triggered;

[0022] The host computer sends a signal to the lower computer of the control system that the handling system has arrived, and triggers the safety grating at the entrance and exit of the feeding station to be closed by modifying the state of data block A of the lower computer;

[0023] The lower computer feeds back a confirmation signal to the host computer by modifying the state of data block B after the grating is successfully closed;

[0024] After receiving the confirmation signal, the host computer issues an instruction to allow entry to the handling system through a preset communication interface, and the handling system responds to the instruction to allow entry: if a confirmation signal is returned, the next step is executed; if a negative signal or no return is returned, an alarm device is triggered;

[0025] The handling system executes the operation of entering the feeding station, releasing the trolley, and withdrawing;

[0026] The lower computer controls the air cylinder to clamp the trolley and feeds back a clamping signal to the host computer, and the host computer controls the robot to perform an identification operation or a grabbing operation based on the clamping signal and the case state of the feeding station.

[0027] In some embodiments, the steps of releasing the material cart and removing it include:

[0028] The conveying system is lowered to the placement height of the material cart;

[0029] The handling system leaves the loading station along the preset transport channel and sends a departure signal to the host computer through the preset communication interface;

[0030] The host computer responds to the departure signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers the alarm device.

[0031] The host computer triggers the safety light curtain to open by modifying the state of data block C of the slave computer.

[0032] In some embodiments, obtaining the recognition result of the recognition operation includes:

[0033] The robot moves to the top of the material cart according to a preset path, and the vision system captures the type or quantity of the top layer of the material cart and feeds it back to the control system.

[0034] The ranging system measures the distance between the chassis and the foam, calculates the number of stacked layers and the chassis thickness based on the foam thickness, and feeds the result back to the control system.

[0035] The steps of the grabbing operation include:

[0036] Based on the recognition result of the recognition operation, preset grasping parameters are invoked and the robot control program is sent out;

[0037] After the empty plate of the inspection line is in place, the robot grabs the chassis to the plate based on the control program, the robot returns to the origin and sends a placement completion signal;

[0038] Based on the placement completion signal, the blocking cylinder is controlled to drop and release the carrier plate;

[0039] The robot sequentially grabs the chassis and foam until all chassis and foam are installed online.

[0040] In some embodiments, the step of controlling the handling system to transport the material cart to the sorting area for chassis loading includes:

[0041] The conveying system is controlled to enter the loading station, and the conveying system sends an arrival signal to the host computer of the control system through a preset communication interface;

[0042] The host computer responds to the arrival signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers the alarm device.

[0043] The host computer sends a signal to the slave computer that the transport system has arrived, and triggers the safety light curtain to close by modifying the state of data block A of the slave computer;

[0044] After the grating is successfully turned off, the lower-level machine sends a confirmation signal to the upper-level machine by modifying the state of data block B.

[0045] After receiving the confirmation signal, the host computer sends a permission to leave command to the transport system through a preset communication interface. The transport system then lifts the material cart at the loading station to the transport height and moves the material cart away from the loading station along a preset transport channel.

[0046] In some embodiments, after the handling system leaves the loading station, it sends a departure signal to the host computer through a preset communication interface;

[0047] The host computer responds to the "left" signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers an alarm device.

[0048] The host computer modifies the state of data block C of the slave computer to trigger the operation of opening the safety light curtain.

[0049] A chassis loading system, comprising:

[0050] The control system is used to acquire the real-time status of the material cart and chassis at the loading station, and output corresponding control signals based on the following statuses:

[0051] When a box is detected on the material cart, the first control signal is output;

[0052] When a material cart is detected but no machine box is present, a second control signal is output;

[0053] When no material car is detected, a third control signal is output;

[0054] The material handling system performs the operation of transporting the material cart to the sorting area for chassis loading based on the second control signal, or performs the operation of transporting the fully loaded material cart to the loading station based on the third control signal;

[0055] The robot, which integrates a vision system and a ranging system, is used to perform identification or grasping operations on the chassis under the control of the first control signal.

