High-voltage drop-out fuse automatic assembly production line and control method thereof

Abstract

The application discloses a kind of high-pressure drop-out fuse automatic assembly production line and control method thereof, it is related to high-voltage fuse production line equipment technical field.The application is controlled by PLC, system main control can be communicated with host computer through network port, it is convenient to collect production information to MES system, realize the digitization and intelligentization of production, degree of automation is high, flexibility is strong, small space occupation, it is suitable for large-area popularization and application;Sheath and color mark automatic detection process based on visual system are designed, to avoid the disadvantages that sheath is placed wrong in packing box and cannot be effectively checked;Coordinate system calibration method based on 4-axis gantry robot, visual correction calibration and teaching method, packing box falling judgment method based on grabbing detection sensor and vacuum degree combination, accurate positioning stacking control method based on 4-axis gantry robot are designed, improve the production efficiency of production, ensure the safety of production and product quality.

Description

Technical Field

[0001] This invention relates to the field of high-voltage fuse production line equipment technology, specifically to an automated assembly line for high-voltage drop-out fuses and its control method. Background Technology

[0002] High-voltage drop-out fuses are key protection devices in power distribution networks, widely used in 10kV transmission lines, and play a crucial role in power distribution networks.

[0003] The existing drop-out fuse production line has the following defects: 1. Currently, the automation level of high-voltage drop-out fuse production is low, with most assembly done at a tabletop. Personnel allocation is unclear, the assembly process is not easy to manage uniformly, and the assembly process is too cumbersome, which makes it easy for product parts to be missed or misassembled, and product quality is difficult to control effectively. 2. The production line has a low level of automation and digitalization, poor flexibility, and forms information silos, making it difficult to integrate into the MES system and achieve digital and intelligent collaborative management for manufacturers. 3. The fuse product is special. The three phases (A, B, and C) are packaged separately, but when shipping, it must be shipped as a complete set of three phases (A, B, and C). Incorrect, missing, or mixed packaging will seriously affect product quality and the manufacturer's reputation. At present, the production process mainly relies on the diligence of employees and lacks automatic detection processes and methods. 4. After the sealing and plastic sealing of the fuse packaging box is completed, the box stops at the end of the conveyor line. The stopping position is uncertain. Due to the large number of stacking layers, the uncertainty of the stopping position will lead to uneven stacking of the boxes, which may cause the boxes to fall off during the stacking process and the stack to collapse, thus causing safety accidents and product damage. 5. Since the packaging box of the fuse is a corrugated cardboard box, the suction cup end effector of the gantry robot is prone to falling off during handling due to air pressure fluctuations, which may lead to safety accidents and product damage. Because the corrugated cardboard is relatively soft and has a certain degree of air permeability, the conventional method of judging whether the cardboard box has fallen off or partially fallen off by detecting the vacuum degree is prone to misjudgment and affects production efficiency. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides an automated assembly line for high-voltage drop-out fuses and its control method. The production line is highly flexible and automated, and can be integrated into a MES system. The intelligent control system and control method enable digital and intelligent collaborative management, greatly improving production safety and product quality.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An automated assembly line for high-voltage drop-out fuses includes a double-speed chain head lifting platform, a porcelain insulator transfer area, a pallet transfer double-speed chain, a fuse pre-assembly area, a double-speed chain tail lifting platform, an unpacking area, an intelligent integrated packaging area, a line tail parking and visual correction area, a palletizing area, a pallet transfer area, an automatic wrapping packaging area, and an intelligent control system. The double-speed chain head lifting platform, pallet transfer double-speed chain, double-speed chain tail lifting platform, intelligent integrated packaging area, tail line parking and visual correction area, and palletizing area are arranged and connected in sequence. The porcelain bottle transfer area and the molten component pre-assembly area are located on one side of the pallet transfer double-speed chain. The molten component pre-assembly area is equipped with three assembly stations: trunnion small assembly, main conductive assembly, and support small assembly. The pallet transfer double-speed chain is equipped with upper support assembly, lower support assembly area, overall assembly area, and pallet rotation area. The unpacking area is located on one side of the intelligent integrated packaging area, and is equipped with an automatic unpacking machine and a conveyor line, which is connected to the intelligent integrated packaging area. The intelligent integrated packaging area is equipped with five processes: box packing, automatic detection of protective sleeves and color marks, automatic marking, automatic box sealing, and automatic plastic sealing. The tail-end parking and visual correction area is equipped with a vision system for correction, and the palletizing area is equipped with a palletizing robot for automatic palletizing, and a packaging box falling off judgment process and an automatic color mark detection process after stacking. The pallet transfer area is equipped with a roller conveyor to transfer empty pallets to the empty pallet waiting position. When palletizing is required, the empty pallets are transferred to the palletizing position in the palletizing area for palletizing. The palletizing area is connected to the automatic wrapping area, which is equipped with a waterproof film wrapping machine for automatic wrapping. The intelligent control system is controlled by a PLC and communicates with the actuators and equipment in various areas of the production line via fieldbus. It controls the automatic operation of the actuators and equipment, collects various sensor signals on the production line through switch input ports to ensure coordinated operation of each link, and communicates with the host computer through the network port to collect production information to the MES system, thereby realizing the digitalization and intelligentization of production.

