Station mechanism based on free increase, decrease and replacement of guide rail and control method of station mechanism

Abstract

The invention discloses a conveying technology, and aims to provide a station mechanism based on free increase, decrease and replacement of guide rails and a control method of the station mechanism. According to the technical scheme, the station mechanism comprises a mechanism body used for conveying tool assemblies, and the mechanism body comprises a first rack and a second rack; a first group of guide rails and a second group of guide rails along which the tool assembly can linearly move are symmetrically arranged on the rack I; a third group of guide rails perpendicular to the first group of guide rails and the second group of guide rails are arranged on the second rack, a supporting plate capable of linearly moving along the third group of guide rails is arranged on the third group of guide rails, and a fourth group of guide rails capable of being in butt joint with the first group of guide rails / the second group of guide rails are arranged on the supporting plate; a driving motor for driving the supporting plate to move along the third group of guide rails is arranged at the bottom of the rack II; the mechanism body further comprises an adjustable switching structure arranged between the first rack and the second rack. The invention is suitable for the technical field of conveying.

Description

TECHNICAL FIELD

[0001] The present application relates to a conveying technology, more particularly, to a work station mechanism based on free increase and decrease of guide rails and replacement and a control method thereof. BACKGROUND

[0002] In modern automatic production lines, the work station mechanism as a core component undertakes the task of precise transmission of tooling assemblies and process connection; the traditional work station mechanism usually adopts a fixed guide rail design, the number, layout and docking relationship of the guide rails are determined at the initial stage of production, and it is difficult to flexibly adjust according to actual production needs; for example, when the production line needs to increase or decrease processing stations, replace tooling assemblies of different specifications, or optimize the process sequence, the traditional fixed guide rail structure often cannot respond quickly, and overall transformation is needed to achieve it, which not only consumes time and effort, but also may cause equipment precision to decrease and failure rate to increase due to frequent adjustments, seriously affecting production efficiency and flexible manufacturing capability. SUMMARY

[0003] In view of the deficiencies of the prior art, the purpose of the present application is to provide a work station mechanism based on free increase and decrease of guide rails and replacement and a control method thereof.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a work station mechanism based on free increase and decrease of guide rails and replacement, comprising a mechanism body for conveying tooling assemblies, the mechanism body comprising a rack one and a rack two, the rack one being provided with a first group of guide rails and a second group of guide rails symmetrically for the tooling assemblies to move linearly therealong; the rack two being provided with a third group of guide rails perpendicular to the first group of guide rails and the second group of guide rails, the third group of guide rails being provided with a supporting plate movable linearly along the third group of guide rails, the supporting plate being provided with a fourth group of guide rails dockable with the first group of guide rails / the second group of guide rails, the bottom of the rack two being provided with a driving motor for driving the supporting plate to move along the third group of guide rails; the mechanism body further comprising an adjustable docking structure provided between the rack one and the rack two.

[0005] The present application is further provided as follows: the adjustable docking structure comprising a rack three, the rack three being provided with a fifth group of guide rails dockable with the first group of guide rails and a sixth group of guide rails dockable with the second group of guide rails symmetrically; the mechanism body being provided with a first power assembly on one side of the first group of guide rails for driving the tooling assemblies to move in the direction of the rack two along the first group of guide rails, the rack one being provided with a second power assembly on one side of the second group of guide rails for driving the tooling assemblies to move along the second group of guide rails from the rack two, and the transmission directions of the first power assembly and the second power assembly being opposite.

[0006] The first power assembly comprises slide rails arranged on one side of the rack one, the rack two and the rack three, the slide rails are butt-jointed to form a horizontal line, the rack one and the rack two are both fixedly provided with supporting pieces, the supporting pieces are rotationally connected with lead screws, a plurality of locking pieces which are driven by the lead screws and can lock tooling assembly to drive the tooling assembly to move synchronously are slidably connected on the slide rails, the interval distance of the locking pieces is the length of one tooling assembly, the first power assembly further comprises a driving structure for driving the lead screw to rotate forwardly / reversely; and the first power assembly and the second power assembly are the same in structure.

