Container door plate overturning control method and device based on automation

Abstract

The invention discloses a container door plate turnover control method and device based on automation, and relates to the technical field of door plate turnover. The method comprises the steps that in response to door plate feeding, the position of a door plate is adjusted and fixed through a first position control mechanism, and position control data is obtained; the turnover mechanism is controlled based on the position control data so that the door plate can be turned over, and door plate turnover data are generated; and in response to stopping of overturning of the door plate, controlling the second position control mechanism to fix the door plate to a preset position according to the door plate overturning data and the position control data. The door plate turnover device has the effects that automatic door plate turnover is achieved, so that the door plate production efficiency and the automation level are improved, and the logistics turnover accuracy is guaranteed.

Description

Technical Field

[0001] This application relates to the field of door panel flipping technology, and in particular to an automated container door panel flipping control method and device. Background Technology

[0002] Currently, automated production lines can integrate welding machines and other devices to automate processes such as door panel welding. However, in automated production lines, especially in large door panel production lines, door panels may require welding on multiple sides. After completing the welding process on one side, manual flipping is required. This process not only significantly reduces production efficiency but also wastes a large amount of human resources, failing to meet the high-efficiency requirements of automated production. Summary of the Invention

[0003] The purpose of this application is to at least solve one of the technical problems existing in the prior art, and to provide an automated container door panel flipping control method and device, which aims to realize automated door panel flipping, so as to improve door panel production efficiency and automation level and ensure the accuracy of logistics flipping.

[0004] In a first aspect, embodiments of this application provide an automated container door panel flipping control method, applied to a door panel flipping device, the door panel flipping device including a first position control mechanism, a second position control mechanism, and a flipping mechanism; The control method includes: In response to the door panel being loaded, the position of the door panel is adjusted and fixed by the first position control mechanism to obtain position control data; The flipping mechanism is controlled based on the position control data to flip the door panel, and door panel flipping data is generated. In response to the door panel flipping stop, the second position control mechanism is controlled according to the door panel flipping data and the position control data to fix the door panel position to a preset position.

[0005] According to the technical solution of the embodiments of this application, at least the following beneficial effects are achieved: after the door panel is loaded, the position of the door panel can be adjusted and fixed by the first position control mechanism to ensure that the door panel is currently in the accurate position, thereby ensuring that the door panel is also in the accurate position after being flipped; by controlling the flipping mechanism through position control data, the flipping parameters of the flipping mechanism can be precisely controlled, thereby precisely controlling the door panel flipping process, so that the door panel will not be damaged by bumps or other collisions during the flipping process and the door panel will not shift its position after being flipped, thereby realizing automated door panel flipping and improving door panel production efficiency.

[0006] According to some embodiments of this application, in response to the door panel being loaded, adjusting and fixing the door panel position via the first position control mechanism to obtain position control data includes: In response to the material being loaded onto the door panel, information about the door panel is obtained; Based on the door panel information, the door panel position is adjusted and fixed by the first position control mechanism to obtain position control data.

[0007] According to some embodiments of this application, controlling the flipping mechanism based on the position control data to flip the door panel and generating door panel flipping data includes: Based on the position control data, a predicted defect type is obtained. The flipping mechanism is controlled according to the predicted defect type to flip the door panel and generate door panel flipping data.

[0008] According to some embodiments of this application, controlling the flipping mechanism based on the position control data to flip the door panel and generating door panel flipping data includes: Based on the position control data and the preset control association, the flipping mechanism is controlled to flip the door panel and generate door panel flipping data.

[0009] According to some embodiments of this application, controlling the second position control mechanism to fix the door panel position to a preset position based on the door panel flipping data and the position control data includes: The current door panel position is obtained based on the door panel flipping data and the position control data; Based on the current door panel position, the second position control mechanism fixes the door panel position to a preset position.

[0010] According to some embodiments of this application, controlling the second position control mechanism to fix the door panel position to a preset position based on the door panel flipping data and the position control data includes: The position of the first door panel is obtained based on the position control data; Based on the position of the first door panel and the door panel flipping data, the position of the second door panel is obtained, and the second position control mechanism is controlled according to the position of the second door panel to fix the position of the door panel to a preset position.

[0011] According to some embodiments of this application, the control method further includes: If the position control data determines that an over-limit defect has occurred, the door panel flipping device is controlled to stop operating and an alarm is triggered.

[0012] Secondly, embodiments of this application provide an operation control device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. The processor executes the program to implement the automated container door tilting control method described in the first aspect above.

[0013] Thirdly, embodiments of this application provide an electronic device including the operation control device described in the second aspect above.

[0014] Fourthly, embodiments of this application provide a computer-readable storage medium storing computer-executable instructions for causing a computer to execute the automated container door tilting control method described in the first aspect above.

[0015] Other features and advantages of this application will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the description, claims and drawings. Attached Figure Description

[0016] The accompanying drawings are used to provide a further understanding of the technical solutions of this application and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions of this application.

[0017] The present application will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a flowchart of a control method provided in one embodiment of this application; Figure 2 This is a schematic block diagram of the structure of a door panel flipping device provided in one embodiment of this application; Figure 3 This is a schematic diagram of the structure of a door panel flipping device provided in one embodiment of this application; Figure 4 This is a flowchart of a control method provided in another embodiment of this application; Figure 5 This is a flowchart of a control method provided in another embodiment of this application; Figure 6 This is a flowchart of a control method provided in another embodiment of this application; Figure 7 This is a flowchart of a control method provided in another embodiment of this application; Figure 8 This is a flowchart of a control method provided in another embodiment of this application; Figure 9 This is a flowchart of a control method provided in another embodiment of this application; Figure 10 This is a schematic diagram of an operation control device for performing a control method according to an embodiment of this application. Detailed Implementation

[0018] This section will describe in detail the specific embodiments of this application. Preferred embodiments of this application are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of this application, but they should not be construed as limiting the scope of protection of this application.

[0019] In the description of this application, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0020] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0021] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0022] The various embodiments of the automated container door tilting control method of this application will be further described below with reference to the accompanying drawings.

[0023] like Figure 1 As shown, Figure 1 This is a flowchart of a control method provided in one embodiment of the present application. The control method can be applied to a door panel flipping device, which includes a first position control mechanism, a second position control mechanism, and a flipping mechanism. The control method may include, but is not limited to, steps S110, S120, and S130.

[0024] Step S110: In response to the door panel being loaded, the door panel position is adjusted and fixed by the first position control mechanism to obtain position control data; Step S120: Control the flipping mechanism based on position control data to flip the door panel, and generate door panel flipping data; Step S130: In response to the door panel flipping stop, control the second position control mechanism according to the door panel flipping data and position control data to fix the door panel position to the preset position.

[0025] refer to Figure 2 , Figure 2 This is a schematic block diagram of a door panel flipping device according to an embodiment of this application. The door panel flipping device includes a first position control mechanism, a second position control mechanism, and a flipping mechanism. The first position control mechanism is used to adjust and fix the position of the door panel, the flipping mechanism is used to flip the door panel, and the second position control mechanism is used to fix the door panel position to a preset position after the door panel is flipped. The first position control mechanism and the second position control mechanism have different functions. The first position control mechanism and the second position control mechanism can be different types of devices, or they can be the same device but set at different positions relative to the door panel to achieve different functions.

[0026] For example, the first position control mechanism can adjust and fix the door panel position in multiple ways, such as adjusting the position, horizontal angle, and direction of the door panel relative to the door panel flipping device, and fixing the door panel position from multiple different points. Therefore, the first position control mechanism can specifically include multiple different components to respectively achieve multi-faceted adjustment and fixation of the door panel position. Similarly, the second position control mechanism is used to fix the door panel position to a preset position after the door panel is flipped. Therefore, the second position control mechanism can adjust and fix the door panel position to a preset position. The second position control mechanism can also specifically include multiple different components to respectively achieve multi-faceted adjustment and fixation of the door panel position.

