Automatic feeding and discharging detection system and detection beat control method

Abstract

The invention relates to an automatic feeding and discharging detection system, which is characterized by comprising a feeding pre-adjusting table (1), a tray fixing device (112), a feeding platform device (11) and a tray fixing device (112), the tray (17) is used for placing workpieces (16) in the tray (17) to form a workpiece tray combination; the blanking pre-adjusting table (12) comprises a blanking device and is used for separating the detected workpiece (16) of the workpiece tray combination (18) from the tray (17); the cache region (13) comprises a feeding frame (131) and a discharging frame (132) and is arranged beside the detection equipment (14); the detection equipment (14) is used for detecting the workpiece (16); according to the invention, through PID control and man-machine cooperation, the beat stability of the system is improved by 40-50%; the utilization rate of the combined AGV is increased by 25-35%; the manual waiting time is reduced by 30-40%; and manual operation time fluctuation and production task change can be effectively coped with.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of industrial automation, in particular to an automatic feeding and discharging detection system comprising manual pre-adjustment operation and composite AGV transfer and a beat control method thereof. BACKGROUND

[0002] In existing automatic detection systems, the beat control of the feeding and discharging process has always been a technical difficulty. Especially when the system contains manual operation links, due to the uncertainty of manual operation time, it often leads to unstable beats of the entire system, affecting production efficiency.

[0003] The traditional solutions mainly have the following problems: 1. Manual operation and automatic equipment lack effective cooperation, and waiting or blocking phenomenon often occurs; 2. The influence of the buffer rack state on the system beat has not been fully considered; 3. The AGV scheduling strategy is single and cannot adapt to the demand of dynamic beat change; 4. There is a lack of overall optimization of the complete work flow (feeding pre-adjustment table → buffer area → detection equipment → buffer area → discharging pre-adjustment table).

[0004] Although existing patent technologies such as CN202211521499.X involve automatic feeding and discharging systems, they cannot effectively solve the beat coordination problem of manual operation and automatic equipment, especially in systems containing rack-type buffer areas, and lack a dynamic beat control mechanism. SUMMARY

[0005] The present application aims to overcome the shortcomings of the prior art and provide an automatic feeding and discharging detection system and a detection beat control method to solve the problem of unstable beats caused by fluctuations in manual operation time and changes in buffer area state.

[0006] An automatic feeding and discharging detection system, characterized in that it comprises: a feeding pre-adjustment table 1 comprising a feeding table device 11 and a tray fixing device 12; for placing workpieces 6 in trays 7 to form a workpiece tray combination; a discharging pre-adjustment table 2 comprising a discharging device for separating the workpieces 6 of the workpiece tray combination 8 that have been detected from the trays 7; a buffer area 3 comprising a feeding rack 31 and a discharging rack 32, arranged beside the detection equipment 4; detection equipment 4 for detecting workpieces 6; The composite AGV 5 is used for transferring the workpiece tray combination between the feeding pre-adjusting table 1 and the buffer area 3, and between the buffer area 3 and the discharging pre-adjusting table 2, and is used for rotating the workpiece tray combination placed in the buffer area 3 to the detection equipment 4 for detection, and transferring the detected workpiece tray combination to the discharging rack 32; The control unit 9 comprises a controller and a PID controller for detecting the beat, the controller is used for controlling the operation of each device and the execution of tasks, and the PID controller is used for coordinating the overall operation beat of the control system; During operation, the worker places the tray 7 in the tray fixing device 12 on the workpiece 6 placed on the feeding table device 11, forming the workpiece tray combination 8; the composite AGV 5 grabs the workpiece tray combination 8 to the composite AGV 5, and the composite AGV 5 carries the workpiece tray combination 8 to the feeding rack 31 in the buffer area 3, until the workpiece tray combinations 8 required for detection in a period of time are all placed on the feeding rack 31; When the detection equipment 4 is started, the composite AGV 5 carries the workpiece tray combination 8 on the feeding rack 31 to the detection equipment 4 for detection; the composite AGV 5 carries the next workpiece tray combination 8 on the feeding rack 31 in the buffer area 3 to the detection equipment 4 for waiting, when the previous workpiece tray combination 8 is detected and pushed out, the composite AGV 5 carries the next workpiece tray combination 8 to the detection equipment 4 for detection; then, the composite AGV 5 takes back the previous workpiece tray combination 8 after detection and carries it back to the discharging pre-adjusting table 2 in the buffer area 3; When all the workpiece tray combinations 8 on the feeding rack 31 are detected, the composite AGV 5 carries the detected workpiece tray combination 8 to the discharging pre-adjusting table 2, the worker separates the workpiece 6 and the tray 7 of the workpiece tray combination 8, the worker takes away the workpiece 6, the composite AGV 5 transfers the tray 7 to the feeding pre-adjusting table 1, the worker places a workpiece 6 to be detected on the tray 7, forming a workpiece tray combination 8, and the composite AGV 5 transfers the workpiece tray combination 8 to the feeding rack 31, until all the workpiece tray combinations 8 to be detected in the next period of time are transferred to the feeding rack 31, and the cycle is repeated.