[0007] A control method of a work station mechanism based on free addition and subtraction and replacement of guide rails, characterized in that a control system for coordinating operation of each component is further included, and the control method comprises the following steps:

[0008] S1, initializing equipment, detecting states of each component of the mechanism body, including butt-joint accuracy of corresponding guide rails, whether the first power assembly and the second power assembly are in initial states and whether the locking pieces are in loosened states, whether the driving motor and each driving structure are in standby states, if all components meet initial conditions, turning to S2, otherwise, issuing a fault prompt and stopping subsequent operations;

[0009] S2: an operator arranges tooling assemblies in order and slidably connects the tooling assemblies on the first group of guide rails, then the control system detects the number and position of the tooling assemblies on the first group of guide rails, when at least one tooling assembly is detected to be in a drivable range of the first power assembly, turning to S3, if no tooling assembly is detected or the position of the tooling assembly exceeds the driving range, issuing a prompt and waiting for the operator to adjust;

[0010] S3: the driving structure of the first power assembly is controlled to pre-start, so that the locking pieces on the slide rails move to corresponding positions of the tooling assembly to be moved currently, the alignment accuracy of the locking pieces and the tooling assembly is detected, when the alignment error is less than a preset threshold, the locking pieces are controlled to lock the tooling assembly, if the alignment error exceeds the threshold, the driving structure is adjusted to fine-tune the position of the locking pieces until the requirement is met, if the adjustment is still not satisfied after multiple adjustments, a fault signal is issued;

[0011] S4: the driving structure of the first power assembly is controlled to rotate forwardly, driving the locking pieces and the locked tooling assembly to move along the first group of guide rails to the direction of the rack two, the moving distance is detected in real time, when the moving distance is equal to the length of one tooling assembly, the driving structure is controlled to stop rotating, at this time, whether the tooling assembly completely enters the next work station area is detected, if yes, turning to S5, if not, the driving structure is continuously fine-tuned to be in place;

[0012] S5: Control the locking component to loosen the current tooling assembly, check whether the locking component is completely loosened, and after confirming that it is loosened, control the drive structure of the first power assembly to reverse so that the locking component is reset to the initial position along the slide rail. Check whether the locking component is reset in place. If it is in place, go to S6. If it is not in place, re-drive the reset.

[0013] S6: Determine whether the current tooling component has moved to the fourth set of guide rails on the support plate via the first set of guide rails. If the tooling component is detected to be completely on the fourth set of guide rails, the first power component will be reset and enter the waiting mode, and then proceed to S7.

[0014] S7: Control the drive motor to start, driving the support plate to move along the third set of guide rails towards the second set of guide rails. Real-time detection of the movement position. When the docking accuracy of the fourth set of guide rails and the second set of guide rails meets the preset requirements, control the drive motor to stop. At this time, detect whether the tooling component is within the range that can be driven by the second power component. If it is within the range, turn to S8; otherwise, the drive motor fine-tunes the position of the support plate.

[0015] S8: Control the locking component of the second power component to lock the tooling assembly. After the locking status is qualified, control the drive structure of the second power component to reverse and drive the tooling assembly to move along the second set of guide rails towards the frame. Stop when the moving distance is equal to the length of one tooling assembly. Check whether the tooling assembly has completely left the fourth set of guide rails. If it has left, turn to S9. If it has not left, continue to drive the movement.

[0016] S9: Control the drive motor to drive the support plate to reset to the initial position along the third set of guide rails, check whether the reset is in place, if it is in place, release the waiting mode of the first power component and turn to S3; at the same time, control the locking part of the second power component to loosen the tooling component, and after confirming that it is loosened, control the drive structure to rotate forward to reset the locking part.

[0017] S10, repeat S3-S9 until there are no tooling components to be transferred on the first set of guide rails.

[0018] The present invention is further configured such that: in step S3, when detecting the alignment accuracy of the locking component and the tooling assembly, a laser positioning sensor in the control system is used to collect the relative position data of the two in real time. When the alignment error collected three times consecutively is less than 0.5mm, the alignment is deemed qualified and the locking component is controlled to lock; if the alignment error collected five times consecutively is ≥0.5mm, the alignment is deemed to have failed, a fault signal is issued and the error data is recorded.

[0019] The present invention is further configured such that: in step S6, when determining whether the tooling assembly is completely on the fourth set of guide rails, the infrared detection device in the control system is used for detection. The infrared detection device is set at both ends of the fourth set of guide rails. When both ends of the infrared detection device are blocked by the tooling assembly for a duration of more than 2 seconds, the tooling assembly is determined to be completely in place; if only one end is blocked or the blocking duration is less than 2 seconds, it is determined that it is not completely in place.