[0027] For example, in automated production lines, particularly large door panel production lines, such as container door panel manufacturing, if the first and second position control mechanisms are the same equipment, they comprise a series of highly integrated and functionally coordinated components to achieve the task of multi-directional adjustment and fixation of the door panel. For instance, the first and second position control mechanisms may include a base structure employing modular components for easy installation and maintenance, resisting vibration and shock during operation. The base may also be equipped with precision guide rails or sliding platforms to guide movement adjustments, as well as leveling feet or servo leveling mechanisms for fine-tuning the levelness of the mechanism. The first and second position control mechanisms may include a motion adjustment system comprising multiple motion axes, such as three linear axes (X, Y, Z) and three rotary axes (A, B, C), forming a six-degree-of-freedom platform. The linear axes employ high-precision linear modules, driven by servo motors to achieve linear movement via ball screws or synchronous belts. The rotary axes employ direct-drive servo motors or drive the turntable via harmonic reducers to precisely move the door panel from its initial position to the target position and adjust its angle and orientation. For large door panels, the range of motion can be large, thus long-stroke modules or gantry structures can be used. In order to match the production cycle, the servo motors need to have high torque and low inertia to achieve rapid response. The first and second position control mechanisms may include high-resolution encoders or grating rulers to provide position feedback and achieve micron-level positioning. Meanwhile, the movement adjustment system may also include redundant shafts or parallel mechanisms to improve flexibility and load capacity. For example, when adjusting a door panel, it may be necessary to move multiple points simultaneously to avoid twisting or deformation. The first and second position control mechanisms may include a clamping system for fixing the door panel from multiple points. The clamping system may use a pneumatic clamp to hold the panel from the edge or a vacuum suction cup to pick it up from the surface. The clamping system includes clamping arms, grippers, suction cups and other actuators, as well as pneumatic or hydraulic cylinders as power sources. It may also use multiple clamping points, each of which may be independently controlled to accommodate irregular shapes or compensate for tolerances. In addition, the clamping force of the clamp may be adjusted by pneumatic or hydraulic pressure to accommodate door panels of different materials. The system may also integrate sensors to detect the clamping status, ensuring that the door panel is correctly fixed and providing feedback to the control system. The first and second position control mechanisms may include a sensing and detection system for real-time monitoring of the door panel position and mechanism status, including photoelectric switches, proximity switches, inclinometers, encoders, as well as industrial cameras and laser scanners. The accuracy of the sensing and detection system affects the positioning accuracy of the entire mechanism, so it is necessary to ensure accurate installation and avoid environmental interference such as dust, vibration, or changes in light. In automated production lines, the sensing and detection system can also be synchronized with other equipment, such as communicating with welding machines to ensure that welding begins in the correct position. The first and second position control mechanisms may include a control and command system, including a PLC, motion control card, industrial computer, and touch screen, etc., to execute pre-programmed sequences, coordinate the actions of all components, process sensor inputs, and communicate with the main control of the production line. For example, in a container door panel production line, the control system receives a signal from the upstream conveyor belt, initiates a position adjustment program, controls the movement adjustment system to move the door panel to the welding station, controls the clamping system to fix the door panel, and then triggers the welding machine to start welding. After flipping, the control system adjusts the position of the door panel again.

[0028] For example, the first position control mechanism, the second position control mechanism, and the flipping mechanism are used for adjusting, fixing, and flipping the position of the door panel to achieve multi-sided welding processes. The equipment selection and installation method of the first position control mechanism, the second position control mechanism, and the flipping mechanism directly affect the performance and stability of the entire production line.

[0029] The first position control mechanism can be a multi-axis robot or a precision positioning stage, used to adjust the position, angle, and orientation of the door panel and fix it before welding. For example, in the production of container door panels, due to the large size and heavy weight of the door panels, a robot or multi-axis positioning system can be used. The installation of the robot's control system involves the positioning of the PLC cabinet and operation panel, which can be placed nearby but away from heat sources and vibrations. The robot tool end is equipped with a fixture system, which needs to be aligned and locked through a quick-change interface. After installation, calibration is required. For example, the tool center point is calibrated using a calibration tool or vision system to determine the precise position of the fixture, as well as the workpiece coordinate system is set so that the robot can accurately identify the position of the door panel. If the second position control mechanism is the same as the first position control mechanism, the equipment selection and installation method are similar, but the position is after the flipping mechanism. It is used to receive the flipped door panel. Therefore, the docking with the flipping mechanism and the continuity of the production line need to be considered during installation. The equipment can also use a robot or a multi-axis positioning table, but its base can be connected to the foundation of the flipping mechanism or fixed independently to ensure accurate relative position. The tilting mechanism is used to flip a door panel from one side to the other. In container door panel production, either a hydraulic tilting machine or a rack and pinion tilting machine can be used. A hydraulic tilting machine includes a frame, tilting arm, hydraulic cylinder, clamps, and a hydraulic station, while a rack and pinion tilting machine includes a motor-driven gear. The selection of the tilting mechanism must be based on the door panel's size and weight, calculating the tilting torque and inertia, and selecting an appropriate drive power. During installation, a level can be used to ensure the tilting shaft is horizontal. Electrical connections include motor power, control valve lines, and sensor lines. The hydraulic system can be equipped with pressure sensors and flow valves for precise control. The clamps of the tilting mechanism... The fixtures need to be coordinated with the position control mechanism's clamps. For example, a compatible interface should be used to ensure that the door panel is securely fixed during the flipping process. The control system programming needs to integrate safety logic to confirm that the door panel is fixed before flipping, detect abnormal vibrations during flipping, and interlock with the front and rear workstations. For example, after the first position control mechanism completes welding and releases the door panel, the flipping mechanism moves to the material pick-up position, the clamps tighten and then slowly flips the door panel. After the flipping is completed, a signal is sent to the second position control mechanism. The entire installation process requires multiple rounds of debugging, including no-load testing, load testing and collaborative testing, to optimize the flipping speed curve to reduce impact and to check whether the door panel slides or deforms during flipping.

[0030] Understandably, the first and second position control mechanisms have different functions and can differ in their component composition. The first position control mechanism deals with the raw door panel from the upstream conveyor line or storage system. The position, orientation, and state of the door panel have significant initial uncertainties. Therefore, the first position control mechanism has adaptability, rapid acquisition capabilities, and preliminary correction capabilities to provide a relatively regular foundation for subsequent precision welding and flipping. The second position control mechanism receives the door panel that has already undergone the first welding and flipping process. At this point, the door panel may have experienced thermal stress and considerable minor deformation due to welding, and its spatial position has also changed discretely due to the flipping action. However, subsequent welding requires high positioning accuracy and stability. Therefore, the second position control mechanism has extremely high precision, active compensation for deformation, and ultra-strong rigidity maintenance under strong welding interference.

[0031] The first position control mechanism includes a door panel detection and coarse positioning system with a wide range of rapid response capabilities. This system comprises a group of distributed laser scanners or high-frame-rate industrial vision cameras for rapidly scanning the door panel entering the workstation, identifying its contours, corners, or preset identification marks, and calculating the deviation of the door panel from its theoretical position. It also includes a large-stroke, high-speed moving platform, constructed based on heavy-duty linear modules, rack and pinion gears, or a large-span gantry structure, driven by a high-power servo motor. This platform moves the entire fixture unit quickly to a coarse position capable of capturing the door panel, based on the results of the detection system. It also includes a self-... Adapted to flexible clamping systems, it employs a multi-degree-of-freedom floating pneumatic gripper array, coupled with passively adjustable positioning blocks or spring-buffered positioning pins, to achieve tolerance-tolerant gripping without rigid collision damage to the door panel. That is, even with a certain degree of positional and angular error in the door panel, the clamp can initially hold the door panel tightly through its own floating or adaptive mechanism. It also includes an initial attitude correction unit integrated into the clamp. For example, through several individually jogable servo push rods, it performs a straightening operation on the door panel, eliminating obvious tilt and ensuring that the main plane of the door panel is roughly parallel to the receiving plane of the flipping mechanism, preparing for a smooth handover.

[0032] The second position control mechanism should include a high-precision reference reconstruction and measurement system, comprising a precision optical measurement system fixed to a robust base or a temperature-compensated high-precision contact probe. This system is used to precisely measure several key process reference points on the door panel immediately after it is transferred from the flipping mechanism, assessing all deviations between the actual geometry of the door panel and the ideal model caused by welding thermal deformation and flipping errors. It also includes a multi-axis ultra-precision fine-tuning platform, built upon the large-stroke platform of the first position control mechanism after coarse positioning and transfer. This platform is itself a six-degree-of-freedom precision micro-motion stage with extremely high repeatability, capable of adjusting the position based on feedback data from the measurement system. The door panel undergoes extremely precise position and angle compensation adjustments to ensure that the error between its critical welding parts and the predetermined trajectory of the welding torch is eliminated within the allowable range of the process. It also includes a full-area rigid locking and vibration damping fixture system, which uses a large-area distributed hydraulic clamping cylinder, mechanical wedges with deadlock mechanisms, or vacuum adsorption areas to maximize the overall rigidity of the fixture workpiece system and resist various dynamic interference forces and vibrations generated during subsequent high-speed and high-heat welding. It also includes a process deformation monitoring and closed-loop compensation module. For example, micro-displacement sensors are installed at key points of the fixture to monitor the welding thermal deformation trend in real time and feed it back to the fine-tuning platform or welding machine for dynamic path compensation.