[0056] The beneficial effects of this invention are that, based on the status of the material carts and chassis at the loading station, the control system can control the handling system or the robot to perform identification and gripping operations, realizing automatic gripping and updating of chassis at the loading station. Sorting personnel only need to place the chassis on the material carts, greatly reducing labor intensity, labor costs, and improving loading efficiency. Simultaneously, the robot can automatically identify the thickness and number of layers of the chassis through a vision system and a ranging system, enabling precise gripping of different types of chassis and ensuring efficient chassis loading. Attached Figure Description

[0057] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0058] Figure 1 A flowchart of a chassis loading method provided in an embodiment of the present invention;

[0059] Figure 2 This is an overall flowchart of a chassis loading method provided in an embodiment of the present invention. Detailed Implementation

[0060] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present invention.

[0061] The terms "comprising" and "having," and any variations thereof, in the specification and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the steps or units listed, but may include steps or units not listed.

[0062] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0063] Next, a chassis loading method provided by an embodiment of the present invention will be described in detail. Figure 1 This is a flowchart of a chassis loading method provided in an embodiment of the present invention. Figure 2 This is an overall flowchart of a chassis loading method provided by an embodiment of the present invention. The method includes:

[0064] S1. The control system obtains the status of the material cart and the chassis on the material cart in real time at the current loading station. The control computer includes a host computer and a slave computer. The host computer monitors the slave computer (such as PLC, microcontroller, etc.), collects data and issues instructions through a combination of software and hardware, and realizes information interaction with the handling system through a preset communication structure.

[0065] The above states include: the loading station has a material cart with a machine box on it; the loading station has a material cart but no machine box on it; and the loading station has no material cart.

[0066] The host computer sends different control signals according to the different detected states. In this embodiment, the lower-level computer is described using a PLC system as an example. The PLC system detects the state of the material cart and the chassis in stages through sensors. The first-level sensor detects whether there is a material cart at the loading station, and the second-level sensor detects whether there is a chassis on the material cart. The sensors can be photoelectric sensors, and the second-level sensor can be a through-beam photoelectric sensor. The through-beam photoelectric sensor must detect at least the chassis at the bottom of the material cart. If the bottom chassis is not detected, it means that there is no chassis on the material cart.

[0067] Based on the detection results obtained through two levels of sensors, there are three possible detection outcomes, corresponding to three states of the material cart and the chassis: the first is that there is a material cart and a chassis; the second is that there is a material cart but no chassis; and the third is that there is no material cart. In these three states, the host computer will generate three corresponding control signals, denoted here as the first control signal, the second control signal, and the third control signal.

[0068] S2. When a box is detected on the material cart, the host computer sends a first control signal, and the robot performs an identification operation or a grasping operation based on the first control signal.

[0069] The identification operation includes identifying the chassis type through a vision system and identifying the number of chassis layers and thickness in combination with a ranging system. The vision system can be an industrial camera, which is integrated on the robot and can move to the target position under the guidance of the robot's manipulator. The ranging system can be a rangefinder, which is also integrated on the robot and can also move to the corresponding target position under the guidance of the manipulator.

[0070] The grasping operation involves calling the gripper parameters according to the recognition structure of the recognition operation, thereby controlling the robot to grasp the chassis sequentially onto the production line.

[0071] Specifically, obtaining the recognition result of the recognition operation includes the following steps:

[0072] S21. The robot moves to the top of the material cart according to the preset path. The vision system takes a picture of the topmost chassis of the material cart and determines the chassis type based on the number of chassis, or by taking a picture of the chassis area and determining the chassis type through the image recognition algorithm of the vision system.