[0006] A control method for an automated assembly line of high-voltage drop-out fuses is achieved through the following steps: 1) Place the porcelain bottles in the porcelain bottle transfer area on the tooling pallet. The trunnion, lower tube sleeve assembly, melting tube assembly, and support base assembly are assembled at three stations in the pre-assembly area of ​​the melting components. Then, the upper and lower supports are assembled and formed on the pallet transfer double-speed chain. The assembled fuses are packed into packaging boxes. The tooling pallet used to carry the assembly is transferred to the beginning of the production process via the double-speed chain tail lifting platform, the pallet rotation area, and the double-speed chain head lifting platform to receive the porcelain bottles for the next round of production. 2) The batch packaging boxes containing fuses are opened by the automatic box opener in the box opening area and become independent open packaging boxes stacked in sequence. They are then conveyed to the intelligent integrated packaging area in sequence via the conveyor line. 3) In the packing process, each package contains a protective sleeve of the phase sequence color corresponding to the fuse, as well as an instruction manual and a certificate of conformity. The outer packaging box is affixed with a color mark of the corresponding phase sequence color. In the automatic detection process of protective sleeve and color mark, the vision system automatically judges whether the protective sleeve is missing, whether the color mark is missing, and whether the color of the protective sleeve and the color mark are consistent. An alarm is issued in case of missing, missing, or inconsistent colors. If the detection is correct, it enters the automatic marking process, where the production serial number and other information are printed on the outside of the packaging box. Then, it enters the automatic sealing process and the automatic plastic sealing process. 4) The sealed packaging boxes automatically stop at the end of the line and the visual correction area. After visual positioning, they are automatically stacked by the palletizing robot in the palletizing area. Before stacking, the empty pallets are transferred from the waiting position to the stacking position in the pallet transfer area. During stacking, there are 6 containers per layer, arranged in two rows on the left and right in an axially symmetrical manner, with 3 containers in each row. Each row is arranged in the order of A, B, C, and D with the three color markings facing outwards. After placement, the palletizing robot rotates 180° to place another row. During the stacking process, it is judged whether the packaging boxes have fallen off. After stacking 10 layers and 60 boxes, the vision system checks whether the color markings on the left and right sides are correct. If misplacement, miscounting, or confusion occurs, the system alarms. After the detection is correct, the entire stack of fuses, along with the bottom pallet, enters the automatic wrapping packaging area for automatic wrapping packaging. The roller conveyor in the pallet transfer area automatically transfers the empty pallets from the waiting position to the stacking position to start a new stacking process. After automatic wrapping packaging, the single-trip fuse production process ends, and the intelligent control system completes the cycle of the entire production process.

[0007] In step 4), the palletizing robot uses a 4-axis gantry robot. Its coordinate system is established with X-axis, Y-axis, Z-axis and rotation end A-axis. When the A-axis is at the origin, the end effector direction is parallel to the X-axis. Based on this, the transformation relationship between the coordinates of the object in the gantry robot coordinate system and the coordinates in the camera coordinate system is established, which is achieved through the following steps: First, place the calibration board at the location where the fuse packaging box is parked, which is near the center of the camera's field of view. The camera takes pictures and converts the coordinates of the feature points on the calibration board. There must be at least three feature points; when there are three, no three points should be on the same straight line. The vision system then calculates the position of each feature point within the camera coordinate system. ; Next, a needle-like object is vertically placed at the center of the A-axis rotation of the 4-axis gantry robot, which is also the center of the end effector. The tip of the needle-like object is then moved to the location of the visual recognition feature point, and the position coordinates of each feature point in the robot's coordinate system are recorded. Let the position of the origin of the camera coordinate system within the coordinate system of the gantry manipulator be a constant. The relationship between the camera coordinate system and the truss coordinate system can be obtained as follows: ; Finally, the transformation relationship between the gantry robot coordinate system and the camera coordinate system was calculated using equations as follows: That is, to obtain the constant vector: , Rotation matrix: .

[0008] The calibration and teaching methods used for the tail-end parking and visual correction zone in step 4) are as follows: First, a reference fuse box is parked at the designated parking area. The camera visually identifies the position of the box's geometric center point in the camera coordinate system, as well as the initial angle between the box's long side and the camera's X-axis. and By transforming the coordinates, the position and angle of this reference fuse packaging box in the camera coordinate system are converted into its position in the gantry robot coordinate system, as well as the angle between it and the X-axis of the gantry robot coordinate system. and ; Next, move the gantry robot directly above the reference fuse packaging box, aligning the center of the rotation axis A with the center of the packaging box. Rotate the end effector until all suction cups on the end effector are in contact with the packaging box and as centered as possible. Record the position coordinates and angle of the end effector at this point. and To verify the correctness of the calibration and the accuracy of the test, let the difference between the two be denoted as _____. If the difference is small enough, the camera is considered to be calibrated correctly; otherwise, it is recalibrated. Next, the vacuum generator is triggered to draw air, and the suction cup of the end effector lifts the reference fuse packaging box. The end effector is then moved vertically to a position approximately 20cm above the initial position, and this position is recorded as the upper position of the initial position. and angle Move the reference fuse box towards the stacking direction. When it is out of the camera's field of view from the reference position of the box, save this position as the end effector's waiting position. Move the reference fuse box to the left row, A phase position on the pallet, with the label facing outwards. Record this position as the reference position for placing the reference fuse box, i.e., the first A phase position of the first layer, denoted as [missing information]. The placement of the remaining 59 boxes will be based on this; Finally, after any subsequent package is sealed in plastic, it is parked in its parking position. The vision system sends the position information to the control system according to the above steps. The control system controls the gantry robot to move to the position directly above the package based on the coordinates, and moves vertically downward to grab the package. At this time, the relative position of the end effector of the gantry robot and the package is the same as the relative position of the end effector and the package in the reference state (ignoring the positioning detection error of the vision system). The end effector lifts the package and moves it to the end effector waiting position. At this time, the position of the package is the same as the position of the package in the reference state, and the position of the gantry robot is the same as the position of the gantry robot in the reference state. After this, the process only needs to execute the set palletizing program.