[0007] The composite AGV comprises: The AGV trolley 55 is a carrier for carrying materials; The multi-station bearing platform is provided with at least two independent tray positioning mechanisms, and can simultaneously bear at least two workpiece tray combinations 8; The multi-degree-of-freedom mechanical arm has a double-clamp or multi-clamp system, and can simultaneously grab and place different workpieces in one operation cycle; The visual positioning system is configured as a device for identifying the position and attitude of the workpiece tray combination 8; Navigation system: A navigation device configured to move autonomously along a preset path.

[0008] The PID controller includes: Beat monitoring module: Used to monitor the running time of each stage in real time; PID control module: used to recalculate the control output cycle time based on the cycle error; AGV cycle adjustment module: used to adjust the operating parameters of the composite AGV according to the latest calculated control output cycle time; Human-computer interaction module: used to provide operators with cycle status information.

[0009] The loading pre-adjustment platform is equipped with a loading platform cycle status display 13 and the unloading platform is equipped with a cycle status display 21.

[0010] An automatic loading / unloading detection cycle control method, utilizing the aforementioned system, is characterized by comprising the following steps: Step 1: Establish a complete cycle time model that includes manual operation time, AGV transfer time, and detection time; Step 2: Based on the results obtained from the beat monitoring module: a. Time required for the composite AGV to transfer a workpiece pallet assembly 8 from the unloading rack 32 to the unloading pre-adjustment table 2; b. Time required for the composite AGV to return from the pre-adjustment table 2 to the unloading rack 32; c. Time required for the composite AGV to transfer a workpiece pallet assembly 8 from the loading pre-adjustment table 1 to the loading rack 31; d. Time required for the composite AGV to return from the loading rack 31 to the loading rack 31; e. Time required for manual placement of workpiece 6 into pallet 7 at the loading pre-adjustment table 1, forming workpiece pallet assembly 8; f. Time required for manual placement of workpiece 6 into pallet 7 at the unloading pre-adjustment table 2; g. Time required for the composite AGV to deliver the workpiece pallet assembly 8 to be inspected from the loading rack 31 to the inspection position of the inspection equipment 4; h. Time required for the composite AGV to deliver the inspected workpiece pallet assembly 8 to the unloading rack 32 at the inspection equipment 4; i. Time t0 required for the inspection equipment 4 to inspect one workpiece pallet assembly 8. Step 3: Based on the detection time of the detection equipment 4, before the detection equipment 4 is turned on, set the loading rack 31 to pre-store n sets of workpiece pallet combinations 8, and calculate the working time required for the composite AGV to be earlier than the detection equipment 4 as t1: t1=(a+b+c+d+e+f)*n; thereby determine the latest start time of the composite AGV. Step 4: The composite AGV5 delivers a workpiece pallet assembly 8 from the loading rack 31 to the inspection equipment 4, and delivers the previous workpiece pallet assembly 8 inspected by the inspection equipment 4 to the unloading rack 32 at a time t2: t2 < t0 (1-m), where m is the buffer coefficient, 0.1 < m < 0.2; Step 5: If t2 cannot satisfy: t2 < t0 (1-m), adjust and increase the speed of the composite AGV5 through the PID controller until t2 < t0 (1-m) is satisfied.