[0033] For example, in response to the loading of the door panel, the position of the door panel is adjusted and fixed by the first position control mechanism to obtain position control data. The position control data can be the specific control parameters of each different component of the first position control mechanism, that is, the set of specific instruction parameters issued by the first position control mechanism to its internal different components at the control level in order to achieve a specific door panel posture adjustment and fixing target. Specifically, the position control data can include motion parameters of the moving adjustment system. The first position control mechanism includes multiple linear axes and rotational axes to form a multi-degree-of-freedom platform. Therefore, the data will record in detail the target set point of each axis in this adjustment task. For example, the absolute coordinate values ​​or offsets relative to the origin of the three linear axes X, Y, and Z represent the final horizontal position and height of the door panel in space. It also includes the target angle values ​​of the three rotational axes A, B, and C to represent the pitch, yaw, and roll attitude of the door panel after rotating around the X, Y, and Z axes, so that the door panel can tilt at a specific angle to optimize the accessibility of the welding torch. It can also include dynamic motion parameters, such as the peak velocity, acceleration and deceleration curves of each axis during the motion process, stored in parameterized form to ensure smooth and efficient motion, and to avoid door panel inertial slippage or mechanism vibration caused by sudden start and stop. For multiple axes that need to move in coordination, the data will also store interpolation motion parameters, such as the path point sequence in linear interpolation or circular interpolation, the interpolation accuracy tolerance value, and the speed look-ahead control parameters of each axis, to ensure that each axis can be strictly synchronized even when making complex trajectory adjustments, so that the door panel moves smoothly along the predetermined path. It can also include the closed-loop control parameters of each axis servo drive, such as the proportional-integral-derivative gain of the position loop, the speed feedforward coefficient, and the integral anti-saturation limit. Although these parameters are set during the commissioning phase, they can be fine-tuned according to load changes during actual operation. Therefore, the data record of each adjustment task includes the real-time application values ​​of these parameters for analyzing motion stability. It may also include clamping and force control parameters of the clamping system. Since the first position control mechanism needs to fix the door panel from multiple points, the clamping system includes multiple independently controlled gripper or suction cup units. Therefore, the position control data will record the activation state sequence of each gripper unit in detail, such as which gripper extends and retracts when, and the opening angle or stroke position of the gripper. For pneumatic or hydraulic clamps, the data will include the pressure setpoint of each clamping point, i.e., the pressure of the driving cylinder or hydraulic cylinder. The clamping force needs to be accurately distributed, so the data can be further refined to the pressure curve of each gripper, including the pressurization rate, holding time, and depressurization release time. It also includes the position data of the clamp, such as the installation position coordinates of each gripper relative to the mechanism base, the orientation vector of the gripper, and the contact point coordinates of the clamping surface. This is used to build the working model of the clamp in the control system to ensure that the gripper can accurately reach the predetermined clamping position. Especially when dealing with door panels of different sizes, the clamp can have an adjustable spacing function. Therefore, the data will also record the spacing adjustment value of each gripper. It can also include measurement and feedback parameters from the sensing and detection system, such as a vision system or laser scanner used for initial door panel positioning. The data will include the trigger time of camera shooting, exposure time, feature point template matching parameters used by the image processing algorithm, and the final calculated door panel pose deviation value, namely three translational deviations and three rotational deviations. At the same time, the calibration parameters of the sensor itself can also be recorded, such as camera intrinsic parameters and calibration coefficients of the laser rangefinder, to ensure measurement accuracy. During the adjustment process, the readings of the linear encoder or rotary encoder installed on the moving axis will be continuously recorded to form the actual position trajectory data of each axis. These data are compared with the target trajectory to generate a following error curve, which is also part of the position control data. It may also include system status and alarm information, such as warnings or error codes recorded by the control system during the adjustment process, health status indicators of each component, and trigger records of safety interlock devices.

[0034] Understandably, the first position control mechanism completes the precise capture, positioning, and fixation of the door panel after it is loaded. The position control data records the spatial pose, geometric features, clamping point distribution, and force conditions of the door panel after adjustment. This information is the prerequisite for the flipping mechanism to accurately execute the flipping action. If the flipping mechanism does not rely on this data but independently re-detects and repositions the door panel, it will not only increase the production cycle time and reduce the overall efficiency, but also introduce uncontrollable errors in two independent positioning attempts, causing positional deviations in the door panel during handover or flipping. Therefore, by transmitting the position control data, the work results completed by the first station are essentially transferred to the next process, ensuring the continuity of the production process and the consistency of the status. In addition, the actual center of gravity position of the door panel, the exact size and shape of the door panel, and the constraint points and forces applied to the door panel by the clamps in the position control data are the basis for the tilting mechanism to plan a safe tilting path. For example, for container door panels with asymmetrical shapes or uneven weight distribution, their center of gravity is not at the geometric center. If the tilting mechanism tilts at a constant speed according to an ideal symmetrical model, it may generate additional overturning torque due to the shift of the center of gravity during the tilting process, causing the door panel to slide and vibrate in the clamps. Based on the data provided by the first position control mechanism, the control system of the tilting mechanism can calculate the actual center of gravity trajectory in advance, thereby planning a tilting speed curve that can maintain torque balance, or dynamically adjusting the position of its own auxiliary support points to counteract the effects of eccentricity and ensure that the tilting process is smooth and reliable.

[0035] When adjusting the door panel, the first position control mechanism can detect and compensate for the initial deformation or incoming material error of the door panel itself. The compensation information is recorded in the position control data. After learning this information, the flipping mechanism can optimize its actions accordingly. For example, if the data indicates that the door panel has slight warping, the flipping mechanism can adjust the closing sequence or force distribution of the grippers during clamping to avoid aggravating the deformation; or, when planning the flipping path, it can reserve a larger safety space for the warped part to prevent scratching with the equipment. In addition, for workpieces that need to be flipped for a second welding after welding, the thermal deformation generated by the first welding will also be indirectly reflected in the current position and attitude data of the door panel. Controlling the flipping based on this data allows the entire system to handle workpieces with cumulative errors in a more intelligent way, thereby improving the overall quality consistency of the final product.

[0036] For example, in controlling the flipping mechanism to flip the door panel, in addition to controlling the basic parameter of flipping speed, the control of acceleration and jerk can also be included. This is because the speed parameter determines the speed of flipping, while acceleration and its rate of change determine whether the motion is smooth and whether impacts will occur. For heavy door panels such as container door panels, the enormous inertia makes the planning of the acceleration curve crucial. An S-shaped speed curve can be adopted, that is, the acceleration slowly increases to its maximum value, maintains it for a period of time, and then smoothly decreases to zero, reaching uniform speed before smoothly decelerating symmetrically. Controlling the acceleration parameter can minimize the impact on the transmission mechanism during start-up and stopping, and prevent the door panel from slightly slipping in the fixture due to inertia. The control of the flipping angle and position can also be included. The flipping process can be divided into multiple stages, for example... First, it leaves the safety zone of the first workstation at a relatively slow speed, then accelerates in the middle section to improve efficiency, and decelerates in advance before approaching the target angle to achieve a precise stop. The control system needs to accurately set the target angle for each stage and the corresponding tolerance range. For special processes that require intermediate pauses, multiple intermediate dwell points and their holding times also need to be set. It can also include the control of synchronization and trajectory parameters, because many large flipping mechanisms are not single-axis movements. They can be double-ended synchronously driven flipping or the flipping arm itself has auxiliary adjustment degrees of freedom. In this case, controlling the synchronization between multiple axes can prevent structural distortion or additional torque on the door panel. It can also include the control of the flipping trajectory. For example, for extra-long door panels, in order to avoid other equipment, a non-standard composite flipping trajectory with a small translational offset needs to be planned. It can also include dynamic control of clamping force and contact state. The clamps of the flipping mechanism are not locked in a constant state during the flipping process, and their clamping force may need to be dynamically adjusted according to the door panel's posture and stress conditions. For example, at the beginning and end of the flipping phase, the door panel is in a horizontal or near-horizontal state and is mainly subjected to the vertical force of gravity. The clamps may need a large static friction force to resist gravity. However, when flipped to a vertical state, the direction of gravity is parallel to the clamping surface. At this time, the door panel tends to slide along the clamps. The control system needs to dynamically increase the clamping force or activate additional mechanical locking devices based on the door panel weight and friction coefficient model provided in the position control data. For some easily deformable door panels, the clamping force may need to be appropriately reduced at certain angles to avoid crushing. Therefore, the magnitude, point of application, and direction of application of the clamping force can all be used as parameters for closed-loop control.