[0009] The method for determining whether the packaging box has fallen off in step 3) is achieved by installing a material gripping detection sensor at each of the four corners of the end effector: Under normal conditions, the material gripping sensor is inactive and its signal status is on. When the end effector lifts the packaging box by vacuuming, the packaging box triggers the material gripping detection sensor, and the signal status is off. When a corner comes off during the handling process, the signal of the corresponding material gripping detection sensor changes from off to on; The controller can use the signals from the material handling detection sensor as a criterion for diagnosing packaging box detachment; Under the premise of criterion 1, the threshold of vacuum degree criterion can be relaxed and used as criterion 2; When the two are combined, if any of the material handling detection sensors shows an off signal or the vacuum level is unqualified, the system will diagnose it as a packaging box falling off and trigger an alarm.

[0010] The material handling detection sensor includes, but is not limited to, limit switches. The precise positioning and palletizing control method based on a 4-axis gantry robot in step 4) is implemented through the following steps: Step S1: The gantry robot moves to the gripping waiting position, which is close to the packaging box parking position but does not obstruct the positioning camera's field of view; Step S2: The packaging box is conveyed to the parking position after the plastic sealing process. After it stops, the control system sends a signal to the camera to trigger the camera to take pictures and locate the position. Step S3: After receiving the trigger signal, the camera takes a picture and performs recognition, positioning, and coordinate transformation; Step S4: If identification fails, send an alarm message to the controller; if identification is successful, calculate the positional deviation between the current packaging box position and the reference packaging box position. Step S5: If the position deviation between the front packaging box and the reference packaging box exceeds the deviation threshold, an alarm message is sent to the controller; Step S6: If the position deviation is within the deviation threshold, send the position coordinates to the controller; Step S7: The controller drives the gantry robot to move to the position above the material gripper. This position is the position after visual correction. It moves vertically downwards to the gripping position. Step S8: Control the vacuum generator to draw in air; Step S9: After a delay to ensure the suction cup is firmly attached, the controller drives the gantry robot to move to the position above the material gripper; Step S10: Detect vacuum level and sensor information; Step S11: Determine if the vacuum level is normal. If it is abnormal, it means the packaging box has fallen and an alarm will be triggered. If it is normal, proceed to the next step. Step S12: Determine if the signal from the packaging box grabbing detection sensor is normal. If it is abnormal, an alarm will be triggered. If it is normal, proceed to step 13. Step S13: The controller drives the gantry robot to move to the gripping waiting position; Step S14: Determine whether the package being grabbed is placed on the right side. If yes, proceed to step 15; otherwise, proceed to step 16. Step S15: Rotate the A-axis of the gantry robot by 180°; Step S16: The gantry robot passes through the transition point; Step S17: The gantry robot places the packaging box in the corresponding position; Step S18: Control the vacuum generator to blow air; Step S19: The gantry robot passes through the transition point; Step S20: The gantry robot returns to the gripping waiting position.

[0011] This invention designs an automated assembly line for high-voltage drop-out fuses. Controlled by a PLC, it communicates with various components and equipment on the production line via fieldbus, ensuring coordinated operation. The main control system can communicate with a host computer via Ethernet, facilitating the collection of production information into the MES system, achieving digital and intelligent production. It boasts a high degree of automation, flexibility, and small footprint, making it suitable for widespread application. The design also includes an automatic detection process for protective sleeves and color marks based on a vision system. This process automatically detects whether protective sleeves or color marks are missing from the packaging, and whether the sleeve color matches the external marking color, preventing incorrect placement of protective sleeves within the packaging box. This paper addresses the shortcomings of conventional handling equipment that relies solely on vacuum levels to determine whether a box has fallen off. It proposes a coordinate system calibration method based on a 4-axis gantry robot, a visual correction calibration and teaching method, a method for judging box detachment based on a combination of material handling sensors and vacuum levels, and a precise positioning and palletizing control method based on a 4-axis gantry robot. These methods effectively correct box positioning deviations without requiring mechanical contact with the boxes, ensuring neat stacking of 10-layer boxes and preventing tilting or collapse. This overcomes the limitations of conventional handling equipment that relies solely on vacuum levels to determine box detachment, significantly reducing the false positive rate, improving production efficiency, and ensuring production safety and product quality. This approach is suitable for widespread application within the industry. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the production line structure of the present invention; Figure 2 Flowchart of the automatic inspection process for three-phase complete stacking of fuse products after assembly; Figure 3 This is a schematic diagram of the arrangement of the left and right rows of color marks after the stacking of the present invention; Figure 4 This is a schematic diagram showing the relative positions of the coordinate system of the gantry manipulator, the camera coordinate system, and the calibration points of the present invention. Figure 5 This is a flowchart of the precise positioning and palletizing method of the present invention. Detailed Implementation