[0011] If the inspection time t0 of the inspection equipment 4 is relatively long, it can satisfy (a+b+c+d+e+f)+t2<t0(1-m); after the composite AGV 5 sends a workpiece pallet assembly 8 from the loading rack 31 to the inspection equipment 4 and sends the previous workpiece pallet assembly 8 inspected by the inspection equipment 4 to the unloading rack 32, it can complete one transfer of workpiece pallet assembly 8 from the unloading rack 32 to the unloading pre-adjustment table 2 and the return of the composite AGV from the unloading pre-adjustment table 2 to the unloading rack 32; thus, it can ensure that the inspection equipment 4 runs continuously.

[0012] Regulating via a PID controller includes: (1) The system operating cycle is dynamically adjusted by a PID controller; (2) Monitor the status of the buffer rack in real time and calculate the buffer impact factor; (3) Adjust the operating parameters of the composite AGV according to the control output; (4) Provide guidance on human-machine collaborative operation.

[0013] Beneficial effects Compared with the prior art, the present invention has the following beneficial effects: (1) Improved cycle stability: Through PID control and human-machine collaboration, the cycle stability of the system is improved by 40-50%; (2) Equipment utilization optimization: The utilization rate of composite AGVs is increased by 25-35%; (3) Improved labor efficiency: Labor waiting time reduced by 30-40%; (4) Enhanced system adaptability: It can effectively cope with fluctuations in manual operation time and changes in production tasks; (5) Improved caching efficiency: The utilization rate of rack-type buffer area is increased by 20-30%. Attached Figure Description

[0014] Figure 1 A schematic diagram of the device structure of the present invention; Figure 2 1. Detailed schematic diagram of the device of the present invention.

[0015] Among them, 1 is the loading pre-adjustment platform, 2 is the unloading pre-adjustment platform, 3 is the buffer area, 4 is the detection equipment, 5 is the composite AGV, 6 is the workpiece, 7 is the pallet, 8 is the workpiece pallet combination, 9 is the control unit, 10 is the safety guardrail, 11 is the loading platform device, 12 is the pallet fixing device, 31 is the loading rack, 32 is the unloading rack, 51 is station A, 52 is station B, 53 is the robotic arm, and 54 is the vision camera. Detailed Implementation

[0016] This invention provides an automatic loading and unloading detection system, comprising: The loading pre-adjustment table is equipped with a workpiece positioning device and a pallet fixing device, where operators can complete the precise combination of workpieces and pallets. The unloading pre-adjustment table is equipped with a workpiece separation auxiliary device, where operators can separate the workpiece from the pallet. The buffer area adopts a rack-type structure, divided into a loading buffer area and a unloading buffer area, with each material position equipped with a status sensor; the composite AGV integrates a multi-degree-of-freedom robotic arm, a vision positioning system, and an autonomous navigation system, enabling precise transfer of workpiece pallet combinations in complex environments; the control unit integrates cycle time monitoring, PID control, AGV scheduling, and human-machine interaction functions, and connects to various devices via Ethernet or industrial bus.

[0017] The present invention also provides a method for detecting beat control, comprising: System modeling steps: Establish a cycle time model that considers the variability of manual operation time: T_load = T_mc_avg + T_mc_var + T_AGV1 + T_AGV2; T_test = T_detect; T_unload = T_AGV3 + T_AGV4 + T_ms_avg + T_ms_var; T_cycle = max(T_load, T_test) + T_unload + F_cache × T_penalty; Where T_mc_avg is the average artificial combination time, T_mc_var is the variability of artificial combination time, T_ms_avg is the average artificial separation time, and T_ms_var is the variability of artificial separation time.