[0037] For example, after the first position control mechanism completes the adjustment and fixation of the door panel, the control system will send the complete position control data packet generated by this task to the main controller of the production line or directly to the control system of the flipping mechanism via industrial Ethernet or fieldbus. After receiving the data packet, the control unit of the flipping mechanism first parses it and extracts the information necessary to control the flipping action, including the final pose matrix of the door panel, the geometric dimensions and contour information of the door panel, the contact point coordinates and normal vectors of the door panel and the clamp of the first position control mechanism (used to calculate the clamping state), the clamping force data of each jaw of the first position control mechanism (used to estimate the state of the door panel being firmly constrained), and the estimated coordinates of the center of gravity of the door panel obtained by sensor measurement or calculation. Subsequently, the control system of the flipping mechanism incorporates a motion planning algorithm. This algorithm takes the received door panel state characteristics as input and combines the flipping mechanism's own kinematic model, dynamic parameters, and a preset safety rule base to plan an optimal flipping trajectory. For example, the algorithm uses the door panel's pose and size data to calculate the precise gripping position that the flipping mechanism's clamp needs to move to, and uses the door panel's center of gravity coordinates and weight information to perform dynamic simulation or calculation of the flipping process to determine the speed and acceleration curves that can maintain a smooth flipping. If the data indicates that the door panel is severely eccentric, the planning algorithm will generate an asymmetric flipping speed curve, slowing down the speed when the center of gravity is away from the rotation axis to reduce dynamic load, or planning a small compensating oscillation to actively counteract the vibration caused by eccentricity. At the same time, the planning algorithm will also determine the optimal gripping point, gripping sequence, and required gripping force distribution of the flipping mechanism's own clamp based on the door panel's contour and gripping point information to ensure a stable grip without damaging the door panel. After planning is completed, the algorithm discretizes the continuous trajectory into a series of time-based control commands, including the target position, target speed, and target torque / current of each motion axis of the flipping mechanism in each control cycle. The commands are sent to the servo drives or hydraulic proportional valve controllers of each axis in real time. During this process, the door panel pose information extracted from the first position control data is used to initialize the relative coordinate system relationship between the flipping mechanism and the door panel. After the flipping action is started, it is not a simple open-loop execution of the preset commands. The flipping mechanism's own sensor network will provide real-time feedback on the actual execution status. The control system will compare this feedback with the expected state planned based on the first position control data. Continuous comparisons are made, such as comparing the actual angle fed back by the encoder with the planned angle, and comparing the actual load torque fed back by the torque sensor with the expected torque calculated based on the center of gravity data. If a deviation is found, the control system will dynamically adjust the control parameters. The benchmark or expected value for adjustment comes from the planning model initially established based on the first position control data. For example, it will try to pull the actual torque back to the expected curve. At the beginning stage of the flipping action, that is, when the flipping mechanism fixture and the door panel are handed over, the control system will rely on the information about the precise position of the door panel in the first position control data to guide the fixture to perform the final stage of slow approach and contact sensing.

[0038] It is understandable that the physical processes in production introduce errors. Although the adjustment of the first position control mechanism is precise, its operation itself has systematic and random errors from mechanical and sensor components. These errors are recorded in the position control data, such as the slight deviation between the actual stopping position and the theoretical position, and the amount of elastic deformation caused by the clamping. The subsequent flipping process, as a large-scale, highly dynamic rigid body motion, also introduces new and potentially larger sources of error, including backlash in the flipping mechanism's transmission chain, elastic deformation of gears, dynamic swaying due to the misalignment of the door panel's center of gravity with the rotation axis, and positioning accuracy errors at the stop. These errors are recorded in the door panel flipping data, which also includes information such as the final angle of the flipping axis, torque fluctuation curve, and vibration spectrum. If the second position control mechanism acts solely based on an ideal, static, preset position model, it completely ignores the cumulative errors actually caused by the first two processes, leading to grasping failure, inaccurate positioning, or even collisions. Therefore, by using these two datasets as error correction inputs to the ideal model, the second position control mechanism can understand the actual state of the door panel in space and thus plan a path that can accurately grasp and compensate for these cumulative deviations.

[0039] For example, position control data represents the initial geometric properties, pose, and constraints of the door panel, while door panel flipping data represents how the door panel's state changes after flipping. The combination of these two data constitutes the complete journey of the door panel from station A to station B. For instance, when a container door panel is adjusted at the first station, position control data shows that its lower left corner is locally corrected and pressurized by the clamp due to a slight warping of the incoming material. During the flipping process, door panel flipping data shows that when flipped to 90 degrees, the release of the gravitational torque of the warped part leads to an abnormal torque peak and a brief vibration. When the second position control mechanism is ready to receive the data, it integrates these two pieces of information. From the position control data, it knows the original position and corrective force of the warped point, and from the door panel flipping data, it knows that the point exhibits an unstable tendency during the dynamic process. Therefore, it can adjust the clamping strategy of the clamp for this area, for example, by adopting a more compliant contact method or adding auxiliary support to avoid stress concentration or unstable gripping.

[0040] For example, the position control data represents the preparation state before the first side welding, implying information about the raw materials. The door panel flipping data represents the impact of the flipping process on the workpiece, indirectly reflecting the quality of the first side welding. By analyzing the two sets of data, the control system can infer the current health status of the workpiece and dynamically adjust the preset position. For example, if the data analysis shows that the flipping process is abnormally smooth and the torque curve is highly consistent with the standard part, then the second position control mechanism can use the standard preset position for high-precision positioning. If the data analysis shows abnormal vibration or angle deviation, it can be determined that the workpiece has large deformation or clamping problems. At this time, not only can the gripping posture of the second position control mechanism be adjusted, but the preset position can also be offset by coordinates or compensated by angle to ensure that subsequent welding can still be carried out in the correct relative position, thereby minimizing the impact of fluctuations in the preceding process and realizing online quality control and process self-adaptation.

[0041] refer to Figure 3 , Figure 3This is a schematic diagram of the structure of a door panel flipping device provided in one embodiment of this application. The first position control mechanism may include two parts: a double roller clamping and adjusting mechanism and an edge limiting mechanism. It can perform preliminary horizontal and vertical centering and coarse position adjustment by rotating and clamping one or more pairs of power rollers while driving the door panel to move. Subsequently, movable or fixed edge limiting blocks or guide strips mechanically limit the edge of the door panel, forcing it to reach a preset accurate reference position and fix it. The flipping mechanism consists of an arc-shaped track meshing with a speed-changing gear of the driving component. It can be understood that the door panel is clamped between two sets of large coaxial circular tracks or a rigid frame with tracks. The two sets of tracks constitute the skeleton of the flipping mechanism, driving... The device drives the entire track, along with the clamped door panel, to rotate around the central axis through gear meshing with a gear ring installed on the outer edge of the arc track. It can use variable speed gears or speed control to smoothly change speed during the start and stop phases of the flipping to reduce impact, and quickly pass through the middle section to improve efficiency. The second position control mechanism is used for braking and positioning after flipping. It can achieve mechanical hard stop by colliding a physical stop block with a specific structural block on the arc track. Then, the clamping cylinder is activated, and the piston rod extends and presses against a stable part of the arc track, such as a specific slot or plane, to form additional locking force. This prevents the track from slightly rebounding or moving due to inertia or external force, thereby locking the door panel in the end position after flipping.

[0042] Based on this, necessary sensors, including encoders, displacement sensors, pressure sensors, and vision sensors, are integrated into components such as double rollers, edge limiters, variable speed gear drive systems, stop blocks, and clamping cylinders. This ensures that each action state, position control data, and door panel flipping data serve as carriers to carry and transmit status information and control commands from specific mechanical components, thereby using data flow to drive the precise execution and optimization of the entire physical process.

[0043] For example, in response to the door panel being loaded, a first position control mechanism with integrated sensors adjusts and fixes the door panel, generating multi-dimensional position control data. The door panel enters the first workstation via a conveyor line, where a vision sensor or laser scanner installed at the entrance quickly scans the door panel to obtain its rough outline, position, and angular deviations as input for pre-adjustment. Based on the sensed data, the control system instructs a double-roller clamping and adjusting mechanism to operate, controlling the servo motors of the two rollers to rotate in opposite directions at specific speeds and torques to clamp the door panel. Based on the sensed deviations, the control system controls the roller group to rotate synchronously forward or backward, driving the door panel to move on the plane for centering and coarse position adjustment. During this process, the roller motor encoder records the rotation angle and speed in real time, and the force sensor monitors the clamping force, generating roller drive parameters, including the displacement, speed curve, and clamping force curve of each roller, as part of the position control data. When the door panel is driven by the rollers to approach the preset reference area, the edge limiting mechanism extends and contacts the edge of the door panel according to the instruction. Under the continuous micro-movement of the rollers, the door panel finally completely fits the limiting block. The high-precision displacement sensor or micro switch on the limiting block confirms the contact completion, generating an edge positioning confirmation signal and precise limit coordinates. At this time, the rollers stop driving and maintain a certain holding torque, and the door panel is mechanically fixed. Subsequently, the system integrates all sensor information to form complete position control data, including the theoretical position finally reached by the door panel and the process parameters for reaching this position: roller adjustment trajectory, final clamping force distribution, and actual contact point coordinates of the edge limiter.

[0044] Subsequently, based on the position control data, the intelligent control of the arc-shaped track-type flipping mechanism implements variable-speed flipping and generates door panel flipping data. The arc-shaped track clamp of the flipping mechanism moves to the accurate gripping position according to the precise contour and gripping point information of the door panel in the position control data. Upon receiving the handover signal, the rollers of the first position control mechanism orderly release the door panel, which is then gripped and received by the flipping mechanism clamp. The handover process can be visually monitored to ensure smoothness and no collisions. The control system performs dynamic planning based on the position control data. If the data indicates that the door panel's center of gravity is symmetrical, a standard slow-fast-slow S-shaped speed curve is executed; if the data indicates that the door panel is eccentric, the control... The system dynamically adjusts the torque and speed curves of the gear drive motor, actively increasing torque in phases where the center of gravity is far from the rotation axis, resulting in increased resistance torque, and smoothly transitioning in other phases to achieve torque balance throughout the flipping process and minimize vibration. During the entire flipping process, door panel flipping data is generated and recorded synchronously, including the real-time angle, speed, and torque feedback curves of the drive gear servo motor; the rotation angle encoder value of the arc track itself; vibration sensor data installed on the track; micro-displacement sensor data monitoring whether the door panel slips; and the precise timing and status of key points such as the start of flipping, reaching 90 degrees, and approaching 180 degrees.