[0020] The present invention is further configured such that: in S10, when determining whether there are still tooling components to be conveyed on the first set of guide rails, a weight sensor is set in the initial placement area of ​​the first set of guide rails. When the weight detected by the sensor is greater than 50% of the weight of a single tooling component, it is determined that there are still tooling components to be conveyed; if the weight is less than or equal to 50% of the weight of a single tooling component, visual recognition is further used to confirm whether there are tooling components.

[0021] The beneficial effects of this invention are:

[0022] 1. Compared to existing technologies, this invention utilizes a workstation mechanism based on freely adjustable and replaceable guide rails. The first and second sets of guide rails symmetrically arranged on frame one enable linear transport of tooling components. Combined with a support plate on frame two that can move along a third set of guide rails and a fourth set of guide rails, it can flexibly connect to different guide rail sets. Furthermore, the adjustable adapter structure breaks the traditional limitations of fixed workstation guide rails. Guide rails can be freely added, removed, and replaced, and the position of the support plate can be adjusted according to production needs, adapting to different specifications of tooling components and production processes, significantly improving the mechanism's versatility and adaptability. Simultaneously, the drive motor precisely moves the support plate, ensuring guide rail connection accuracy, reducing tooling component transport deviations, improving production stability, and lowering equipment replacement and debugging costs. It is suitable for multi-process, batch production scenarios. In addition, it reduces hardware modification costs due to production line adjustments and shortens production transport time. Moreover, the adjustable adapter structure between frame two and frame one further enhances system compatibility.

[0023] 2. This invention, based on a workstation mechanism with freely addable, removeable, and replaceable guide rails, achieves efficient and directional transmission of tooling components between multiple workstations by adding a third frame and its symmetrically configured fifth and sixth sets of guide rails, along with independent first and second power components. Its advantages are threefold: First, the third frame acts as a transition hub, seamlessly connecting the fifth and sixth sets of guide rails with the first and second sets, eliminating the risk of jamming caused by gaps or misalignments in traditional transfer structures, ensuring the smoothness of tooling component transmission. Second, the reverse-drive first and second power components form a coordinated transmission mechanism, avoiding unilateral power overload or tooling component stagnation, thus improving transmission efficiency. Third, this structure is independent of the basic guide rail system, allowing selective activation or adjustment of the third frame's position according to actual process requirements, further enhancing the flexibility of the workstation layout. In summary, this design not only solves the alignment difficulty of tooling component transmission between multiple workstations but also optimizes production cycle time through bidirectional power control.

[0024] 3. In this invention, the combined design of slide rail, lead screw, and locking component achieves precise positioning and synchronous driving of tooling components during the conveying process. Its core advantages are: First, the horizontal line formed by the slide rail connection provides a stable moving track for the locking component. Combined with the lead screw transmission fixed by the support component, rotational motion can be precisely converted into linear displacement, ensuring that each locking component moves at a fixed interval, avoiding collisions or offsets between tooling components. Second, the locking component not only has a driving function but can also fix the tooling components through mechanical clamping or magnetic attraction, preventing displacement deviations caused by vibration or inertia during conveying, thus improving transmission reliability. Third, the driving structure can precisely control the forward and reverse rotation and speed of the lead screw, achieving individual pushing or batch synchronous movement of tooling components according to preset programs, adapting to different production rhythm requirements. Furthermore, the identical structure of the first and second power components reduces maintenance costs, and the reverse transmission further optimizes the collaborative efficiency between multiple workstations. Overall, this power component structure solves the problems of inaccurate positioning and poor synchronization found in traditional conveyor belts or simple push rods, providing support for high-precision tooling transmission.

[0025] 4. The present invention has a reasonable structure, is easy to operate, avoids the defects of the prior art, and is suitable for promotion and application. Attached Figure Description

[0026] Fig. 1 This is a structural diagram of the workstation mechanism based on the free addition, reduction, and replacement of guide rails according to the present invention.

[0027] Fig. 2 This is a structural diagram of the workstation mechanism based on the free addition, reduction and replacement of guide rails, applied to a winding machine.

[0028] Figs. 1-2Reference numerals in the attached drawings: 1. Mechanism body; 2. Frame 1; 3. Frame 2; 4. First set of guide rails; 5. Second set of guide rails; 6. Third set of guide rails; 7. Support plate; 8. Fourth set of guide rails; 9. Frame 3; 10. Fifth set of guide rails; 11. Sixth set of guide rails; 12. Slide rail; 13. Support component; 14. Lead screw; 15. Locking component; 16. Drive structure. Detailed Implementation

[0029] Reference Figs. 1-2 The embodiments of the workstation mechanism and its control method based on the free addition, reduction and replacement of guide rails of the present invention are further described.

