Intelligent screw machine control system and method

Abstract

The invention relates to the technical field of automatic assembly of screw machines, in particular to an intelligent screw machine control system and method, and the system comprises a handheld box, a motion controller and an input / output interface module. The system realizes automatic detection of the material taking state under two feeding modes of material blowing and material suction through fusion of sensor signals and process parameters, intelligently judges the floating lock or loose tooth fault based on the minimum / maximum locking time, and supports an automatic restriking or skipping strategy. Parameters such as torsion, speed and lifting coordinates can be independently configured for each locking point, and efficient programming functions such as batch editing and array copying are achieved. The controller drives an external execution mechanism through a standard interface, does not depend on a specific hardware structure, supports data uploading of the Internet of Things, and achieves remote monitoring and quality tracing. According to the invention, the locking reliability, the production continuity and the process flexibility are improved, and the method is suitable for multi-variety intelligent manufacturing scenes.

Description

Technical Field

[0001] This invention relates to the field of automated assembly technology for screw machines, and in particular to an intelligent screw machine control system and method. Background Technology

[0002] In manufacturing industries such as electronics, automobiles, and home appliances, screw fastening is a common assembly process. Traditional screw fastening machines mostly use fixed program control, lacking the ability to monitor the screw's positioning and fastening quality in real time. Once problems such as loose screws, stripped threads, or missed screws occur, manual intervention is often required, affecting production efficiency and product yield.

[0003] In existing technologies, although some equipment incorporates sensors for screw detection, it typically only supports a single feeding mode (blowing or suction), and its fault handling strategies are rigid (such as direct shutdown), failing to achieve intelligent retry or skipping. Furthermore, process parameters (such as torque and fastening time) are difficult to configure independently at each point, making it difficult to adapt to the needs of flexible production with multiple varieties and small batches. To address these issues, we propose an intelligent screw machine control system and method. Summary of the Invention

[0004] In view of this, the purpose of this invention is to propose an intelligent screw machine control system and method to solve the problems of existing screw machines lacking a unified intelligent detection and adaptive fault handling mechanism in multi-feed mode, resulting in uncontrollable fastening quality, poor production continuity, and insufficient process flexibility.

[0005] To achieve the above objectives, the present invention provides an intelligent screw machine control system, including a handheld box, a motion controller, and an input / output interface module;

[0006] The handheld box is equipped with a graphical user interface for creating, editing and storing processing files. Each processing file contains multiple locking instructions, and each locking instruction includes at least the target coordinates (X,Y,Z,A) and the corresponding process parameters.

[0007] The motion controller is connected to the handheld box via a communication interface, and is connected to a multi-axis driver, an external locking actuator, and multiple sensors via the input / output interface module. The multiple sensors include a screw positioning detection sensor, a vacuum pressure sensor, and a workpiece position sensor.

[0008] The motion controller is configured to:

[0009] During the material handling stage, the corresponding sensor signals are read according to the current feeding mode. In the suction mode, the screw is successfully picked up based on the signal change of the vacuum pressure sensor. In the blowing mode, the screw is successfully blown based on the jump signal of the screw arrival detection sensor. If no valid signal is detected, the retry is performed according to the preset number of repetitions. If the limit is exceeded, an alarm is triggered.

[0010] During the locking phase, a control signal is output to drive the external locking actuator to press down and initiate the locking action. At the same time, the locking duration is timed, and fault judgment is performed based on the preset minimum locking time and maximum locking time: if the locking time is less than the minimum locking time, it is determined to be a floating lock; if it is greater than the maximum locking time, it is determined to be a stripped tooth. When a floating lock or stripped tooth fault is determined, the current locking point is automatically re-engaged or skipped according to the user-defined strategy, and an OK or NG status signal is issued through the output interface module.

[0011] The motion controller supports independent configuration of process parameters for different locking points. The process parameters include at least one of the following: screw length, locking speed, locking lifting coordinate, torque value, slow lifting distance, and slow lifting speed.

[0012] Preferably, the handheld box also supports array copying, coordinate offsetting, batch parameter modification, and insertion / deletion operations for locking instructions to achieve efficient programming.

[0013] Preferably, the motion controller is further configured to: read the signal from the workpiece in-place sensor before starting processing; if the workpiece is not detected to be in place, pause execution and wait for the workpiece to be placed.