[0045] Next, in response to the door panel's rotation stopping, based on the door panel rotation data and position control data, the enhanced second position control mechanism is controlled to fix the door panel position to a preset position; when the rotation approaches the end point, deceleration begins, and the stop block provides the final mechanical hard limit. At the moment of braking, the system reads the final door panel rotation data and compares the actual stopping angle in the door panel rotation data with the expected stopping posture calculated based on the initial posture in the position control data and the theoretical 180-degree rotation. If the deviation is within tolerance, proceed to the next step; if the deviation exceeds the limit, a warning is triggered; the clamping cylinder, as the execution unit of the second position control mechanism, extends according to a preset program and pressure under normal circumstances, locking the arc track; Additionally... In addition, if the verification reveals a slight angular deviation within the allowable range, or if the door panel flipping data shows a large braking impact, the control system can dynamically adjust the clamping strategy. For example, it can instruct the clamping cylinder to press against a specific compensation surface on the track with higher pressure to correct slight elastic rebound. Alternatively, it can perform sub-millimeter-level precise positioning compensation while clamping based on the deviation data. The pressure sensor on the clamping cylinder feeds back the final locking pressure data, which is archived together with the position control data and door panel flipping data to form a complete process file for the door panel at this station. After the clamping and locking are completed through data verification and enhanced control, the door panel is firmly and precisely fixed on the preset welding station after flipping, awaiting the next welding process.

[0046] like Figure 4 As shown, Figure 4 This is a flowchart of a control method provided in another embodiment of this application; regarding the above step S110, it may include, but is not limited to, steps S210 and S310.

[0047] Step S210: In response to the door panel being loaded, obtain the door panel information; Step S310: Adjust and fix the position of the door panel according to the door panel information through the first position control mechanism to obtain position control data.

[0048] For example, in response to the loading of a door panel, door panel information is obtained. This information includes control parameters for a preset first position control mechanism corresponding to the door panel, and may also include identification data such as the door panel number, serial number, batch number, and corresponding production order number. It may also include detailed physical properties and geometric feature data, used as the basis for calculating the preset control parameters and as the original input for adaptive adjustment of the mechanism. This may include the theoretical three-dimensional dimensions of the door panel, design weight and measured weight, center of gravity coordinates, material type, and surface characteristics. For workpieces like container doors that may have pre-punched holes, folded edges, or local reinforcement structures, it may also include a three-dimensional CAD model or simplified key feature point cloud data and feature positions. In some embodiments, the door panel information may also include quality status and historical process data, such as whether it is a rework part, whether there is an initial deformation within the allowable range and its deformation mode, and the process parameters and test results applied in the previous process. The quality status and historical process data directly affect whether the first position control mechanism performs compensatory adjustments or standard processing in this instance.

[0049] For example, after reading the door panel information, the control system retrieves or directly uses the preset first position control mechanism control parameters embedded in the information package based on the identification identifier. These parameters include the target position of each moving axis, the distribution of the target clamping points of the clamp, the clamping force, and the movement speed. However, the control system does not simply execute these preset values. Next, the system compares the real-time status information in the door panel information with the physical attribute data, calculates the deviation between the current actual posture of the door panel and the ideal loading posture, and combines historical process data to predict the potential impact of this deviation on clamping stability. The preset control parameters are then fine-tuned in real time to generate the final execution parameters adapted to the specific door panel. For example, if the preset clamping force is 500N, but a scan reveals a slight warping at one end of the door panel, the corresponding area's clamps can be instructed to adopt a more compliant force control mode during the contact phase or the clamping force at that point can be slightly increased to correct the deformation. Based on the actual weight and center of gravity data of the door panel, the system dynamically calculates and allocates the torque limit values ​​for each moving axis during acceleration and deceleration to prevent overshoot or jitter.

[0050] The first position control mechanism begins its operation based on dynamically generated final execution parameters. Its movement adjustment mechanism carries the clamp towards the target position calculated using theoretical coordinates and real-time deviation compensation from the door panel information. During this movement, the mechanism's own sensors and external monitoring sensors form a closed loop to ensure accurate movement trajectories. Once the clamp reaches the predetermined clamping area, the clamping system guides each gripper or suction cup to precise positioning based on the clamping point coordinates and geometric features specified in the door panel information. At the moment of contact, force-position hybrid control is employed, smoothly applying clamping force using the surface characteristics and physical properties provided in the door panel information as a reference, until the target force value after dynamic adaptation is reached. For door panels with historical deformation records, the system can instruct the clamp to execute a pre-correction sequence, actively correcting the door panel to a more ideal shape within the elastic deformation range through the coordinated force application of multiple grippers.

[0051] After the door panel is fixed, the first position control mechanism verifies whether the adjustment and fixing results meet the standards using built-in sensors or auxiliary measurement systems. The actual verification data includes the final actual pose, the actual applied clamping force distribution, and the time consumed during the adjustment process. This data can be used as a new actual process data package to update the dynamic information of the door panel, becoming part of its historical process data and providing more accurate input for subsequent processes. Based on this, all static attributes, dynamic measurements, and historical records in the door panel information are transformed into the perception and decision-making basis of the control system, driving the first position control mechanism to complete the entire operation from intelligent perception to dynamic planning to precise execution and feedback optimization.

[0052] like Figure 5 As shown, Figure 5 This is a flowchart of a control method provided in another embodiment of this application; regarding the above step S120, it may include, but is not limited to, step S220.

[0053] Step S220: Based on the position control data, obtain the predicted defect type, control the flipping mechanism according to the predicted defect type to flip the door panel, and generate door panel flipping data.

[0054] For example, defect types are predicted based on position control data. This position control data reflects the dynamic state of the interaction between the first position control mechanism and the door panel throughout the entire process. Therefore, the core of prediction lies in deeply comparing and analyzing the actual high-dimensional position control data sequence—such as multi-axis motion trajectory deviation, velocity / acceleration fluctuations, clamping force establishment curves, and vibration spectra—with the benchmark data model that should be generated when executing the same preset control parameters under ideal defect-free conditions. This achieves multi-dimensional diagnosis integrating time-domain analysis, frequency-domain analysis, and statistical process control. Specifically, the system first needs to establish a health benchmark model. During the initial commissioning of the production line or after regular maintenance, a standard defect-free door panel is used. Preset control parameters for the first position control mechanism are run, and data from all sensors are collected multiple times during execution. Through machine learning or statistical analysis, normal value ranges, variation curve templates, and allowable fluctuation envelopes are established for each key parameter. The actual position control data collected in real time during production is compared with the benchmark model. For example, if the comparison finds that the X and Y coordinates of the door panel are accurate, but the positioning process of the Z axis shows abnormally high-frequency micro oscillations, and the clamping force establishment curve shows a slow rise rather than a rapid stabilization, then it cannot be defined by a single parameter exceeding the standard. However, its combined characteristics suggest that there are local protrusions or contamination on the lower surface of the door panel, causing the mechanism to encounter resistance and generate vibration during the clamping process. If the following error between the actual trajectory of each motion axis and the preset trajectory shows a systematic deviation in the same direction throughout the entire path, and the final clamping force of each clamp reaches the preset value, but the visual inspection of the key corner points of the door panel still has deviations, then it may indicate that the basic dimensions of the door panel itself, such as the diagonal, are out of tolerance, causing the mechanism to move into place and clamp according to the instructions, but it cannot correct the door panel to the theoretical position. Therefore, by extracting abnormal feature patterns that deviate from the baseline model from actual data and mapping them to a pre-defined defect feature library through experiments or simulations, the system can predict the type of physical defect from data anomalies. By interpreting the subtle tactile and kinematic feedback of the mechanism, it can predict potential problems in the door panel or process in advance.

[0055] For example, the types of defects that can be predicted based on the comparison between actual and preset control parameters can include basic defects such as defects in the door panel itself, the door panel position not being properly adjusted by the first position control mechanism in the previous step, or the door panel not being properly secured by the first position control mechanism in the previous step. Additionally, it can include predicting performance degradation or early signs of failure of the first position control mechanism itself. For instance, if the current curve of the servo motor driving a linear axis shows that, under the same load and speed command, the torque output needs to continuously increase to reach the target and is accompanied by slight vibration, it predicts insufficient lubrication or premature wear of the axis guide rail; if the pressure build-up time of a pneumatic clamp becomes significantly longer and unstable, it predicts leakage in the clamp's air circuit or slow valve response.

[0056] Predicting defect types can also include predicting defects left over from upstream processes or abnormalities in the condition of incoming materials, including dimensional deviations, uneven distribution of door panel rigidity (i.e., missing local reinforcing ribs leading to abnormal deformation during clamping, reflected as an asymmetrical distribution on the force sensor), abnormal surface condition of the door panel (i.e., excessive oil stains causing a sharp drop in the coefficient of friction, resulting in slippage during adjustment), and hidden damage inside the door panel (i.e., internal cracks, which may emit specific acoustic emission signals or produce atypical strain responses under clamping force).