[0073] It should be noted that because server chassis and computer chassis have different sizes, the number of server chassis and computer chassis placed on each layer of a material cart of the same specification will also differ. In this embodiment, four computer chassis and two server chassis can be placed on each layer of the material cart, and the layers are separated by foam. Therefore, when determining the chassis type, the type can be determined by photographing the number of chassis on the top layer, and the type information is fed back to the PLC system after the type is determined.

[0074] S22. The distance measurement system measures the distance between the chassis and the foam, and combines the foam thickness with the number of stacked computer chassis layers and the chassis thickness.

[0075] The robotic arm carries a rangefinder to measure the distance between the top layer of the chassis and the top layer of foam to obtain the thickness of each chassis layer. Then, it measures the distance of the bottom layer of foam using the rangefinder. Combining the chassis thickness and foam thickness, it calculates how many layers of chassis are currently placed on the material cart and feeds the calculated chassis thickness back to the PLC system.

[0076] Specifically, measure the vertical distance between the top layer of the chassis and the reference plane of the robot (denoted as H1); measure the vertical distance between the top layer of foam and the reference plane of the robot (denoted as H2); measure the vertical distance between the bottom layer of foam and the reference plane of the robot (denoted as H3).

[0077] The PLC system calculates the number of stacked cabinet layers (N) and the thickness of a single cabinet layer (T) in the material cart based on H1, H2, H3 and the preset foam thickness parameter (D) using the following formula:

[0078] T = H2 - H1;

[0079] N = (H3 - H1) / (D + T);

[0080] The calculation results and chassis type are fed back to the PLC system.

[0081] Furthermore, the steps of the robot's grasping operation include:

[0082] S23. Based on the feedback information (chassis type, chassis thickness, number of chassis layers, etc.) obtained in steps S21 and S22, the PLC system calls the preset gripping parameters (gripper gripping distance, downward probe distance, etc.) and sends the parameters to the robot control program.

[0083] S24. When the PLC system detects that the empty board on the production line has been placed, it issues a grabbing operation to the robot. The robot grabs the chassis to the empty board based on the control program in S23, and after placement, the robot returns to the origin and sends a chassis placement completion signal to the PLC system, waiting for the next grabbing operation.

[0084] After receiving the signal that the chassis placement is complete, the S25 and PLC systems control the blocking cylinder to drop and release the carrier plate, which then flows with the production line to the next workstation.

[0085] S26. After all the top layer of the chassis has been removed, the robot uses the vertical distance H2 between the top layer of foam and the robot's reference plane to control the suction cup to pick up the foam. Following the preset path, the robot moves to the top of the foam cart and delivers the foam to the foam material cart. After placement, the robot returns to the origin and sends a foam placement completion signal to the PLC system, waiting for the next grabbing operation.

[0086] Repeat steps S23-S26 until the chassis and foam are fully installed.

[0087] At this time, under the real-time monitoring state of the PLC system, the first-level sensor detects a material cart at the loading station, and the second-level sensor detects that the material cart is empty. The PLC program then changes the value of address block D from false to true, where address block D serves as an indicator of the empty status of the material cart's housing. Upon detecting the change in the value of address block D to true, the host computer stops sending the first control signal and sends a second control signal through the communication interface with the material handling system, controlling the material handling system to remove the empty material cart. Specifically, the following steps are included:

[0088] S3. When a material cart is detected at the loading station but no machine box is found, the host computer sends a second control signal. The second control signal is used to control the material handling system to move the material cart to the sorting area for machine box loading, and generates a full load signal after it is fully loaded.

[0089] The control system controls the material handling system to transport the material carts to the sorting area for loading into the machine, including the following steps:

[0090] S31. The host computer sends an instruction to the idle material handling system to enter the loading station. After receiving the information to enter the loading station, the material handling system responds to the information: if the material handling system returns an acknowledgment signal, it means that the material handling system has accepted the task and proceeds to step S32; if the material handling system returns a negative signal or there is no response, the alarm device is triggered.