[0018] PID control steps: Incremental PID algorithm is used: Δu(k) = Kp × [e(k) - e(k-1)]+ Ki × e(k) + Kd × [e(k) - 2e(k-1) +e(k-2)]; u(k) = u(k-1) + Δu(k); Cache status monitoring steps: Real-time monitoring of rack status, and calculation of cached influencing factors based on fuzzy logic: Inputs: number of empty buffer slots, material dwell time, and supply-demand balance; Output: Cache impact factor F_cache ∈ [0.8, 1.5]; AGV dynamic scheduling steps: Dynamically adjust AGV parameters based on cycle time: Speed ​​adjustment: v_AGV = v_base × [1 + 0.3 ×tanh(u(k))] × F_cache; Acceleration adjustment: a_AGV = a_base × [1 + 0.2 ×tanh(u(k))]; Path selection: Select the time-optimal path based on real-time cycle pressure; Human-machine collaboration optimization steps: Achieving human-machine rhythm coordination through multiple methods: Visual cue: The three-color indicator light shows the beat status; Auditory cue: A cue tone is emitted when the beat deviation exceeds the threshold; Operating instructions: The display screen shows the recommended operating speed.

[0019] Example 1 refer to Figure 1 The automatic loading and unloading detection system of the present invention comprises the following hardware components: Loading pre-adjustment station 1: Equipped with workpiece positioning fixture 14, pallet fixing device 11, and operation guidance loading station display 13. Operators complete the combination operation of workpiece 6 and pallet 7 at this station.

[0020] Composite AGV5: Equipped with a multi-degree-of-freedom robotic arm 53, a vision camera 54, A station 51, and B station 52. The composite AGV5 has a load capacity of 50kg and a maximum operating speed of 1.5m / s.

[0021] Buffer Zone 3: Employs a heavy-duty rack structure, including an upper rack 31 and a lower rack 32. Each rack has 8 material positions, each equipped with an infrared sensor and a status indicator light.

[0022] Testing equipment 4: Performs various performance tests on the workpiece.

[0023] Material pre-adjustment station 2: Operators complete the separation operation between the workpiece and the pallet at this station.

[0024] Control Unit 9: An industrial computer is used as the main controller, which is connected to each device via a PROFINET network and runs detection cycle control software.

[0025] Example 2 refer to Figure 2 The detection cycle control method of the present invention is implemented according to the following steps: Step S201: System initialization; Set the target beat time: T_target = 20 seconds; Initialize PID parameters: Kp=0.6, Ki=0.12, Kd=0.2; Configure buffer parameters: Total number of material locations: 16; upper and lower limits of warning thresholds: 85% and 15%, respectively. Step S202: Beat data acquisition; The actual cycle time is collected by sensors at each workstation. Record manual operation time, AGV transfer time, and inspection time; Calculate the actual clock cycle T_actual(k) for the current cycle; Step S203: PID control calculation; Calculate the cycle time error: e(k) = 20 - T_actual(k); Calculate control output: Δu(k) = 0.6×[e(k)-e(k-1)] + 0.12×e(k) +0.2×[e(k)-2e(k-1)+e(k-2)]; u(k) = u(k-1) + Δu(k); Step S204: Cache status assessment; Monitor the number of empty spaces on each material rack; Calculate cache utilization U_cache; F_cache is calculated based on fuzzy logic. Step S205: AGV parameter adjustment; Speed ​​adjustment: v_AGV = 1.2 × [1 + 0.3 × tanh(u(k))] × F_cache m / s; Path optimization: Select the optimal path based on cache status; Task scheduling: Prioritize scheduling tasks on the critical path of the time-critical path; Step S206: Human-machine collaboration guidance; The current beat status is displayed on the operation guidance monitor; The operation speed is indicated by color (green / yellow / red); A prompt will be issued when the manual operation time is abnormal; Step S207: Performance evaluation and parameter self-tuning; Assess the effectiveness of control measures; Perform PID parameter self-tuning if necessary; Update system parameters; Step S208: Loop control; If the system continues to run, return to step S202; Otherwise, terminate the control process; Example 3 Based on Example 2, an intelligent learning function is added: The system analyzes historical data using machine learning algorithms to build a model for predicting manual operation time, thus anticipating trends in operation time and enabling proactive cycle time control. Simultaneously, the system can automatically adjust target cycle time and control parameters based on different product types.