[0030] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0031] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0032] Figs. 1-2 The illustrated workstation mechanism, based on the free addition, reduction, and replacement of guide rails, includes a mechanism body 1 for conveying tooling components. The mechanism body 1 includes a first frame 2 and a second frame 3. The first frame 2 is symmetrically equipped with a first set of guide rails 4 and a second set of guide rails 5, allowing the tooling components to move linearly along them. The second frame 3 is equipped with a third set of guide rails 6 perpendicular to the first set of guide rails 4 and the second set of guide rails 5. The third set of guide rails 6 is equipped with a support plate 7 that can move linearly along the third set of guide rails 6. The support plate 7 is equipped with a fourth set of guide rails 8 that can dock with the first set of guide rails 4 and the second set of guide rails 5. The bottom of the second frame 3 is equipped with a drive motor for driving the support plate 7 to move along the third set of guide rails 6. The mechanism body 1 also includes an adjustable transition structure disposed between the first frame 2 and the second frame 3.

[0033] This workstation mechanism achieves linear transmission of tooling components through the first and second sets of guide rails symmetrically arranged on frame 2. Combined with the support plate 7 and the fourth set of guide rails 8 on frame 3, which can move along the third set of guide rails 6, it can flexibly connect to different guide rail sets. Furthermore, the adjustable adapter structure breaks the traditional fixed limitations of workstation guide rails. Guide rails can be freely added, removed, or replaced, and the position of the support plate 7 can be adjusted according to production needs, adapting to different specifications of tooling components and production processes, significantly improving the mechanism's versatility and adaptability. Simultaneously, the drive motor drives the support plate 7 to move precisely, ensuring guide rail connection accuracy, reducing tooling component transmission deviation, improving production stability, and lowering equipment replacement and debugging costs. It is suitable for multi-process, batch production scenarios. In addition, it reduces hardware modification costs caused by production line adjustments and shortens production transmission time. Furthermore, the adjustable adapter structure between frame 3 and frame 2 further enhances the system's compatibility.

[0034] The adjustable adapter structure includes a frame 3 9, on which a fifth set of guide rails 10, which docks with the first set of guide rails 4, and a sixth set of guide rails 11, which docks with the second set of guide rails 5, are symmetrically arranged. The mechanism body 1 is provided with a first power component on one side of the first set of guide rails 4 for driving the tooling assembly to move along the first set of guide rails 4 toward the frame 2 3. The frame 1 2 is provided with a second power component on one side of the second set of guide rails 5 for driving the tooling assembly to move from the frame 2 3 along the second set of guide rails 5, and the transmission directions of the first power component and the second power component are opposite. The frame 1 2, the frame 2 3, and the frame 3 9 are fixedly connected by connectors. The frame 3 9 is slidably inserted between the frame 1 2 and the frame 2 3.

[0035] By adding a frame 3 (9) and its symmetrically configured fifth and sixth guide rails (10 and 11), along with independent first and second power components, efficient and directional transmission of tooling components between multiple workstations is achieved. The specific advantages are threefold: First, frame 3 (9) acts as a transition hub, seamlessly connecting the fifth and sixth guide rails (10 and 11) with the first and second guide rails (4 and 5), eliminating the risk of jamming caused by gaps or misalignments in traditional transfer structures, ensuring the smoothness of tooling component transmission. Second, the counter-drive first and second power components form a coordinated transmission mechanism, avoiding unilateral power overload or tooling component stagnation, thus improving transmission efficiency. Third, this structure is independent of the basic guide rail system, allowing selective activation or adjustment of the frame 3 (9) position according to actual process requirements, further enhancing the flexibility of workstation layout. In summary, this design not only solves the alignment difficulty of tooling component transmission between multiple workstations but also optimizes production cycle time through bidirectional power control.