[0013] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments: like Figure 1 As shown, the automated assembly line for high-voltage drop-out fuses includes a double-speed chain head lifting platform 1, a porcelain insulator transfer area 2, a pallet transfer double-speed chain 3, a fuse pre-assembly area 4, a double-speed chain tail lifting platform 5, an unpacking area 7, an intelligent integrated packaging area 6, a line tail parking and visual correction area 8, a palletizing area 9, a pallet transfer area 10, an automatic wrapping packaging area 11, and an intelligent control system.

[0014] The double-speed chain head lifting platform 1, pallet transfer double-speed chain 3, double-speed chain tail lifting platform 5, intelligent integrated packaging area 6, tail line parking and visual correction area 8, and palletizing area 9 are arranged adjacent to each other in sequence. The porcelain bottle transfer area 2 and the molten component pre-assembly area 4 are located on one side of the pallet transfer double-speed chain 3. The molten component pre-assembly area 4 is provided with three assembly stations: trunnion small assembly 41, main conductive assembly 42, and support small assembly 43. The pallet transfer double-speed chain 3 is provided with upper support assembly area 31, lower support assembly area 32, overall assembly area 33, and pallet rotation area 34.

[0015] After the fuse is assembled in the overall assembly area 33, the pallet is transferred back to the double-speed chain head lifting platform 1 via the double-speed chain tail lifting platform 5 and the pallet rotation area 34, and re-enters the production process. The fuse is then loaded into the packaging box by the assembly personnel and enters the intelligent integrated packaging area 6.

[0016] The unpacking area 7 is located on one side of the intelligent integrated packaging area 6, and includes an automatic case opener 71 and a conveyor line 72. The conveyor line 72 is connected to the intelligent integrated packaging area 6. After being opened by the automatic case opener 71, a batch of packaging boxes are conveyed to the intelligent integrated packaging area 6 via the conveyor line 72.

[0017] The intelligent integrated packaging area 6 is equipped with five processes: boxing process 61, automatic detection process for protective sleeves and color marks 62, automatic marking process 63, automatic box sealing process 64, and automatic plastic sealing process 65.

[0018] The tail-end parking and visual correction area 8 is equipped with a vision system for correction, and the palletizing area 9 is equipped with a palletizing robot for automatic palletizing, as well as a packaging box detachment judgment process and an automatic color mark detection process after stacking.

[0019] The pallet transfer area 10 is equipped with a roller conveyor to transfer empty pallets to the empty pallet waiting position. When palletizing is required, the empty pallets are transferred to the palletizing position in the palletizing area 9 for palletizing. The palletizing area 9 is connected to the automatic wrapping area 11, which is equipped with a waterproof film wrapping machine for automatic wrapping.

[0020] The intelligent control system is controlled by a PLC and communicates with the actuators and equipment in various areas of the production line via fieldbus. It controls the automatic operation of the actuators and equipment, collects various sensor signals on the production line through switch input ports to ensure coordinated operation of each link, and communicates with the host computer through the network port to collect production information to the MES system, thereby realizing the digitalization and intelligentization of production.

[0021] Specifically, in this embodiment, the PLC communicates with servo drives, frequency converters, sheath and color mark visual inspection systems, packaging box correction cameras, palletizing color mark visual inspection systems, automatic carton openers, automatic carton sealers, coding machines, plastic sealers, and waterproof film wrapping machines via fieldbus communication. It collects various sensor signals on the production line through switch input ports to ensure coordinated operation of each link. It can also communicate with the host computer via network port to facilitate the collection of production information into the MES system, thereby realizing the digitalization and intelligentization of production.