[0091] Specifically, during the information response process of the material handling system:

[0092] If the handling system returns OK, proceed to step S32;

[0093] If the material handling system returns NG, the host computer will rewrite the address block status of the PLC system, for example, write the alarm address block to True, trigger the alarm light to light up, and require manual handling.

[0094] If the handling system does not return, it will repeat the response three times. If it still does not return after three attempts, the host computer will rewrite the address block status of the PLC system, and the PLC system will control the alarm light to light up, requiring manual intervention.

[0095] S32. The conveying system enters the loading station (only when the conveying system enters the loading station does it not need to close the light curtain; the light curtain is only closed when the material cart enters or leaves the loading station), and sends an arrival signal to the host computer through a preset communication interface. The host computer responds to the arrival signal: if it returns a confirmation signal, it executes the next step; if it returns a negative signal or there is no response, it triggers the alarm device.

[0096] Specifically, during the host computer's response to the arriving signal:

[0097] If the host computer returns OK, it means that the host computer has confirmed the arrival status of the handling system and the system status is normal. Proceed to step S33.

[0098] If the host computer returns NG, it may be due to a logic error (such as the workstation should not have an empty material cart) or a system conflict. In this case, the material handling system will trigger its own alarm device and require manual handling.

[0099] If the host computer does not respond, the response will be repeated three times. If there is still no response after three attempts, the handling system will alarm and require manual intervention.

[0100] S33. The host computer sends a signal to the PLC system that the transport system has arrived, and triggers the safety light curtain to close by modifying the state of data block A in the PLC program. Specifically, the host computer establishes communication with the PLC (such as the S7-1200 / 1500 series) through the S7.NET library. The address mapping relationship of data blocks A / B needs to be predefined in the PLC program. After receiving the arrival signal of the transport system, the host computer changes the value of the corresponding data block A in the PLC program from false to true, and the PLC controls the light curtain to close.

[0101] S34. If the PLC detects that the grating feedback signal is unobstructed, it indicates that the grating has been successfully turned off. The PLC changes the value of the corresponding data block B from false to true and returns an OK signal to the host computer through the communication interface, and then proceeds to step S35.

[0102] If the grating does not close within the preset time (e.g., 2 seconds), the PLC triggers an alarm program and returns an NG signal to the host computer.

[0103] S35. The host computer monitors the data stored in data block B in real time. When the stored data in data block B changes and becomes true, it notifies the transport system through a preset communication interface that the raster has been turned off and sends a permission to leave command to the transport system.

[0104] Once the handling system confirms receipt of the permission instruction to leave, it returns OK to the host computer and executes step S36.

[0105] If the material handling system returns NG or no return, the host computer writes True to the PLC alarm address block, triggering the PLC alarm program for manual handling.

[0106] S36. After receiving the signal that the grating has been successfully closed, the conveying system lifts the material cart at the loading station to the transport height and moves the material cart away from the loading station.

[0107] S37. After the material handling system leaves the loading station, it sends a departure signal to the host computer through a preset communication interface, which can open the light curtain.

[0108] The host computer responds to the departure signal: if it returns a confirmation signal, it executes step S38; if it returns a negative signal or there is no response, it triggers the alarm device.

[0109] S38. After the host computer receives the signal indicating that the transport system has left, it changes the value of the corresponding data block C of the PLC from false to true, and the PLC controls the light grid to open.

[0110] If the PLC returns OK, it means that the grating is turned on normally, and proceed to step S39;

[0111] The PLC returns NG or no response, and repeats the response three times. If there is still no response after three times, the host computer writes the PLC alarm address block to True, the PLC triggers the alarm program, and manual handling is required.

[0112] S39. The handling system moves along the preset transport channel to the sorting area.