[0036] The first power assembly includes a slide rail 12 disposed on one side of frame 2, frame 3, and frame 9. The slide rails 12 are aligned horizontally. Frame 2 and frame 3 are each fixedly provided with a support member 13. A lead screw 14 is rotatably connected to the support member 13. Several locking members 15, driven by the lead screw 14 and capable of locking the tooling assembly to move synchronously, are slidably connected to the slide rail 12. The spacing between the locking members 15 is the length of one tooling assembly. The first power assembly also includes a drive structure 16 for driving the lead screw 14 to rotate forward / reverse. The first power assembly and the second power assembly have the same structure. The transmission time can be adjusted according to requirements. For example, when this mechanism is used on a winding machine, there may be operations such as inserting paper, winding, and embedding wire into the tooling assembly. In this case, the transmission time can be adjusted according to the specific operation time.

[0037] The combined design of slide rail 12, lead screw 14, and locking element 15 achieves precise positioning and synchronous drive of the tooling components during the conveying process. Its core advantages are: First, the horizontal line formed by the docking of slide rail 12 provides a stable moving track for the locking element 15. Combined with the lead screw 14 fixed by support member 13, rotational motion is precisely converted into linear displacement, ensuring that each locking element 15 moves at fixed intervals, preventing collisions or misalignment between tooling components. Second, the locking element 15 not only has a driving function but can also fix the tooling components through mechanical clamping or magnetic attraction, preventing damage during the conveying process. The displacement deviation caused by vibration or inertia is reduced, thus improving transmission reliability. Furthermore, the drive structure 16 can precisely control the forward and reverse rotation and speed of the lead screw 14, and combined with the preset program, realize the individual pushing or batch synchronous movement of tooling components to adapt to different production rhythm requirements. In addition, the identical structure of the first power component and the second power component reduces maintenance costs, and the reverse transmission further optimizes the coordination efficiency between multiple workstations. Overall, this power component structure solves the problems of inaccurate positioning and poor synchronization of traditional conveyor belts or simple push rods, providing support for high-precision tooling transmission.

[0038] A control method for a workstation mechanism based on the free addition, reduction, and replacement of guide rails, characterized in that it further includes a control system for coordinating the operation of each component, specifically comprising the following steps:

[0039] S1. Initialize the equipment and check the status of each component of the main body 1, including the docking accuracy of the corresponding guide rail, whether the first power component and the second power component are in the initial state and whether their locking parts 15 are in the loose state, and whether the drive motor and each drive structure 16 are in the standby state. If all components meet the initial conditions, proceed to S2; otherwise, issue a fault prompt and stop subsequent operations.

[0040] S2: The operator arranges the tooling components in an orderly manner and slides them onto the first set of guide rails 4. Then the control system detects the number and position of the tooling components on the first set of guide rails 4. When at least one tooling component is detected to be within the drive range of the first power component, the system switches to S3. If no tooling component is detected or the position of the tooling component exceeds the drive range, a prompt is issued and the system waits for the operator to make adjustments.

[0041] S3: Control the drive structure 16 of the first power component to start pre-start, so that the locking part 15 on the slide rail 12 moves to the corresponding position of the tooling component to be moved, detect the alignment accuracy between the locking part 15 and the tooling component, when the alignment error is less than the preset threshold, control the locking part 15 to lock the tooling component, if the alignment error exceeds the threshold, the drive structure 16 fine-tunes the position of the locking part 15 until the requirements are met, if multiple adjustments still do not meet the requirements, a fault signal is issued;

[0042] S4: Control the drive structure 16 of the first power component to rotate forward, driving the locking part 15 and the locked tooling assembly to move along the first set of guide rails 4 towards the frame 2 3. The moving distance is detected in real time. When the moving distance is equal to the length of one tooling assembly, the drive structure 16 is controlled to stop rotating. At this time, it is detected whether the tooling assembly has completely entered the next work station area. If it has entered, then turn to S5. If it has not completely entered, the drive structure 16 continues to fine-tune until it is in place.

[0043] S5: Control the locking component 15 to release the current tooling assembly, check whether the locking component 15 is completely released, and after confirming that it is released, control the drive structure 16 of the first power assembly to reverse, so that the locking component 15 is reset to the initial position along the slide rail 12. Check whether the locking component 15 is reset in place. If it is in place, turn to S6. If it is not in place, re-drive the reset.

[0044] S6: Determine whether the current tooling component has moved to the fourth set of guide rails 8 on the support plate 7 via the first set of guide rails 4. If the tooling component is detected to be completely on the fourth set of guide rails 8, the first power component will be reset and enter the waiting mode, and then proceed to S7.