[0057] The predicted defect types can also include transient problems caused by environmental or system interactions. For example, the short-term broadband vibration characteristics appearing in the data correspond to instantaneous impacts on the workshop floor or interference from the start-up and shutdown of nearby large equipment; all temperature-sensitive parameters in the data show a systematic slow shift, indicating that the change in ambient temperature has exceeded the automatic compensation range of the system.

[0058] For example, based on the comparison between the position control data representing the actual preset control parameters of the first position control mechanism and the preset control parameters of the first position control mechanism, the predicted defect type is obtained. Here, the system can first collect and cache a complete set of high-resolution time-series data of the first position control mechanism performing a complete task in real time, including the position of each axis encoder, servo drive current / torque, readings of each clamp force / displacement sensor, overall vibration accelerometer signal, etc. Then, the raw data is preprocessed and feature-engineered to extract scalar features, such as final position error, maximum following error, force set-up time, peak vibration acceleration, etc., as well as time-series / spectral features, such as the power spectral density of the position error, the shape of the clamping force curve, the amplitude of specific harmonic components of the current signal, etc. The extracted features are used as feature vectors describing the execution process.

[0059] Subsequently, the current feature vector is compared with the expected feature vector range and relationship derived from the health baseline model. For example, the statistical comparison analyzer checks whether each scalar feature exceeds the control limit, the time series pattern matching analyzer compares the actual curve with the baseline template to generate similarity scores or difference features, and the multivariate association analyzer checks whether the correlation between different parameters is abnormal. For example, in a healthy state, there is a certain statistical correlation between the X-axis positioning error and the clamping force F1. If this relationship is disrupted, it is considered abnormal.

[0060] Finally, the outputs of all analyzers are fed into the defect classification inference engine. The defect classification inference engine can predict the defect type as surface contamination causing clamping instability based on predefined expert rules, such as IF force settling time > threshold AND vibration high-frequency energy > threshold THEN. Alternatively, it can use a trained machine learning classification model to map multi-feature anomaly patterns to specific defect type labels and output a confidence probability.

[0061] For example, different defect types represent different risk levels and failure modes, thus requiring differentiated flipping strategies. For defects predicted to be low-risk or minor process mismatches, such as slight, uniform elastic deformation of the door panel or ambient temperature drift, the control strategy mainly involves parameter fine-tuning and enhanced monitoring. For instance, lower acceleration values ​​can be used during the flipping start-up and stop phases to reduce dynamic loads, or the clamping force setting of the flipping mechanism's own fixtures can be slightly increased as additional compensation. Simultaneously, the sampling frequency and alarm threshold of vibration monitoring can be increased during the flipping process. For defects predicted to be medium-risk, such as localized instability or slight asymmetry in the door panel, the control strategy needs to adjust the motion trajectory and force distribution. The flipping mechanism can be instructed to use an asymmetrical speed-changing curve, reducing speed when rotating upwards on the predicted weak side. Alternatively, if the flipping mechanism has multi-degree-of-freedom adjustment capabilities, a compensation trajectory can be calculated in real time to actively counteract the swaying tendency that may be caused by the door panel defect. For defects predicted to be high-risk, such as serious dimensional deviations in the door panel leading to a high risk of interference with the flipping mechanism fixture, or serious mechanical failures in the first position control mechanism, the control strategy is upgraded to a conservative or interrupted process. This includes forcibly reducing the entire flipping speed to a safe low speed before the flipping begins; setting more virtual checkpoints on the flipping path and performing additional sensor confirmation at each point; and in the most severe case, abandoning automatic flipping, keeping the mechanism in a safe position, triggering an audible and visual alarm, and waiting for manual intervention.

[0062] like Figure 6 As shown, Figure 6 This is a flowchart of a control method provided in another embodiment of this application; regarding the above step S120, it may include, but is not limited to, step S320.

[0063] Step S320: Based on the position control data and the preset control association, control the flipping mechanism to flip the door panel and generate door panel flipping data.

[0064] For example, the preset control association relationship can refer to a set of rules or a mathematical model that maps the door panel state characteristics finally achieved by the first position control mechanism to the control parameters required for the drive flipping mechanism to achieve the optimal flipping action. It can be a multi-input multi-output function relationship that considers continuous quantity changes, used to dynamically customize the flipping strategy based on the actual processing result of the door panel at present.

[0065] For example, the first position control mechanism obtains the specific spatial pose and force state of the door panel through the actions of each component. The spatial pose and force state can be characterized by a state feature vector, including but not limited to the actual three-dimensional coordinates of the door panel's center of gravity, the pitch and roll angles of the door panel relative to the mating surface of the flipping mechanism, the frictional torque margin of the contact area between the door panel and the clamp, the equivalent rigidity of the door panel itself, and whether the door panel has residual stress or minor deformation. The control parameters of the flipping mechanism are also a multi-dimensional vector, including at least the start-stop acceleration curve of the main flipping axis, the rotational speed in the uniform speed stage, the phase difference compensation value during multi-axis synchronous flipping, the clamping force setting of the auxiliary clamp of the flipping mechanism itself, and the active damping control coefficient that may be introduced in some advanced systems to counteract sway. The preset control correlation defines a mapping function between the door panel state characteristic vector output from the first position control mechanism and the optimal control parameter vector required by the flipping mechanism. For example, when the state characteristics show that the offset ΔX of the door panel's center of gravity in the flipping axis direction is positive and large, the mapping relationship will calculate that during the flipping start-up phase, when the center of gravity rotates upward on the side away from the axis, the angular acceleration in that range should be reduced, and an auxiliary balance axis of the flipping mechanism will be instructed to apply a small compensation displacement proportional to the center of gravity offset. When the state characteristics show that the contact stiffness between the door panel and the main clamp is low, the mapping relationship will output that the auxiliary clamp of the flipping mechanism should intervene before the main motion begins, providing additional clamping force, and the maximum angular velocity of the entire flipping process should be limited to a low value. The preset control correlation can take the form of a multi-dimensional lookup table, a conditional empirical formula, or a trained neural network model, enabling the control system to predict the door panel's behavior during dynamic flipping based on the data left by the first position control mechanism and inject targeted control commands in advance, thereby suppressing risks such as vibration, slippage, and overload, and achieving a seamless transition from static precise positioning to dynamic smooth conveying.

[0066] For example, to obtain the preset control correlation, a multibody dynamics model of the entire system can be established, including the precise dynamic relationship of the first position control mechanism, the door panel, and the flipping mechanism. The final state of the first position control mechanism can be parameterized, and the flipping process can be simulated in a simulation environment. The dynamic response results produced by different flipping control strategies under different initial state parameters can be observed, such as maximum stress, sliding displacement, and residual vibration energy. Then, the flipping control parameters that optimize the dynamic performance index for each initial state can be found through optimization algorithms, thereby initially establishing a correlation lookup table based on physical laws. The acquisition of preset control relationships can be achieved through induction based on expert experience and historical data. During production line debugging and long-term operation, for example, when the clamping pressure on the left side is 10% higher than that on the right side, the flipping start is slower, or a certain model of door panel is prone to shaking when quickly flipping to 90 degrees. This can be formalized into a set of IF-THEN rules, forming the initial core of the relationship. Furthermore, by collecting and archiving the preceding position control data and the current flipping mechanism control parameters corresponding to each successful and smooth flipping process over a long period of time, a historical operation database can be formed. Statistical analysis of the data can reveal strong statistical correlations between certain preceding state parameters and subsequent successful flipping parameters. Then, data mining methods such as regression analysis can be used to extract empirical mapping relationships. The acquisition of preset control relationships can be based on adaptive modeling and continuous optimization using machine learning. The system can continuously learn and initially possess a rough relationship generated by the two methods mentioned above. In actual operation, the system collects a complete data chain before and after each flip, including the state characteristics of the first position control mechanism as input, the flip control parameters used this time, and the actual performance monitoring data during the flip process. All of these data are input into an online learning engine to continuously evaluate the performance of the current relationship. If an abnormal vibration occurs during a flip but is ultimately successful, the learning engine will analyze whether the parameters recommended by the relationship are not optimized enough and automatically fine-tune the internal mapping model so that when encountering a similar preceding state, it can recommend more stable control parameters. Through continuous iteration of massive production data, the relationship will become more and more accurate, eventually forming a highly robust control strategy that can adapt to equipment wear, door panel batch changes, and environmental fluctuations.

[0067] like Figure 7 As shown, Figure 7 This is a flowchart of a control method provided in another embodiment of this application; regarding the above step S130, it may include, but is not limited to, steps S230 and S330.

[0068] Step S230: Obtain the current door panel position based on the door panel flipping data and position control data; Step S330: Fix the door panel position to the preset position using the second position control mechanism according to the current door panel position.