[0014] Preferably, it also includes an Internet of Things (IoT) communication module, through which the motion controller periodically uploads the device operating status, the quantity of completed processing, and fault records to a remote server, wherein the upload frequency is controlled by a user-defined time interval parameter.

[0015] Preferably, the motion controller supports a dual-work platform mode, allowing loading and unloading on one platform while processing on the other, and automatically switching between Y1 and Y2 axis programs via switching commands.

[0016] A method for controlling an intelligent screwdriver includes the following steps:

[0017] S1. Create a processing file using the handheld box, and set the coordinates and process parameters of each locking point;

[0018] S2. Download the processing file to the motion controller and start the automatic operation mode;

[0019] S3. For each locking cycle, the following steps are included:

[0020] S3.1 Move to the material picking position and perform the material picking action;

[0021] In step S3.1, if the rotary feeding function is enabled, the external locking actuator is controlled to rotate at a low speed during the screw picking process to calibrate the alignment of the screwdriver head and the screw slot.

[0022] S3.2 Read the corresponding sensor signal according to the feeding mode and verify whether the screw has been successfully acquired. If it fails and the number of retries has not reached the upper limit, return to step S3.1; otherwise, alarm and terminate or skip.

[0023] S3.3 Move to the target locking point, control the external locking actuator to press down and start locking, and start timing at the same time;

[0024] In step S3.3, after the locking is completed, the product is first slowly raised a specified distance and then retracted at high speed to avoid the product being lifted or damaged due to the rapid lifting of the Z-axis.

[0025] S3.4 After the locking is completed, the actual locking time is compared with the preset minimum / maximum locking time to determine whether there is a floating lock or a stripped tooth;

[0026] S3.5 If a fault exists, retry or skip according to the preset strategy, and record the result;

[0027] S4. After all locking points have been processed, the control equipment moves to the preset stop position or stops at the end point and outputs a processing completion signal.

[0028] The beneficial effects of this invention are as follows:

[0029] I. Achieve multi-mode compatible intelligent detection: Through a unified control architecture, it supports both blowing and suction feeding methods, and automatically verifies the feeding status based on screw position sensors and vacuum pressure sensors, respectively, which significantly improves the reliability of feeding.

[0030] 2. Accurate identification of locking anomalies: Combining preset minimum / maximum locking times with real-time timing, it intelligently identifies typical faults such as floating locks and stripped teeth, preventing defective products from flowing into the next process and improving product yield.

[0031] 3. Enhance production continuity and flexibility: When a fault is detected, the current workstation can be automatically re-run or skipped according to the preset strategy, and the production line can be maintained without manual intervention. It is especially suitable for unmanned or high-cycle production scenarios.

[0032] IV. Support for refined process management: Allows independent configuration of parameters such as torque, speed, and lifting height for each screw point, and provides efficient programming functions such as batch editing and array copying to meet the needs of flexible manufacturing of multiple varieties and small batches. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a flowchart of the control system of the present invention;

[0035] Figure 2 This is a flowchart of the control method of the present invention;

[0036] Figure 3 This is a schematic diagram of the operation page of the handheld box of the present invention. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0038] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this invention should have the ordinary meaning understood by those skilled in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0039] like Figure 1 , Figure 2 , Figure 3 As shown, an intelligent screw machine control system includes a handheld box, a motion controller, and an input / output interface module;

[0040] Handheld controller: Equipped with a 320×240 color LCD screen and physical buttons, operating with a fully Chinese interface. Users can create new machining files or import existing files via teach-through. Each machining file contains up to 2000 locking instructions, and each instruction must include at least the target coordinates (X,Y,Z,A) and a set of process parameters. A-axis: rotation angle.

[0041] Motion controller: Built-in 64M storage space, supports 4–6 axis pulse output (up to 800KHz), and features 14 optocoupler-isolated inputs and 12 NPN open-circuit outputs. The controller communicates with the handheld box via serial port, receives machining files, and parses and executes them.

[0042] Input / output interface module: used to connect external devices, including:

[0043] Multi-axis driver: Receives pulse / direction signals and drives XYZA equiaxial motion.

[0044] External locking actuators include electric screwdrivers (rotary drive assembly), pressure cylinders, vacuum generators, air blowing solenoid valves, etc., which receive start / stop, enable, direction and other control signals output by the controller;

[0045] Multiple sensors:

[0046] Screw positioning detection sensor (used in blowing mode, such as photoelectric switch);

[0047] Vacuum pressure sensor (used in suction mode to detect changes in negative pressure);

[0048] Workpiece in-place sensor (such as a proximity switch, to confirm whether the workpiece is placed in the correct position);

[0049] Cylinder upper and lower limit sensors (used for status monitoring and timeout alarm).