[0045] S7: Control the start of the drive motor to move the support plate 7 along the third set of guide rails 6 towards the second set of guide rails 5. Detect the movement position in real time. When the docking accuracy between the fourth set of guide rails 8 and the second set of guide rails 5 meets the preset requirements, control the drive motor to stop. At this time, detect whether the tooling assembly is within the range that can be driven by the second power assembly. If it is within the range, turn to S8; otherwise, the drive motor fine-tunes the position of the support plate 7.

[0046] S8: Control the locking part 15 of the second power component to lock the tooling component. After the locking status is qualified, control the drive structure 16 of the second power component to reverse and drive the tooling component to move along the second set of guide rails 5 towards the frame 2. Stop when the moving distance is equal to the length of one tooling component. Check whether the tooling component has completely left the fourth set of guide rails 8. If it has left, turn to S9. If it has not left, continue to drive the movement.

[0047] S9: Control the drive motor to drive the support plate 7 to reset to the initial position along the third set of guide rails 6, check whether the reset is in place, if it is in place, release the waiting mode of the first power component and turn to S3; at the same time, control the locking part 15 of the second power component to loosen the tooling component, and after confirming that it is loosened, control the drive structure 16 to rotate forward to reset the locking part 15.

[0048] S10, cycle through S3-S9 until there are no tooling components to be transferred on the first set of guide rails 4;

[0049] By coordinating the operation of various components through the control system, the entire tooling component transfer process is fully automated and highly reliable. From equipment initialization detection to tooling component loading identification, precise locking, directional movement, cross-rail transfer, and cyclic operation, each step is equipped with multiple verification mechanisms to effectively avoid the risks of missed transfers, misalignments, or equipment damage. Secondly, this method standardizes complex operations through step-by-step logic, reducing the need for manual intervention, while supporting real-time fault prompts for quick troubleshooting. This control method not only improves production efficiency but also significantly enhances the applicability of the equipment by intelligently adapting to different tooling component specifications.

[0050] In step S3, when detecting the alignment accuracy between the locking component 15 and the tooling assembly, the laser positioning sensor in the control system is used to collect the relative position data of the two in real time. When the alignment error of three consecutive acquisitions is less than 0.5mm, the alignment is deemed qualified and the locking component 15 is controlled to lock. If the alignment error of five consecutive acquisitions is ≥0.5mm, the alignment is deemed to have failed, a fault signal is issued and the error data is recorded.

[0051] By collecting relative position data in real time using a laser positioning sensor and setting a standard of "passing if the error is less than 0.5mm for three consecutive tests", the system solves the misjudgment problem of traditional manual visual inspection or coarse sensors. Specifically, the advantages are: laser positioning is non-contact and high-resolution, capable of real-time feedback of micron-level displacement deviations, ensuring strict alignment between the locking component 15 and the central axis of the tooling assembly; continuous multiple tests filter out accidental interference, and locking is only triggered when the standard is consistently met, significantly reducing the risk of transmission jams or tooling damage due to misalignment; if the error is ≥0.5mm for five consecutive tests, the system is considered a failure and the data is recorded, avoiding blind operation of the equipment and providing a basis for fault tracing for subsequent process optimization; this solution integrates the high-precision requirements of precision manufacturing into the automated process, ensuring the stability of the tooling assembly at the beginning of the transmission stage, which is a key link in improving the overall transmission reliability.

[0052] In step S6, when determining whether the tooling component is completely on the fourth set of guide rails 8, the infrared detection device in the control system is used for detection. The infrared detection device is set at both ends of the fourth set of guide rails 8. When both ends of the infrared detection device are blocked by the tooling component for more than 2 seconds, the tooling component is determined to be completely in place. If only one end is blocked or the blocking time is less than 2 seconds, it is determined that it is not completely in place.

[0053] By employing a "double-end obstruction + 2-second duration" judgment logic in the infrared detection device, the problems of interference and misjudgment inherent in traditional proximity switches or single sensors are solved. Infrared detection, with its non-contact and electromagnetic interference-resistant characteristics, can accurately detect physical obstructions of tooling components. Simultaneous detection at both ends ensures that the tooling component completely covers the guide rail length, rather than partially entering, avoiding subsequent transmission failures due to incomplete positioning. The 2-second duration threshold filters out momentary obstruction signals caused by brief pauses or vibrations; only stable obstruction is considered as complete, improving detection accuracy. Furthermore, this solution is linked with the control system in real time. If the detection fails, the drive motor automatically fine-tunes the position of the support plate 7 until the requirements are met, achieving closed-loop control of "detection-adjustment." This significantly reduces the risk of tooling components falling or shifting during cross-guide rail transfers, ensuring smooth multi-station collaborative operations.