[0069] Understandably, the position control data comes from the first position control mechanism, which records the precise pose of the door panel before it flips, including the three-dimensional coordinates of the door panel relative to the mechanism's reference coordinate system, the orientation represented by Euler angles or quaternions, and the center of gravity coordinates and local geometric features that may be obtained by back-derived from sensors; the door panel flipping data comes from the control system of the flipping mechanism, including the execution parameters of the flipping action, and the actual rotation trajectory fed back by the inertial measurement unit or encoder that may be installed on the flipping mechanism. Therefore, to obtain the current door panel position based on the door panel flipping data and position control data, a unified coordinate transformation chain can be constructed. After the first position control mechanism completes the door panel fixing, it records the final pose in the position control data in the form of a homogeneous transformation matrix. The matrix defines the transformation relationship from the local coordinate system of the door panel to the base coordinate system of the first position control mechanism. Then, since the flipping mechanism and the first position control mechanism are relatively fixed in physical space, the transformation relationship between their base coordinate systems has been accurately measured and stored as system parameters by a laser tracker or professional calibration tool during equipment installation and debugging. Therefore, the door panel pose can be transformed from the base coordinate system of the first position control mechanism to the base coordinate system of the flipping mechanism. In the coordinate system of the flipping mechanism, the door panel is rigidly clamped on the flipping arm or fixture, and its relative position remains unchanged during the flipping process, but it will move together with the movement of the flipping mechanism.

[0070] At this point, by using the flipping angle recorded in the door panel flipping data, for example, a 180-degree rotation around a fixed axis in the flipping mechanism coordinate system, and applying the corresponding rotation transformation matrix to the door panel pose, the theoretical new pose of the door panel in the flipping mechanism coordinate system can be calculated. However, theoretical calculations are often insufficient to handle real-world errors. Therefore, in actual operation, real-time sensor data can be used for correction and fusion. For example, a vision camera or laser displacement sensor installed at the end of the flipping mechanism will immediately perform a rapid scan of the feature points on the door panel after the flipping stops, obtaining the measured 3D coordinates of key points on the door panel surface. This is then compared with the theoretically calculated pose, and through iterative nearest-point registration algorithms or least-squares optimization, a more realistic optimal pose estimate is calculated. In addition, the dynamic information in the door panel flipping data is also used to correct the theoretical model. For example, if abnormal vibration or sliding is detected during the flipping process, the final stopping position can be estimated probabilistically. Combined with data fusion algorithms such as Kalman filters, the theoretical kinematic predictions are fused with the observations of multiple sensors to obtain a more confident current door panel position, including the three-dimensional coordinates of the door panel in space and its attitude angle, forming a complete six-degree-of-freedom pose description, providing accurate input for the next process.

[0071] For example, after obtaining the current door panel position, the control system compares the calculated current door panel position with a preset position. The preset position is also a six-degree-of-freedom pose description, and the difference between the two is a pose deviation vector, including three translational components and three rotational components. The path planner of the second position control mechanism can generate a smooth, collision-free motion trajectory based on the deviation vector, combined with the mechanism's own kinematic model and dynamic constraints, optimizing the acceleration and velocity curves of the entire movement process to avoid generating excessive inertial forces or vibrations on the door panel.

[0072] Before the movement is executed, the gripper of the second position control mechanism first adjusts its posture according to the current door panel position data to ensure that it can safely and reliably grasp the door panel. The grasping process adopts force-position hybrid control, that is, when the gripper contacts the door panel, it gently fits through feedback from the force sensor, and then applies a preset gripping force to firmly grasp it, avoiding changes in the position of the door panel due to grasping impact. After the grasp is firm, each motion axis of the second position control mechanism begins to move in coordination according to the planned trajectory, moving the door panel from the current position to the preset position. During this process, the high-resolution encoder on the mechanism provides actual position feedback of each axis and compares it with the command position to form a position closed loop. At the same time, the vision system or laser interferometer installed at the end of the mechanism tracks the feature marks on the door panel in real time to form a second outer loop feedback to correct the positioning deviation caused by mechanical errors or elastic deformation of the mechanism. When the door panel is transported to the vicinity of the preset position, the movement speed is reduced to a very low level. The control system performs the final servo assembly based on the micron-level deviation fed back in real time until the position deviation is reduced to within the allowable tolerance range. When it is confirmed that the preset position has been reached, the locking mechanism of the second position control mechanism is activated, including the insertion of a pneumatic or hydraulic locking pin into the positioning hole, the electromagnet being energized to attract, or the action of an additional lateral clamping cylinder, to rigidly connect the door panel to the worktable or fixture, eliminating any possibility of movement of any degree of freedom.

[0073] like Figure 8 As shown, Figure 8 This is a flowchart of a control method provided in another embodiment of this application; regarding the above step S130, it may include, but is not limited to, steps S430 and S530.

[0074] Step S430: Obtain the position of the first door panel based on the position control data; Step S530: Based on the position of the first door panel and the door panel flipping data, obtain the position of the second door panel, and control the second position control mechanism according to the position of the second door panel to fix the position of the door panel to the preset position.

[0075] It is understandable that the position of the first door panel is obtained solely through position control data because the position control data itself is a set of information that encapsulates the final state of all execution ends of the first position control mechanism. When the first position control mechanism completes the adjustment and fixation of the door panel, the control system will record the precise physical quantities of each key component when this state is achieved, which directly or indirectly defines the pose of the door panel in space. Specifically, the position control data includes high-resolution absolute encoder readings of each motion axis servo drive, directly providing the precise coordinates and angles of the end effector in its own mechanism coordinate system. It also includes the extension amount, clamping force, and known installation position of each gripper or suction cup in the fixture system in the fixture coordinate system. Through the kinematic model calibrated at the factory or during installation, the readings of the axes and fixtures can be accurately converted to a unified first position control mechanism base coordinate system, and the spatial coordinates and normal vector of each tool center point in contact with the door panel on the fixture can be calculated. Furthermore, since the door panel is constrained by the fixture in a defined geometric relationship, the three-dimensional coordinates and attitude angles of the key feature points of the door panel itself in the base coordinate system can be calculated in reverse using these known contact point coordinates and constraint rules. Therefore, the position of the first door panel can be obtained solely through the position control data.

[0076] For example, after obtaining the position of the first door panel, the position of the second door panel needs to be obtained by combining the door panel flipping data. Here, the position of the first door panel is a description under static ideal conditions, while the flipping process is a physical event affected by various dynamic factors. The door panel flipping data records the actual information in the dynamic process. For example, the backlash between the drive gear of the flipping mechanism and the circular arc track gear ring will cause a small systematic deviation between the commanded rotation angle and the actual rotation angle; the acceleration and deceleration process during the start and stop of the flipping will produce dynamic elastic deformation and residual vibration due to the misalignment of the door panel's center of gravity and the rotation axis, resulting in micron-level slippage of the door panel in the fixture. If the position of the first door panel is only mathematically transformed according to an ideal theoretical 180-degree rotation matrix to predict the position after flipping, these unpredictable errors that actually occur will be completely ignored, resulting in an unacceptable deviation between the predicted position and the true position. Therefore, the sensor feedback of the actual motion process recorded by the door panel flipping data is used to correct and compensate for the kinematic transformation results. Combining the two to obtain the position of the second door panel is actually using the data of the actual motion process to verify and correct the ideal motion model, thereby ensuring that the position information transmitted to the next process is true and reliable.

[0077] Specifically, taking the position of the first door panel, represented by a homogeneous transformation matrix relative to the coordinate system of the flipping mechanism, as the initial state, a theoretical position of the second door panel is calculated using a rigid body rotation transformation matrix in three-dimensional space based on the preset rotation axis and theoretical flipping angle in the flipping command. Then, the door panel flipping data is analyzed to extract key actual motion parameters, including but not limited to the actual rotation angle, which can be read by a high-precision absolute encoder directly mounted on the flipping spindle; dynamic offset, which can be estimated by analyzing the data from the vibration accelerometer or laser displacement sensor mounted on the flipping arm during the flipping process, to determine the minute linear offset perpendicular to the rotation direction caused by dynamic deformation or sliding; and axial movement, which can be obtained by detecting the minute movement of the door panel or flipping arm in the direction of the rotation axis using an axial displacement sensor. Finally, an actual motion error vector is formed using the actual motion parameters. Finally, the theoretically predicted position is fused with the actual motion error vector. These errors can be regarded as correction terms for the theoretical rotation transformation matrix. For example, the difference between the actual rotation angle and the theoretical angle is used to correct the angle parameters of the rotation matrix; the dynamic offset and axial movement are used to correct the translation components in the transformation matrix. A state estimation filter is used, with the theoretical kinematic model as the predictor and the real-time sensor readings in the door panel flipping data as the observer. Through iterative calculation, a statistically optimal second door panel position estimate is obtained. Finally, the second door panel position is sent to the second position control mechanism as the most reliable spatial state description of the current door panel.

[0078] like Figure 9 As shown, Figure 9 This is a flowchart of a control method provided in another embodiment of this application; the control method described above may also include, but is not limited to, step S140.