[0050] As a standardized controlled object, the specific structure of the external locking actuator (such as pneumatic / electric grippers, DC / AC screwdrivers) does not affect the operating logic of this control system, thereby realizing the "platformization of control algorithms".

[0051] The intelligent control logic of the motion controller is as follows:

[0052] (1) Multi-mode material sampling and detection

[0053] Suction mode: The controller sends a "suction" signal at the material pick-up point while monitoring the vacuum pressure sensor. If negative pressure is detected within the preset "material pick-up delay" (such as a voltage jump), the material pick-up is considered successful; otherwise, a retry is initiated, with a maximum of "material pick-up repetition count" times.

[0054] Blowing mode: After the controller triggers the blowing signal, it monitors the screw positioning sensor. If a signal change is detected within the "blowing time" (indicating that the screw has passed the sensing area), the process is considered successful; otherwise, it will retry according to the "blowing repetition count".

[0055] (2) Intelligent judgment of locking quality

[0056] When the locking begins, the controller starts an internal timer;

[0057] Real-time comparison of payment duration Compared with preset threshold:

[0058] like (Minimum locking time) indicates a floating lock (screw not fully screwed in);

[0059] like (Maximum locking time) is determined to be stripped (thread damage or misalignment);

[0060] The judgment result is used to trigger subsequent strategies.

[0061] (3) Fault adaptive handling

[0062] Users can enable the "Automatic Reprint" function in the "Lock Payment Process" settings and set the "Number of Reprints" (including the first time).

[0063] When a floating lock or stripped tooth is detected:

[0064] If reprinting is enabled, the Z-axis will revert to the upward coordinate and the locking will be re-executed;

[0065] If the number of retries has been exhausted and the process still fails, select either skip or stop the process based on the "Execution Method" settings.

[0066] At the same time, an NG signal (low level) is sent through the output interface for the host system to record.

[0067] (4) Process parameters are configured at specific points.

[0068] Each locking instruction can be independently configured with: screw length (mm); locking speed (mm / s); locking lift coordinate (Z-axis position); torque value (N·m, applicable to smart electric screwdrivers); slow lift distance and speed (to avoid lifting the product); supports "batch modification" function to improve programming efficiency.

[0069] It also has the following extended functions

[0070] Dual platform support: The Y1 / Y2 axis program can be switched via the "switch" command, supporting machining on one platform and loading / unloading on the other;

[0071] IoT communication: The controller has a built-in TCP / IP protocol stack, which can be configured with server IP, port and push interval, and upload output, status and fault codes at regular intervals;

[0072] Workpiece detection linkage: If "workpiece detection" is enabled, a workpiece presence signal must be detected before each startup; otherwise, the process will pause and wait.

[0073] Safe shutdown: After processing is completed, the machine can return to the preset "stop position" or stay at the end point.

[0074] A method for controlling an intelligent screwdriver includes the following steps:

[0075] S1. Create a processing file using the handheld box, and set the coordinates and process parameters of each locking point;

[0076] S2. Download the processing file to the motion controller and start the automatic operation mode;

[0077] S3. For each locking cycle, the following steps are included:

[0078] S3.1 Move to the material picking position and perform the material picking action;

[0079] In step S3.1, if the rotary feeding function is enabled, the external locking actuator is controlled to rotate at a low speed during the screw picking process to calibrate the alignment of the screwdriver head and the screw slot.

[0080] S3.2 Read the corresponding sensor signal according to the feeding mode and verify whether the screw has been successfully acquired. If it fails and the number of retries has not reached the upper limit, return to step S3.1; otherwise, alarm and terminate or skip.

[0081] S3.3 Move to the target locking point, control the external locking actuator to press down and start locking, and start timing at the same time;

[0082] In step S3.3, after the locking is completed, the product is first slowly raised a specified distance and then retracted at high speed to avoid the product being lifted or damaged due to the rapid lifting of the Z-axis.

[0083] S3.4 After the locking is completed, the actual locking time is compared with the preset minimum / maximum locking time to determine whether there is a floating lock or a stripped tooth;

[0084] S3.5 If a fault exists, retry or skip according to the preset strategy, and record the result;

[0085] S4. After all locking points have been processed, the control equipment moves to the preset stop position or stops at the end point and outputs a processing completion signal.