[0054] In S10, when determining whether there are still tooling components to be transferred on the first set of guide rails 4, a weight sensor is set in the initial placement area of ​​the first set of guide rails 4. When the weight detected by the sensor is greater than 50% of the weight of a single tooling component, it is determined that there are still tooling components to be transferred; if the weight is less than or equal to 50% of the weight of a single tooling component, visual recognition is used to further confirm whether there are tooling components.

[0055] By detecting load changes in the initial placement area, it is possible to quickly identify whether there are tooling components to be transferred, avoiding the limitations of visual recognition in occluded environments. When the weight signal is ambiguous, visual recognition serves as a supplement for further confirmation, accurately determining the presence of small or irregularly shaped tooling components through image analysis, thus improving the comprehensiveness of the inspection. This dual verification mechanism ensures both inspection efficiency and accuracy, effectively preventing equipment idling due to missed inspections or material jamming caused by misjudgments.

[0056] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.

Claims

1. A workstation mechanism based on the free addition, reduction, and replacement of guide rails, characterized in that: The mechanism includes a main body (1) for conveying tooling components. The main body (1) includes a frame one (2) and a frame two (3). The frame one (2) is symmetrically provided with a first set of guide rails (4) and a second set of guide rails (5) for tooling components to move linearly along. The frame two (3) is provided with a third set of guide rails (6) perpendicular to the first set of guide rails (4) and the second set of guide rails (5). The third set of guide rails (6) is provided with a support plate (7) that can move linearly along the third set of guide rails (6). The support plate (7) is provided with a fourth set of guide rails (8) that can dock with the first set of guide rails (4) and the second set of guide rails (5). The bottom of the frame two (3) is provided with a drive motor for driving the support plate (7) to move along the third set of guide rails (6). The main body (1) also includes an adjustable transition structure disposed between the frame one (2) and the frame two (3).

2. The workstation mechanism based on the free addition, reduction, and replacement of guide rails according to claim 1, characterized in that, The adjustable transfer structure includes a frame three (9), on which a fifth set of guide rails (10) is symmetrically arranged to connect with the first set of guide rails (4) and a sixth set of guide rails (11) is connected to the second set of guide rails (5); the mechanism body (1) is provided with a first power component on one side of the first set of guide rails (4) for driving the tooling assembly to move along the first set of guide rails (4) toward the frame two (3); the frame one (2) is provided with a second power component on one side of the second set of guide rails (5) for driving the tooling assembly to move from the frame two (3) along the second set of guide rails (5), and the transmission directions of the first power component and the second power component are opposite.

3. A workstation mechanism based on freely increasing, decreasing, and replacing guide rails according to claim 2, characterized in that, The first power assembly includes a slide rail (12) disposed on one side of frame one (2), frame two (3), and frame three (9). The slide rails (12) are connected in a horizontal line. Both frame one (2) and frame two (3) are fixedly provided with support members (13). A lead screw (14) is rotatably connected to the support member (13). Several locking members (15) driven by the lead screw (14) and capable of locking the tooling assembly to move synchronously are slidably connected to the slide rail (12). The spacing between the locking members (15) is the length of one tooling assembly. The first power assembly also includes a drive structure (16) for driving the lead screw (14) to rotate forward / reverse. The first power assembly and the second power assembly have the same structure.