[0026] Experimental data Through actual production line testing, the system and method of this invention have shown significant advantages over traditional control methods: 1. Beat stability: Standard deviation reduced from the traditional ±3.2 seconds to ±1.5 seconds; 2. Equipment utilization rate: AGV utilization rate increased from 65% to 87%; 3. Labor efficiency: The proportion of effective manual working time increased from 70% to 92%; 4. Increased production capacity: Overall testing capacity increased by 28%; 5. Failure rate: The system failure rate was reduced by 40%.

[0027] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the invention without departing from the spirit and scope of the present invention.

Claims

1. An automatic loading and unloading detection system, characterized in that, include: Loading pre-adjustment table (11): includes loading table device (11) and pallet fixing device (12); used to place workpieces (6) in pallets (7) to form workpiece pallet assembly; Material pre-adjustment table (2): includes a material unloading device for separating the workpiece (6) from the tray (7) of the pre-tested workpiece tray assembly (8); Buffer area (3): including loading rack (31) and unloading rack (32), located next to the testing equipment (4); Inspection equipment (4): used to inspect workpiece (6); Composite AGV (5): First, it is used to transfer workpiece pallet combinations between the loading pre-adjustment platform (1) and the buffer area (3), and between the buffer area (3) and the unloading pre-adjustment platform (2); Second, it is used to rotate the workpiece pallet combinations placed in the buffer area (3) to the detection equipment (4) for detection, and to transfer the detected workpiece pallet combinations to the unloading rack (32). Control unit (9): includes a controller and a PID controller for detecting the clock cycle. The controller is used to control the operation of each device and the execution of tasks. The PID controller coordinates the overall operating cycle of the control system. During operation, the worker places the pallet (7) into the pallet fixing device (12) on the loading platform device (11) of the workpiece (6) to form a workpiece pallet assembly (8); the composite AGV (5) grabs the workpiece pallet assembly (8) onto the composite AGV (5), and the composite AGV (5) transports the workpiece pallet assembly (8) to the loading rack (31) in the buffer area (3) until all the workpiece pallet assemblies (8) required for inspection for a period of time are placed on the loading rack (31); When the testing equipment (4) is turned on, the composite AGV (5) transports the workpiece pallet assembly (8) on the loading rack (31) to the workpiece position to be tested on the testing equipment (4); the composite AGV (5) sends the next workpiece pallet assembly (8) on the loading rack (31) of the buffer area (3) to the side of the testing equipment (4) to wait. When the previous workpiece pallet assembly (8) is completed and pushed out, the composite AGV (5) sends the next workpiece pallet assembly (8) to the workpiece position to be tested on the testing equipment (4); then, the composite AGV (5) retrieves the previous workpiece pallet assembly (8) that has completed the test and sends it back to the unloading pre-adjustment table (2) of the buffer area (3); After all the workpiece pallet assemblies (8) on the loading rack (31) have been inspected, the composite AGV (5) sends the inspected workpiece pallet assemblies (8) to the unloading pre-adjustment table (2). The staff separates the workpiece (6) and the pallet (7) of the workpiece pallet assembly (8). The staff takes away the workpiece (6), and the composite AGV (5) transfers the pallet (7) to the loading pre-adjustment table (1). The staff then places a workpiece (6) to be tested on the pallet (7) to form a workpiece pallet assembly (8). The composite AGV (5) transfers the workpiece pallet assembly (8) to the loading rack (31) until all the workpiece pallet assemblies (8) to be inspected in the next period of time have been transferred to the loading rack (31), and so on.

2. An automatic loading and unloading detection system according to claim 1, characterized in that, The composite AGV includes: AGV (55): is the carrier for transporting materials; Multi-station carrying platform: It is equipped with at least two independent pallet positioning mechanisms, which can simultaneously carry at least two workpiece pallet combinations (8). Multi-degree-of-freedom robotic arms: equipped with dual or multiple gripper systems, capable of simultaneously gripping and placing different workpieces within one operation cycle; Visual positioning system: a device configured to identify the position and orientation of the workpiece pallet assembly (8); Navigation system: A navigation device configured to move autonomously along a preset path.