[0086] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in detail for the sake of brevity.

[0087] The embodiments of this invention are intended to cover all such substitutions, modifications, and variations falling within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A smart screw machine control system, characterized in that, Includes a handheld box, motion controller, and input / output interface module; The handheld box is equipped with a graphical user interface for creating, editing and storing processing files. Each processing file contains multiple locking instructions, and each locking instruction includes at least the target coordinates (X,Y,Z,A) and the corresponding process parameters. The motion controller is connected to the handheld box via a communication interface, and is connected to a multi-axis driver, an external locking actuator, and multiple sensors via the input / output interface module. The multiple sensors include a screw positioning detection sensor, a vacuum pressure sensor, and a workpiece position sensor. The motion controller is configured to: During the material handling stage, the corresponding sensor signals are read according to the current feeding mode. In the suction mode, the screw is successfully picked up based on the signal change of the vacuum pressure sensor. In the blowing mode, the screw is successfully blown based on the jump signal of the screw arrival detection sensor. If no valid signal is detected, the retry is performed according to the preset number of repetitions. If the limit is exceeded, an alarm is triggered. During the locking phase, a control signal is output to drive the external locking actuator to press down and initiate the locking action. At the same time, the locking duration is timed, and fault judgment is performed based on the preset minimum locking time and maximum locking time: if the locking time is less than the minimum locking time, it is determined to be a floating lock; if it is greater than the maximum locking time, it is determined to be a stripped tooth. When a floating lock or stripped tooth fault is determined, the current locking point is automatically re-engaged or skipped according to the user-defined strategy, and an OK or NG status signal is issued through the output interface module. The motion controller supports independent configuration of process parameters for different locking points. The process parameters include at least one of the following: screw length, locking speed, locking lifting coordinate, torque value, slow lifting distance, and slow lifting speed.

2. The intelligent screw machine control system according to claim 1, characterized in that, The handheld box also supports array copying, coordinate offsetting, batch parameter modification, and insertion / deletion operations for locking commands to achieve efficient programming.

3. The intelligent screw machine control system according to claim 1, characterized in that, The motion controller is also configured to: read the signal from the workpiece in-place sensor before starting processing; if the workpiece is not detected in place, pause execution and wait for the workpiece to be placed.

4. The intelligent screw machine control system according to claim 1, characterized in that, It also includes an Internet of Things (IoT) communication module, through which the motion controller periodically uploads the equipment operating status, the quantity of completed processing, and fault records to a remote server. The upload frequency is controlled by a user-defined time interval parameter.

5. The intelligent screw machine control system according to claim 1, characterized in that, The motion controller supports a dual-work platform mode, allowing loading and unloading on one platform while processing on the other, and automatically switching between Y1 and Y2 axis programs via switching commands.

6. A method for controlling an intelligent screwdriver, employing the system described in any one of claims 1-5, comprising the following steps: S1. Create a processing file using the handheld box, and set the coordinates and process parameters of each locking point; S2. Download the processing file to the motion controller and start the automatic operation mode; S3. For each locking cycle, the following steps are included: S3.1 Move to the material picking position and perform the material picking action; S3.2 Read the corresponding sensor signal according to the feeding mode and verify whether the screw has been successfully acquired. If it fails and the number of retries has not reached the upper limit, return to step S3.1; otherwise, alarm and terminate or skip. S3.3 Move to the target locking point, control the external locking actuator to press down and start locking, and start timing at the same time; S3.4 After the locking is completed, the actual locking time is compared with the preset minimum / maximum locking time to determine whether there is a floating lock or a stripped tooth; S3.5 If a fault exists, retry or skip according to the preset strategy, and record the result; S4. After all locking points have been processed, the control equipment moves to the preset stop position or stops at the end point and outputs a processing completion signal.

7. The intelligent screw machine control method according to claim 6, characterized in that, In step S3.1, if the rotary feeding function is enabled, the external locking actuator is controlled to rotate at a low speed during the screw picking process to calibrate the alignment of the screwdriver head and the screw slot.

8. The intelligent screw machine control method according to claim 6, characterized in that, In step S3.3, after the locking is completed, the product is first slowly raised a specified distance and then retracted at high speed to avoid the product being lifted or damaged due to the rapid lifting of the Z-axis.

Images