[0113] During the loading of chassis in the sorting area, the sorter places the chassis on a material cart. Each material cart is affixed with a unique identification code (which can be a QR code, barcode, etc.). When the number of chassis loaded on the material cart in the sorting area reaches the preset target number, a scanning terminal is triggered to collect data on the identification code of the material cart. For example, a handheld scanning terminal scans the identification code to collect data. The identification system verifies that the collected identification code matches the target material cart, changes the status of the material cart to full load, and feeds back the full load status confirmation signal to the host computer.

[0114] S4. When the loading station is found to be empty, the host computer sends a third control signal. The third control signal is used to control the handling system to move the fully loaded material car to the loading station. However, the premise for controlling the handling system is that the material cars in the sorting area are fully loaded.

[0115] Specifically, after the host computer sends out the third control signal and receives the full load confirmation signal, it controls the handling system to perform the following operations based on the full load signal:

[0116] The transport system moves to the preset location in the sorting area;

[0117] The jacking mechanism lifts the sorting area's material carts to transport height.

[0118] The material carts are moved to the loading station along the pre-set transport channel.

[0119] The process of moving the material cart to the loading station along the pre-designed transport channel includes the following steps:

[0120] S41. The material handling system moves the material cart to the station before the loading station and sends an arrival signal to the host computer through a preset communication interface.

[0121] The host computer responds to the incoming signal: if it returns an acknowledgment signal, it executes step S42; if it returns a denial signal or there is no response, it triggers the alarm device.

[0122] Specifically, during the host computer's response to the arriving signal:

[0123] If the host computer returns OK, it means that the host computer has confirmed the arrival status of the handling system and the system status is normal. Proceed to step S42.

[0124] If the host computer returns NG, it may be due to a logic error (such as the workstation should not have a fully loaded material cart) or a system conflict. In this case, the material handling system will trigger its own alarm device and require manual handling.

[0125] If the host computer does not respond, the response will be repeated three times. If there is still no response after three attempts, the handling system will alarm and require manual intervention.

[0126] S42. The host computer sends a signal to the PLC that the material handling system has arrived, and triggers the safety light curtain at the entrance and exit of the loading station to close by modifying the state of data block A of the PLC.

[0127] When the host computer receives the arrival signal from the material handling system, it will notify the PLC program that the material car has arrived, change the value of the corresponding data block A in the PLC from false to true, and the PLC will control the grating to turn off.

[0128] If the PLC detects that the grating feedback signal is unobstructed, it indicates that the grating has been successfully turned off. The PLC changes the value of the corresponding data block B from false to true and returns an OK signal to the host computer through the communication interface, and then proceeds to step S43.

[0129] If the grating does not close within the preset time (e.g., 2 seconds), the PLC triggers an alarm program and returns an NG signal to the host computer.

[0130] S43. The host computer monitors the data stored in data block B in real time. When the stored data in data block B changes and becomes true, it notifies the transport system through a preset communication interface that the grating has been turned off and sends an instruction to the transport system to allow entry.

[0131] Once the transport system confirms receipt of the permission instruction, it returns OK to the host computer and executes step S44.

[0132] If the material handling system returns NG or no return, the host computer writes True to the PLC alarm address block, triggering the PLC alarm program for manual handling.

[0133] S44. After receiving the signal that the grating has been successfully closed, the conveying system enters the loading station and performs the operations of releasing the material cart and withdrawing.

[0134] S45. After the material handling system is removed, the lower-level machine controls the cylinder to clamp the material cart and sends a clamping signal back to the upper-level machine. The upper-level machine controls the robot to perform recognition or grasping operations based on the clamping signal and the status of the chassis at the loading station.

[0135] The aforementioned operations of releasing the material car and evacuating include the following steps:

[0136] S441, The handling system is lowered to the placement height of the material cart;

[0137] S442. The conveying system leaves the loading station along the preset transport channel and sends a departure signal to the host computer through the preset communication interface, which can open the light curtain.

[0138] The host computer responds to the departure signal: if it returns a confirmation signal, it executes step S443; if it returns a negative signal or there is no response, it triggers the alarm device.