[0022] like Figure 2-3 As shown, a control method for an automated assembly line of high-voltage drop-out fuses is implemented through the following steps: 1) Place the porcelain bottles in the porcelain bottle transfer area 2 on the tooling pallet. The trunnion and lower tube sleeve assembly, the melting tube assembly, and the support base assembly are assembled in the three stations of the melting component pre-assembly 4. Then, the upper bracket and lower bracket of the fuse are assembled and formed on the pallet transfer double speed chain 3. The assembled fuse is put into the packaging box. The tooling pallet used to carry the assembly is transferred to the beginning of the production process via the double speed chain tail lifting platform 5, the pallet rotation area 34, and the double speed chain head lifting platform 1 to receive the porcelain bottles for the next round of production process. 2) The batch packaging boxes containing fuses are opened by the automatic case opener 71 in the case opening area 7, becoming independent open packaging boxes stacked in sequence, and then conveyed sequentially to the intelligent integrated packaging area 6 via conveyor line 72. 3) In the packing process 61, each package contains a protective sleeve of the phase sequence color corresponding to the fuse, as well as an instruction manual and a certificate of conformity. The outer packaging box is affixed with a color mark of the corresponding phase sequence color. In the automatic detection process 62 of the protective sleeve and color mark, the vision system automatically judges whether the protective sleeve is missing, whether the color mark is missing, and whether the color of the protective sleeve and the color mark are consistent. An alarm is issued if there is any missing, missing, or inconsistent situation. If the detection is correct, it enters the automatic marking process 63, where the production serial number and other information are printed on the outside of the packaging box. Then, it enters the automatic sealing process 64 for automatic sealing and the automatic plastic sealing process 65 for automatic plastic sealing. 4) The sealed packaging boxes automatically stop at the end of the line and the visual correction area 8. After visual positioning, they are automatically stacked in the palletizing area 9 by the palletizing robot. Before stacking, the pallet transfer area 10 has already transferred the empty pallets from the waiting position to the stacking position. During stacking, there are 6 containers per layer, arranged in two rows on the left and right in an axially symmetrical manner, with 3 containers in each row. Each row is arranged in the order of A, B, C, and D with the three color markings facing outwards. After placement, the palletizing robot rotates 180° to place another row. During the stacking process, it is judged whether the packaging boxes have fallen off. After stacking 10 layers of 60 boxes, the vision system checks whether the color markings on the left and right sides are correct. If misplacement, miscounting, or confusion occurs, the system alarms. After the detection is correct, the entire stack of fuses, along with the bottom pallet, enters the automatic wrapping packaging area 11 for automatic wrapping packaging. The roller conveyor in the pallet transfer area 10 automatically transfers the empty pallets from the pallet waiting position to the stacking position to start a new stacking process. After automatic wrapping packaging, the single-trip fuse production process ends, and the intelligent control system completes the cycle of the entire production process.

[0023] After the box sealing process is completed, the parking position at the end of the line is uncertain. Since the stacking layer is set to 10 layers, this uncertainty in parking position will lead to uneven stacking of the boxes, easily causing stack collapse and resulting in safety accidents and product damage. Mechanical positioning is prone to damaging the packaging boxes and is inefficient. To solve these problems, this application designs the palletizing robot as a 4-axis gantry robot and designs a precise positioning and palletizing method based on the 4-axis gantry robot and a vision correction system. The specific method is described layer by layer below: like Figure 4 As shown, in a preferred manner, the palletizing robot in step 4) is a 4-axis gantry robot, whose coordinate system is established with X-axis, Y-axis, Z-axis and rotation end A-axis. When the A-axis is at the origin, the end effector direction is parallel to the X-axis. Based on this, the transformation relationship between the coordinates of the object in the gantry robot coordinate system and the coordinates in the camera coordinate system is established, which is achieved through the following steps: First, place the calibration board at the location where the fuse packaging box is parked, which is near the center of the camera's field of view. The camera takes pictures and converts the coordinates of the feature points on the calibration board. There must be at least three feature points; when there are three, no three points should be on the same straight line. The vision system then calculates the position of each feature point within the camera coordinate system. ; Next, a needle-like object is vertically placed at the center of the A-axis rotation of the 4-axis gantry robot, which is also the center of the end effector. The tip of the needle-like object is then moved to the location of the visual recognition feature point, and the position coordinates of each feature point in the robot's coordinate system are recorded. Let the position of the origin of the camera coordinate system within the coordinate system of the gantry manipulator be a constant. The relationship between the camera coordinate system and the truss coordinate system can be obtained as follows: ; Finally, the transformation relationship between the gantry robot coordinate system and the camera coordinate system was calculated using equations as follows: That is, to obtain the constant vector: , Rotation matrix: .

[0024] As a preferred embodiment, the calibration and teaching method used in step 4) of the tail-end parking and visual correction zone 8 is as follows: First, a reference fuse box is parked at the designated parking area. The camera visually identifies the position of the box's geometric center point in the camera coordinate system, as well as the initial angle between the box's long side and the camera's X-axis. and By transforming the coordinates, the position and angle of this reference fuse packaging box in the camera coordinate system are converted into its position in the gantry robot coordinate system, as well as the angle between it and the X-axis of the gantry robot coordinate system. and ; Next, move the gantry robot directly above the reference fuse packaging box, aligning the center of the rotation axis A with the center of the packaging box. Rotate the end effector until all suction cups on the end effector are in contact with the packaging box and as centered as possible. Record the position coordinates and angle of the end effector at this point. and To verify the correctness of the calibration and the accuracy of the test, let the difference between the two be denoted as _____. ,in: If the difference is small enough, the camera is considered to be calibrated correctly; otherwise, it is recalibrated. Next, the vacuum generator is triggered to draw air, and the suction cup of the end effector lifts the reference fuse packaging box. The end effector is then moved vertically to a position approximately 20cm above the initial position, and this position is recorded as the upper position of the initial position. and angle Move the reference fuse box towards the stacking direction. When it is out of the camera's field of view from the reference position of the box, save this position as the end effector's waiting position. Move the reference fuse box to the left row, A phase position on the pallet, with the label facing outwards. Record this position as the reference position for placing the reference fuse box, i.e., the first A phase position of the first layer, denoted as [missing information]. The placement of the remaining 59 boxes will be based on this; Finally, after any subsequent package is sealed in plastic and parked in its designated spot, the vision system detects the position of its geometric center in the camera coordinate system and the angle between its longer side and the X-axis of the camera coordinate system as follows: and At this point, the coordinates are used through a relationship The coordinates converted to the coordinate system of the gantry robot under visual inspection are: and The vision system sends the position information to the control system according to the above steps. The control system controls the gantry robot to move to the position directly above the packaging box according to the coordinates, moves vertically downward to grab the packaging box, and the end effector lifts the packaging box and moves it to the end effector waiting position. After that, the process only needs to execute the set palletizing program.