3. The system according to claim 1, characterized in that, The PID controller includes: Beat monitoring module: Used to monitor the running time of each stage in real time; PID control module: used to recalculate the control output cycle time based on the cycle error; AGV cycle adjustment module: used to adjust the operating parameters of the composite AGV according to the latest calculated control output cycle time; Human-computer interaction module: used to provide operators with cycle status information.

4. The system according to claim 1, characterized in that, The loading pre-adjustment platform is equipped with a loading platform cycle status display (13) and the unloading platform is equipped with a cycle status display (21).

5. An automatic loading / unloading detection cycle control method, utilizing the system described in any one of claims 1-4, characterized in that, Includes the following steps: Step 1: Establish a complete cycle time model that includes manual operation time, AGV transfer time, and detection time; Step 2: Based on the results obtained from the beat monitoring module: a. The time required for the composite AGV (5) to transfer a workpiece pallet assembly (8) from the unloading rack (32) to the unloading pre-adjustment table (2); b. The time required for the composite AGV to return from the unloading pre-adjustment table (2) to the unloading rack (32); c. The time required for the composite AGV to transfer the workpiece pallet assembly (8) from the loading pre-adjustment table (1) to the loading rack (31); d. The time required for the composite AGV to return from the loading rack (31) to the loading rack (31); e. The time taken for the workpiece (6) to be manually placed in the tray (7) at the loading pre-adjustment station (1) to form the workpiece tray assembly (8); f. The time taken for the workpiece pallet assembly (8) to be manually placed on the pallet (7) at the unloading pre-adjustment table (2); g. The time required for the composite AGV to deliver the workpiece pallet assembly (8) to be inspected from the loading rack (31) to the inspection position of the inspection equipment 4; h. The time taken for the composite AGV to deliver the completed workpiece pallet assembly (8) to the unloading rack (32) at the inspection equipment (4); i. The time t0 required for the inspection equipment (4) to inspect a workpiece pallet assembly (8); Step 3: Based on the detection time of the detection equipment (4), before the detection equipment (4) is turned on, set the loading rack (31) to pre-store n sets of workpiece pallet combinations (8), and calculate the working time required for the composite AGV to be earlier than the detection equipment (4) as t1: t1=(a+b+c+d+e+f)*n; thereby determine the latest working time of the composite AGV. Step 4: The composite AGV5 sends a workpiece pallet assembly (8) from the loading rack (31) to the inspection equipment (4), and sends the previous workpiece pallet assembly (8) that has been inspected by the inspection equipment (4) to the unloading rack (32) at a time t2: t2 < t0 (1-m), where m is the buffer coefficient, 0.1 < m < 0.2; Step 5: If t2 cannot satisfy: t2 < t0 (1-m), adjust and increase the speed of the composite AGV (5) through the PID controller until t2 < t0 (1-m) is satisfied.

6. The automatic loading / unloading detection cycle control method according to claim 5, characterized in that, If the detection time t0 of the detection equipment (4) is relatively long, it can satisfy (a+b+c+d+e+f)+t2<t0(1-m); after the composite AGV (5) sends a workpiece pallet assembly (8) from the loading rack (31) to the detection equipment (4) and sends the previous workpiece pallet assembly (8) detected by the detection equipment (4) to the unloading rack (32), it can complete one transfer of workpiece pallet assembly (8) from the unloading rack (32) to the unloading pre-adjustment table (2) and return of the composite AGV (5) from the unloading pre-adjustment table (2) to the unloading rack (32); in this way, the detection equipment (4) can be guaranteed to run continuously.

7. The automatic loading / unloading detection cycle control method according to claim 5, characterized in that, Regulating via a PID controller includes: (1) The system operating cycle is dynamically adjusted by a PID controller; (2) Monitor the status of the buffer rack in real time and calculate the buffer impact factor; (3) Adjust the operating parameters of the composite AGV according to the control output; (4) Provide guidance on human-machine collaborative operation.

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