[0139] S443. After the host computer receives the signal indicating that the transport system has left, it changes the value of the corresponding data block C of the PLC from false to true, and the PLC controls the light grid to turn on.

[0140] If the PLC returns OK, it means that the grating is turned on normally, and proceed to step S45;

[0141] The PLC returns NG or no response, and repeats the response three times. If there is still no response after three times, the host computer writes the PLC alarm address block to True, the PLC triggers the alarm program, and manual handling is required.

[0142] It should be noted that, based on step S45, after the chassis on the material cart is emptied, the host computer will generate a second control signal again based on the detection feedback from the PLC, thereby controlling the handling system to move the empty material cart from the loading station to the sorting area for chassis loading, and then execute step S3; during the execution of step S3, the loading station remains in a state without material carts, the host computer sends a third control signal, and after the material cart in the sorting area is full of chassis, the host computer controls the handling system to move the full material cart to the loading station, and then execute step S4, until step S45 is completed, thereby forming an automatic cyclic loading system and realizing efficient automatic chassis loading.

[0143] This invention also provides a chassis loading system, which includes a control system, a handling system, and a robot. The control system is used to acquire the status of the material cart and chassis at the loading station in real time, and output corresponding control signals according to the following statuses:

[0144] When a box is detected on the material cart, the first control signal is output;

[0145] When a material cart is detected but no machine box is present, a second control signal is output;

[0146] When no material car is detected, a third control signal is output.

[0147] The material handling system can be an AGV, which performs the operation of transporting material carts to the sorting area for loading the chassis based on a second control signal, or the AGV performs the operation of transporting fully loaded material carts to the loading station based on a third control signal.

[0148] The robot integrates a vision system and a ranging system, which are used to perform identification or grasping operations on the chassis under the control of a first control signal.

[0149] The foregoing has provided a detailed description of a chassis loading method and system according to embodiments of the present invention. The various embodiments are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section.

[0150] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0151] The present invention has provided a detailed description of a chassis loading method and system. Specific examples have been used to illustrate the principles and implementation methods of the invention. The descriptions of these embodiments are merely illustrative and are intended to help understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A method for loading chassis, characterized in that, include: Get the status of the material cart and the chassis on the material cart at the current loading station; When a chassis is detected on the material cart, the robot is controlled to perform an identification operation or a gripping operation. The identification operation includes the vision system identifying the chassis type and the ranging system identifying the number of chassis layers and thickness. The gripping operation includes calling the gripper parameters according to the identification results of the identification operation and controlling the robot to grip the chassis sequentially onto the production line. When a material cart is detected but no chassis is available, the control system moves the material cart to the sorting area for chassis loading and generates a full load signal after it is fully loaded. When no material cart is detected and the full load signal is obtained, the handling system is controlled to move the full load material cart to the loading station.

2. The chassis loading method according to claim 1, characterized in that, The steps to obtain the status of the material cart and the chassis on the material cart at the current loading station include: The system controls the first-level sensor to detect whether there is a material cart at the loading station, and controls the second-level sensor to detect whether there is a machine box.

3. The chassis loading method according to claim 1, characterized in that, The step of obtaining the full load signal includes: When the number of boxes loaded on the sorting area carts reaches the preset target number, the scanning terminal is triggered to collect data on the cart identification code; The system verifies that the collected identification code matches the target material vehicle by using an encoding and recognition system, generates a full-load status confirmation signal, and feeds it back to the control system.

4. The chassis loading method according to claim 1, characterized in that, The steps of controlling the conveying system to move a fully loaded trolley to the loading station include: The transport system moves to the preset point in the sorting area; The material carts in the sorting area are lifted to transport height; The material cart is transported to the loading station along the preset transport channel.