[0025] As a preferred embodiment, in step 3), the method for determining whether the packaging box has fallen off is implemented by installing a material gripping detection sensor at each of the four corners of the end effector. Under normal conditions, the material gripping sensor is inactive and its signal status is on. When the end effector lifts the packaging box by vacuuming, the packaging box triggers the material gripping detection sensor, and the signal status is off. When a corner comes off during the handling process, the signal of the corresponding material gripping detection sensor changes from off to on; The controller can use the signals from the material handling detection sensor as a criterion for diagnosing packaging box detachment; Under the premise of criterion 1, the threshold of vacuum degree criterion can be relaxed and used as criterion 2; When the two are combined, if any of the material handling detection sensors shows an off signal or the vacuum level is unqualified, the system will diagnose it as a packaging box falling off and trigger an alarm.

[0026] Specifically, the material handling detection sensor includes, but is not limited to, limit switches. like Figure 5 As shown, in this preferred embodiment, the precise positioning and palletizing control method based on a 4-axis gantry robot in step 4) is implemented through the following steps: Step S1: The gantry robot moves to the gripping waiting position, which is close to the packaging box parking position but does not obstruct the positioning camera's field of view; Step S2: The packaging box is conveyed to the parking position after the plastic sealing process. After it stops, the control system sends a signal to the camera to trigger the camera to take pictures and locate the position. Step S3: After receiving the trigger signal, the camera takes a picture and performs recognition, positioning, and coordinate transformation; Step S4: If identification fails, send an alarm message to the controller; if identification is successful, calculate the positional deviation between the current packaging box position and the reference packaging box position. Step S5: If the position deviation between the front packaging box and the reference packaging box exceeds the deviation threshold, an alarm message is sent to the controller; Step S6: If the position deviation is within the deviation threshold, send the position coordinates to the controller; Step S7: The controller drives the gantry robot to move to the position above the material gripper. This position is the position after visual correction. It moves vertically downwards to the gripping position. Step S8: Control the vacuum generator to draw in air; Step S9: After a delay to ensure the suction cup is firmly attached, the controller drives the gantry robot to move to the position above the material gripper; Step S10: Detect vacuum level and sensor information; Step S11: Determine if the vacuum level is normal. If it is abnormal, it means the packaging box has fallen and an alarm will be triggered. If it is normal, proceed to the next step. Step S12: Determine if the signal from the packaging box grabbing detection sensor is normal. If it is abnormal, an alarm will be triggered. If it is normal, proceed to step 13. Step S13: The controller drives the gantry robot to move to the gripping waiting position; Step S14: Determine whether the package being grabbed is placed on the right side. If yes, proceed to step 15; otherwise, proceed to step 16. Step S15: Rotate the A-axis of the gantry robot by 180°; Step S16: The gantry robot passes through the transition point; Step S17: The gantry robot places the packaging box in the corresponding position; Step S18: Control the vacuum generator to blow air; Step S19: The gantry robot passes through the transition point; Step S20: The gantry robot returns to the gripping waiting position.

[0027] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. An automated assembly line for high-voltage drop-out fuses, characterized in that: It includes a double-speed chain head lifting platform (1), a porcelain bottle transfer area (2), a pallet transfer double-speed chain (3), a pre-loading area for molten parts (4), a double-speed chain tail lifting platform (5), an unpacking area (7), an intelligent integrated packaging area (6), a line tail parking and visual correction area (8), a palletizing area (9), a pallet transfer area (10), an automatic wrapping packaging area (11), and an intelligent control system; The double-speed chain head lifting platform (1), pallet transfer double-speed chain (3), double-speed chain tail lifting platform (5), intelligent integrated packaging area (6), line tail parking and visual correction area (8), and palletizing area (9) are arranged and connected in sequence. The porcelain bottle transfer area (2) and the molten component pre-assembly area (4) are located on one side of the pallet transfer double-speed chain (3). The molten component pre-assembly area (4) is provided with three assembly stations: trunnion small assembly (41), main conductive assembly (42), and support small assembly (43). The pallet transfer double-speed chain (3) is provided with upper support assembly area (31), lower support assembly area (32), overall assembly area (33), and pallet rotation area (34). The unpacking area (7) is located on one side of the intelligent integrated packaging area (6), and is equipped with an automatic unpacking machine (71) and a conveyor line (72), which is connected to the intelligent integrated packaging area (6). The intelligent integrated packaging area (6) is equipped with five processes: box packing (61), automatic detection of protective sleeves and color marks (62), automatic marking (63), automatic box sealing (64), and automatic plastic sealing (65). The tail parking and visual correction area (8) is equipped with a vision system for correction, and the palletizing area (9) is equipped with a palletizing robot for automatic palletizing, and a packaging box falling off judgment process and a color mark automatic detection process after stacking are set up. The pallet transfer area (10) is equipped with a roller conveyor to transfer empty pallets to the empty pallet waiting position. When palletizing is required, the empty pallets are transferred to the palletizing position of the palletizing area (9) for palletizing. The palletizing area (9) is connected to the automatic wrapping area (11). The automatic wrapping area (11) is equipped with a waterproof film wrapping machine for automatic wrapping. The intelligent control system is controlled by a PLC and communicates with the actuators and equipment in various areas of the production line via fieldbus. It controls the automatic operation of the actuators and equipment, collects various sensor signals on the production line through the switch input port to coordinate the operation of each link, and communicates with the host computer through the network port to collect production information to the MES system.