4. A control method applicable to the workstation mechanism based on the free addition, reduction, and replacement of guide rails as described in any one of claims 1-3, characterized in that, It also includes a control system that coordinates the operation of the various components, specifically comprising the following steps: S1. Initialize the equipment and check the status of each component of the main body (1), including the docking accuracy of the corresponding guide rail, whether the first power component and the second power component are in the initial state and whether their locking parts (15) are in the loose state, and whether the drive motor and each drive structure (16) are in the standby state. If all components meet the initial conditions, proceed to S2; otherwise, issue a fault warning and stop subsequent operations. S2: The operator arranges the tooling components in an orderly manner and slides them onto the first set of guide rails (4). Then the control system detects the number and position of the tooling components on the first set of guide rails (4). When at least one tooling component is detected to be within the drive range of the first power component, the system switches to S3. If no tooling component is detected or the position of the tooling component exceeds the drive range, a prompt is issued and the system waits for the operator to make adjustments. S3: Control the drive structure (16) of the first power component to start in advance, so that the locking part (15) on the slide rail (12) moves to the corresponding position of the current tooling component to be moved, detect the alignment accuracy between the locking part (15) and the tooling component, when the alignment error is less than the preset threshold, control the locking part (15) to lock the tooling component, if the alignment error exceeds the threshold, the drive structure (16) fine-tunes the position of the locking part (15) until the requirements are met, if multiple adjustments still do not meet the requirements, a fault signal is issued; S4: Control the drive structure (16) of the first power component to rotate forward, drive the locking part (15) and the locked tooling assembly to move along the first set of guide rails (4) towards the second frame (3), and detect the moving distance in real time. When the moving distance is equal to the length of one tooling assembly, control the drive structure (16) to stop rotating. At this time, detect whether the tooling assembly has completely entered the next work station area. If it has entered, turn to S5. If it has not completely entered, the drive structure (16) continues to fine-tune until it is in place. S5: Control the locking component (15) to release the current tooling assembly, check whether the locking component (15) is completely released, and after confirming that it is released, control the drive structure (16) of the first power assembly to reverse, so that the locking component (15) is reset to the initial position along the slide rail (12), check whether the locking component (15) is reset in place, if it is in place, turn to S6, if it is not in place, drive the reset again; S6: Determine whether the current tooling component has moved from the first set of guide rails (4) to the fourth set of guide rails (8) of the support plate (7). If the tooling component is detected to be completely on the fourth set of guide rails (8), the first power component will be reset and enter the waiting mode, and then proceed to S7. S7: Control the start of the drive motor to drive the support plate (7) to move along the third set of guide rails (6) towards the second set of guide rails (5). Real-time detection of the moving position. When the docking accuracy of the fourth set of guide rails (8) and the second set of guide rails (5) meets the preset requirements, control the drive motor to stop. At this time, detect whether the tooling component is within the range that can be driven by the second power component. If it is within the range, turn to S8. Otherwise, the drive motor fine-tunes the position of the support plate (7). S8: Control the locking part (15) of the second power component to lock the tooling component. After the locking status is qualified, control the drive structure (16) of the second power component to reverse and drive the tooling component to move along the second set of guide rails (5) towards the frame (2). Stop when the moving distance is equal to the length of one tooling component. Check whether the tooling component has completely left the fourth set of guide rails (8). If it has left, turn to S9. If it has not left, continue to drive the movement. S9: Control the drive motor to drive the support plate (7) to reset to the initial position along the third set of guide rails (6), check whether the reset is in place, if it is in place, release the waiting mode of the first power component and turn to S3; at the same time, control the locking part (15) of the second power component to loosen the tooling component, and after confirming that it is loosened, control the drive structure (16) to rotate forward to reset the locking part (15). S10, cycle through S3-S9 until there are no tooling components to be transferred on the first set of guide rails (4).

5. The control method for a workstation mechanism based on the free addition, reduction, and replacement of guide rails according to claim 4, characterized in that, In S3, when detecting the alignment accuracy of the locking component (15) and the tooling assembly, the laser positioning sensor in the control system is used to collect the relative position data of the two in real time. When the alignment error of three consecutive acquisitions is less than 0.5mm, the alignment is deemed qualified and the locking component (15) is controlled to lock. If the alignment error of five consecutive acquisitions is ≥0.5mm, the alignment is deemed to have failed, a fault signal is issued and the error data is recorded.

6. The control method for a workstation mechanism based on the free addition, reduction, and replacement of guide rails according to claim 4, characterized in that, In S6, when determining whether the tooling component is completely on the fourth set of guide rails (8), the infrared detection device in the control system is used for detection. The infrared detection device is set at both ends of the fourth set of guide rails (8). When both ends of the infrared detection device are blocked by the tooling component for more than 2 seconds, the tooling component is determined to be completely in place. If only one end is blocked or the blocking time is less than 2 seconds, it is determined that it is not completely in place.

7. The control method for a workstation mechanism based on the free addition, reduction, and replacement of guide rails according to claim 4, characterized in that, In S10, when determining whether there are still tooling components to be transferred on the first set of guide rails (4), a weight sensor is set in the initial placement area of ​​the first set of guide rails (4). When the weight detected by the sensor is greater than 50% of the weight of a single tooling component, it is determined that there are still tooling components to be transferred; if the weight is less than or equal to 50% of the weight of a single tooling component, visual recognition is used to further confirm whether there are tooling components.

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