5. The chassis loading method according to claim 4, characterized in that, The step of transporting the material cart to the loading station along the preset transport channel includes: The material handling system moves the material cart to the station before the loading station and sends an arrival signal to the host computer of the control system through a preset communication interface. The host computer responds to the arrival signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers the alarm device. The host computer sends a signal to the slave computer of the control system that the conveying system has arrived, and triggers the safety light curtain at the entrance and exit of the loading station to close by modifying the state of data block A of the slave computer. After the grating is successfully turned off, the lower-level machine sends a confirmation signal to the upper-level machine by modifying the state of data block B. After receiving the confirmation signal, the host computer sends an access permission instruction to the transport system through a preset communication interface. The transport system responds to the access permission instruction: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers an alarm device. The material handling system performs the operations of entering the loading station, releasing the material cart, and withdrawing. The lower-level machine controls the cylinder to clamp the material cart and sends a clamping signal back to the upper-level machine. Based on the clamping signal and the status of the chassis at the loading station, the upper-level machine controls the robot to perform recognition or grasping operations.

6. The chassis loading method according to claim 5, characterized in that, The steps of releasing the material cart and removing it include: The conveying system is lowered to the placement height of the material cart; The handling system leaves the loading station along the preset transport channel and sends a departure signal to the host computer through the preset communication interface; The host computer responds to the departure signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers the alarm device. The host computer triggers the safety light curtain to open by modifying the state of data block C of the slave computer.

7. The chassis loading method according to claim 1, characterized in that, Obtaining the recognition result of the recognition operation includes: The robot moves to the top of the material cart according to a preset path, and the vision system captures the type or quantity of the top layer of the material cart and feeds it back to the control system. The ranging system measures the distance between the chassis and the foam, calculates the number of stacked layers and the chassis thickness based on the foam thickness, and feeds the result back to the control system. The steps of the grabbing operation include: Based on the recognition result of the recognition operation, preset grasping parameters are invoked and the robot control program is sent out; After the empty plate of the inspection line is in place, the robot grabs the chassis to the plate based on the control program, the robot returns to the origin and sends a placement completion signal; Based on the placement completion signal, the blocking cylinder is controlled to drop and release the carrier plate; The robot sequentially grabs the chassis and foam until all chassis and foam are installed online.

8. The chassis loading method according to claim 1, characterized in that, The steps for controlling the material handling system to move the material cart to the sorting area for chassis loading include: The conveying system is controlled to enter the loading station, and the conveying system sends an arrival signal to the host computer of the control system through a preset communication interface; The host computer responds to the arrival signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers the alarm device. The host computer sends a signal to the slave computer that the transport system has arrived, and triggers the safety light curtain to close by modifying the state of data block A of the slave computer; After the grating is successfully turned off, the lower-level machine sends a confirmation signal to the upper-level machine by modifying the state of data block B. After receiving the confirmation signal, the host computer sends a permission to leave command to the transport system through a preset communication interface. The transport system then lifts the material cart at the loading station to the transport height and moves the material cart away from the loading station along a preset transport channel.

9. The chassis loading method according to claim 8, characterized in that, After the material handling system leaves the loading station, it sends a departure signal to the host computer through a preset communication interface. The host computer responds to the "left" signal: if it returns a confirmation signal, it proceeds to the next step; if it returns a negative signal or there is no response, it triggers an alarm device. The host computer modifies the state of data block C of the slave computer to trigger the operation of opening the safety light curtain.

10. A chassis loading system, characterized in that, include: The control system is used to acquire the real-time status of the material cart and chassis at the loading station, and output corresponding control signals based on the following statuses: When a box is detected on the material cart, the first control signal is output; When a material cart is detected but no machine box is present, a second control signal is output; When no material car is detected, a third control signal is output; The material handling system performs the operation of transporting the material cart to the sorting area for chassis loading based on the second control signal, or performs the operation of transporting the fully loaded material cart to the loading station based on the third control signal; The robot, which integrates a vision system and a ranging system, is used to perform identification or grasping operations on the chassis under the control of the first control signal.

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