2. The control method for the automated assembly line of high-voltage drop-out fuses as described in claim 1, characterized in that, This can be achieved through the following steps: 1) Place the porcelain bottles in the porcelain bottle transfer area (2) on the tooling tray. The trunnion, lower tube sleeve assembly, melt tube assembly, and support base assembly are assembled at the three assembly stations in the pre-assembly area (4) of the melt-carrying component. Then, the upper bracket, lower bracket, and overall assembly are formed on the pallet transfer double speed chain (3). The assembled fuse is put into the packaging box. The tooling tray used to carry the porcelain bottles is transferred to the beginning of the production process via the double speed chain tail lifting platform (5), the pallet rotation area (34), and the double speed chain head lifting platform (1) to receive the porcelain bottles for the next round of production process. 2) The batch packaging boxes containing fuses are opened by the automatic box opener (71) in the box opening area (7) and become independent open packaging boxes stacked in sequence. They are then conveyed to the intelligent integrated packaging area (6) in sequence via the conveyor line (72). 3) In the packing process (61), each package contains a sheath with the corresponding phase sequence color of the fuse, as well as an instruction manual and a certificate of conformity. The outer packaging box is affixed with a color mark corresponding to the phase sequence color. In the automatic detection process of sheath and color mark (62), the vision system automatically judges whether the sheath is missing, whether the color mark is missing, and whether the color of the sheath and the color mark are consistent. If there is a missing, missing, or inconsistent situation, an alarm will be issued. If the detection is correct, the automatic marking process (63) will be entered, and the production serial number will be printed on the outside of the packaging box. The automatic sealing process (64) will be entered, and the automatic plastic sealing process (65) will be entered. 4) The sealed packaging boxes automatically stop at the end of the line and the visual correction area (8). After visual positioning, they are automatically stacked in the palletizing area (9) by the palletizing robot. Before stacking, the pallet transfer area (10) has already transferred the empty pallets from the waiting position to the stacking position. During stacking, there are 6 containers per layer, arranged in two rows on the left and right in an axially symmetrical manner, with 3 containers in each row. Each row is arranged in three phases (A, B, C) with the color mark facing outwards. After placement, the palletizing robot rotates 180° to place another row. During the stacking process, the packaging boxes are judged to be... If the fuses fall off, after stacking 10 layers of 60 boxes, the vision system checks whether the color marks on the left and right sides are correct. If there is misinstallation, mis-marking, or confusion, the system will alarm. After the detection is correct, the entire stack of fuses, together with the bottom pallet, enters the automatic wrapping and packaging area (11) for automatic wrapping and packaging. The roller line in the pallet transfer area (10) automatically transfers the empty pallets in the pallet waiting position to the stacking position to start a new stacking process. After automatic wrapping and packaging, the single-trip fuse production process ends, and the intelligent control system completes the cycle of the entire production process.

3. The control method for the automated assembly line of high-voltage drop-out fuses according to claim 2, characterized in that, In step 4), the palletizing robot uses a 4-axis gantry robot. Its coordinate system is established with X-axis, Y-axis, Z-axis and rotation end A-axis. When the rotation end A-axis is at the origin, the end effector direction is parallel to the X-axis. Based on this, the transformation relationship between the coordinates of the object in the gantry robot coordinate system and the coordinates in the camera coordinate system is established, which is achieved through the following steps: First, place the calibration board at the location where the fuse packaging box is parked, which is near the center of the camera's field of view. Take pictures and convert the coordinates of the feature points on the calibration board. The number of feature points is greater than or equal to 3. When there are 3 or more feature points, no three points are on the same straight line. The vision system then calculates the position of the feature points in the camera coordinate system. ; Next, a needle-like object is vertically placed at the center of the A-axis of the rotating end of the 4-axis gantry robot, which is also the center of the end effector. The tip of the needle-like object is then moved to the location of the visual recognition feature point, and the position coordinates of each feature point in the gantry robot's coordinate system are recorded. Let the position of the origin of the camera coordinate system within the coordinate system of the gantry manipulator be a constant. The relationship between the camera coordinate system and the gantry robot coordinate system can be obtained as follows: ; Finally, the transformation relationship between the gantry robot coordinate system and the camera coordinate system was calculated using equations as follows: That is, to obtain the constant vector: , Rotation matrix: .