[0079] Step S140: If it is determined through position control data that an over-limit defect has occurred, control the door panel flipping device to stop operating and trigger the mechanism alarm.

[0080] For example, an over-limit defect refers to one or more key physical parameters that exceed the preset safety process allowable range detected during the adjustment and fixing of the door panel by the first position control mechanism, which may lead to the failure of subsequent processes, equipment damage or irreparable waste. Excessive defects include severe misalignment of the door panel's position, meaning that after the door panel is adjusted by the first position control mechanism, the deviation between the actual position and the theoretical target position of key feature points exceeds the mechanism's own error correction capability or the maximum tolerance allowed by the flipping mechanism. For example, the tilt angle between the door panel plane and the theoretical horizontal plane exceeds the threshold or the longitudinal positioning deviation exceeds the threshold, causing the flipping mechanism to fail to grip safely or to cause severe interference. It can also include severe abnormalities in the clamping state, meaning that the clamping system used to fix the door panel exceeds the limits in its force control or position control. For example, the clamping force sensor reading of a key gripper is much lower or much higher than the set value, or the force values ​​of multiple grippers are severely uneven, indicating that the door panel cannot be uniformly constrained due to its own severe deformation and is in an unstable state. It can also include severe abnormalities in the execution of the mechanism itself, meaning that the first position control mechanism exhibits pathological behavior during the movement. For example, the servo motor driving a certain axis continuously reports an overload alarm, the following error between the actual movement trajectory and the command trajectory is continuous and severely out of tolerance, or abnormally severe mechanical vibration is detected during the execution.

[0081] Based on this, determining the current out-of-limit defect through position control data involves online analysis of data streams from multiple sources and real-time comparison and logical judgment with a series of preset safety thresholds and health modes in the system. For example, firstly, the system gathers raw signals from all sensors, including the position and speed of high-resolution encoders for each motion axis, real-time current and torque feedback from servo drives, pressure or force sensor readings for each pneumatic or electric clamp, vibration accelerometer signals for the overall structure, and instantaneous results from any online measurement system. Then, the control system or dedicated monitoring algorithm calculates state characteristic values ​​for judgment in real time from the raw data stream. For example, it calculates the steady-state positioning error of each motion axis after reaching the commanded position, the final clamping force of each clamp and its percentage deviation from the set value, the amplitude of the maximum vibration acceleration during the entire adjustment process, or calculates the straightness or corner position deviation of the door panel edge through several samplings by the vision system. Then, the system compares each calculated real-time characteristic value with the alarm threshold and out-of-limit shutdown threshold preset in the database for this process step of the door panel model. If any key parameter triggers the out-of-limit threshold, an out-of-limit defect alarm will be triggered.

[0082] Based on the control methods of the above embodiments, the following presents various embodiments of the operation control device, electronic device, and computer-readable storage medium of this application.

[0083] like Figure 10 As shown, Figure 10 This is a schematic diagram of an operation control device for executing a control method according to an embodiment of this application. The operation control device 1000 implemented in this application includes: a processor 1020, a memory 1010, and a computer program stored in the memory 1010 and executable on the processor 1020, wherein... Figure 10 The example uses a processor 1020 and a memory 1010.

[0084] The processor 1020 and the memory 1010 can be connected via a bus or other means. Figure 10 Taking the example of a connection between China and Israel via a bus.

[0085] Memory 1010, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs and non-transitory computer-executable programs. Furthermore, memory 1010 may include high-speed random access memory, and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, memory 1010 may optionally include remotely located memories 1010 relative to processor 1020, which can be connected to the operation control device 1000 via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0086] Those skilled in the art will understand that Figure 10 The device structure shown does not constitute a limitation on the operation control device 1000, and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0087] exist Figure 10 In the illustrated operation control device 1000, the processor 1020 can be used to call the control program stored in the memory 1010, thereby implementing the control method described above. Specifically, the non-transitory software program and instructions required to implement the control method of the above embodiment are stored in the memory 1010, and when executed by the processor 1020, the control method of the above embodiment is executed.

[0088] It is worth noting that, since the operation control device 1000 of this application embodiment can execute the control method of any of the above embodiments, the specific implementation method and technical effect of the operation control device 1000 of this application embodiment can refer to the specific implementation method and technical effect of the control method of any of the above embodiments.

[0089] Furthermore, one embodiment of this application also provides an electronic device that includes the operation control device described in the above embodiment.

[0090] It is worth noting that, since the electronic device of this application embodiment includes the operation control device of the above embodiments, and the operation control device of the above embodiments can execute the control method of any of the above embodiments, the specific implementation method and technical effect of the electronic device of this application embodiment can refer to the specific implementation method and technical effect of the control method of any of the above embodiments.

[0091] Furthermore, one embodiment of this application also provides a computer-readable storage medium storing computer-executable instructions for performing the control method described above. Exemplarily, the above-described control method is performed... Figure 1 , Figures 4 to 9 The methods and steps in the text.

[0092] It is worth noting that, since the computer-readable storage medium of this application embodiment can execute the control method of any of the above embodiments, the specific implementation and technical effects of the computer-readable storage medium of this application embodiment can be referred to the specific implementation and technical effects of the control method of any of the above embodiments.

[0093] It will be understood by those skilled in the art that all or some of the steps and systems in the methods disclosed above can be implemented as software, firmware, hardware, and suitable combinations thereof. Some or all of the physical components can be implemented as software executed by a processor, such as a central processing unit, digital signal processor, or microprocessor, or as hardware, or as an integrated circuit, such as an application-specific integrated circuit. Such software can be distributed on a computer-readable medium, which may include computer storage media or non-transitory media and communication media or transient media. As is known to those skilled in the art, the term computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc DVD or other optical disc storage, magnetic cartridges, magnetic tape, disk storage or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible to a computer. Furthermore, as is known to those skilled in the art, communication media may include computer-readable instructions, data structures, program modules, or other data in modulated data signals such as carrier waves or other transmission mechanisms, and may include any information delivery medium.

[0094] In the several embodiments provided in this application, it should be understood that the disclosed systems, instruments, and methods can be implemented in other ways. For example, the instrument embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the shown or discussed mutual couplings, direct couplings, or communication connections may be through some interfaces; indirect couplings or communication connections between instruments or units may be electrical, mechanical, or other forms. Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, i.e., they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0095] It should also be understood that the various implementation methods provided in this application can be combined arbitrarily to achieve different technical effects.

[0096] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

Claims

1. An automated container door tilting control method, characterized in that, An application to a door panel flipping device, the door panel flipping device comprising a first position control mechanism, a second position control mechanism, and a flipping mechanism; The control method includes: In response to the door panel being loaded, the position of the door panel is adjusted and fixed by the first position control mechanism to obtain position control data; The flipping mechanism is controlled based on the position control data to flip the door panel, and door panel flipping data is generated. In response to the door panel flipping stop, the second position control mechanism is controlled according to the door panel flipping data and the position control data to fix the door panel position to a preset position.

2. The automated container door tilting control method according to claim 1, characterized in that, In response to the door panel being loaded, the first position control mechanism adjusts and fixes the door panel position to obtain position control data, including: In response to the material being loaded onto the door panel, information about the door panel is obtained; Based on the door panel information, the door panel position is adjusted and fixed by the first position control mechanism to obtain position control data.

3. The automated container door tilting control method according to claim 1, characterized in that, The step of controlling the flipping mechanism based on the position control data to flip the door panel and generating door panel flipping data includes: Based on the position control data, a predicted defect type is obtained. The flipping mechanism is controlled according to the predicted defect type to flip the door panel and generate door panel flipping data.

4. The automated container door tilting control method according to claim 1, characterized in that, The step of controlling the flipping mechanism based on the position control data to flip the door panel and generating door panel flipping data includes: Based on the position control data and the preset control association, the flipping mechanism is controlled to flip the door panel and generate door panel flipping data.

5. The automated container door tilting control method according to claim 1, characterized in that, The step of controlling the second position control mechanism to fix the door panel position to a preset position based on the door panel flipping data and the position control data includes: The current door panel position is obtained based on the door panel flipping data and the position control data; Based on the current door panel position, the second position control mechanism fixes the door panel position to a preset position.

6. The automated container door tilting control method according to claim 1, characterized in that, The step of controlling the second position control mechanism to fix the door panel position to a preset position based on the door panel flipping data and the position control data includes: The position of the first door panel is obtained based on the position control data; Based on the position of the first door panel and the door panel flipping data, the position of the second door panel is obtained, and the second position control mechanism is controlled according to the position of the second door panel to fix the position of the door panel to a preset position.

7. The automated container door tilting control method according to claim 1, characterized in that, The control method further includes: If the position control data determines that an over-limit defect has occurred, the door panel flipping device is controlled to stop operating and an alarm is triggered.

8. An operation control device, characterized in that, The method includes a memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement the automated container door tilting control method as described in any one of claims 1 to 7.

9. An electronic device, characterized in that, Includes the operation control device as described in claim 8.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions for causing a computer to perform the automated container door tilting control method as described in any one of claims 1 to 7.

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