4. The control method for the automated assembly line of high-voltage drop-out fuses according to claim 3, characterized in that, The calibration and teaching methods used in step 4) for the tail-end parking and visual correction zone (8) are as follows: First, a reference fuse box is parked at the designated parking area. The camera visually identifies the position of the box's geometric center point in the camera coordinate system, as well as the initial angle between the box's long side and the camera's X-axis. and By transforming the coordinates, the position and angle of this reference fuse packaging box in the camera coordinate system are converted into its position in the gantry robot coordinate system, as well as the angle between it and the X-axis of the gantry robot coordinate system. and ; Next, move the 4-axis gantry robot directly above the reference fuse packaging box, aligning the center of the rotating end A-axis with the center of the reference fuse packaging box. Rotate the end effector until the suction cups on the end effector are in contact with the packaging box and as centered as possible. Record the position coordinates and angle of the end effector at this point. and To verify the correctness of the calibration and the accuracy of the test; Next, the vacuum generator is triggered to draw air, and the suction cup of the end effector lifts the reference fuse packaging box. The end effector is then moved vertically to a position approximately 20cm above the initial position, and this position is recorded as the upper position of the initial position. and angle ; Move the reference fuse box towards the stacking direction. When it is out of the camera's field of view from the reference position of the box, save this position as the end effector waiting position. Move the reference fuse box to the left row, A phase position on the pallet, with the label facing outwards. Record this position as the reference position for placing the reference fuse box, i.e., the first A phase position of the first layer, denoted as [missing information]. The placement of the remaining 59 boxes will be based on this; Finally, after any subsequent package is sealed in plastic, it is parked in the parking position. The vision system sends the position information to the intelligent control system according to the above steps. The intelligent control system controls the 4-axis gantry robot to move to the position directly above the package based on the coordinates, moves vertically downward to grab the package, and the end effector lifts the package and moves it to the end effector waiting position. After that, the process only needs to execute the set palletizing program.

5. The control method for the automated assembly line of high-voltage drop-out fuses according to claim 4, characterized in that, The method for determining whether the packaging box has fallen off in step 3) is achieved by installing a material gripping detection sensor at each of the four corners of the end effector: Under normal conditions, the material handling detection sensor is inactive and its signal status is on. When the end effector lifts the packaging box by vacuuming, the packaging box triggers the material gripping detection sensor, and the signal status is off. When a corner comes off during the handling process, the signal of the corresponding material gripping detection sensor changes from off to on; The intelligent control system uses the signals from the material handling detection sensor as the criterion for diagnosing packaging box detachment; Under the premise of criterion 1, the threshold of the vacuum degree criterion is relaxed and used as criterion 2; When the two are combined, if any of the material handling detection sensors shows an off signal or the vacuum level is unqualified, the system will diagnose it as a packaging box falling off and trigger an alarm.

6. The control method for the automated assembly line of high-voltage drop-out fuses according to claim 5, characterized in that, The material handling detection sensor includes a limit switch.

7. The control method for the automated assembly line of high-voltage drop-out fuses according to claim 3, characterized in that, The precise positioning and palletizing control method based on a 4-axis gantry robot in step 4) is implemented through the following steps: Step S1: The 4-axis gantry robot moves to the gripping waiting position. This waiting position is close to the packaging box parking position, but does not obstruct the camera's field of view. Step S2: The packaging box is automatically sealed and then transported to the parking position. After it stops, the intelligent control system sends a signal to the camera to trigger the camera to take a picture and locate the position. Step S3: After receiving the trigger signal, the camera takes a picture and performs recognition, positioning, and coordinate transformation; Step S4: If identification fails, send an alarm message to the intelligent control system. If identification is successful, calculate the positional deviation between the current packaging box position and the reference fuse packaging box position. Step S5: If the positional deviation between the current packaging box and the reference fuse packaging box exceeds the deviation threshold, an alarm message is sent to the intelligent control system. Step S6: If the position deviation is within the deviation threshold, then send the position coordinates to the intelligent control system; Step S7: The intelligent control system drives the 4-axis gantry robot to move to the position above the material gripper. This position is the position after visual correction. It moves vertically downwards to the gripping position. Step S8: Control the vacuum generator to draw in air; Step S9: After a delay to ensure the suction cup is firmly attached, the intelligent control system drives the 4-axis gantry robot to move to the position above the material gripper. Step S10: Detect the vacuum level and material handling sensor signals; Step S11: Determine if the vacuum level is normal. If it is abnormal, it means the packaging box has fallen and an alarm will be triggered. If it is normal, proceed to the next step. Step S12: Determine if the material handling detection sensor signal is normal. If it is abnormal, set an alarm. If it is normal, proceed to step S13. Step S13: The intelligent control system drives the 4-axis gantry robot to move to the gripping waiting position; Step S14: Determine whether the package being grabbed is placed on the right side. If yes, proceed to step S15; otherwise, proceed to step S16. Step S15: The A-axis of the 4-axis gantry robot rotates 180°; Step S16: The 4-axis gantry robot passes through the transition point; Step S17: The 4-axis gantry robot places the packaging box in the corresponding position; Step S18: Control the vacuum generator to blow air; Step S19: The 4-axis gantry robot passes through the transition point; Step S20: The 4-axis gantry robot returns to the gripping waiting position.

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