Wallboard screw robot assembly method with flexible and adjustable assembly process

Abstract

The invention relates to the technical field of wallboard screw assembly, aims to solve the problem that a traditional robot screw assembly method is difficult to adapt to automatic assembly of wallboards which are large in breadth size, diversified in specification and model and large in assembly parameter adjustment, and provides a wallboard screw robot assembly method with the flexible and adjustable assembly process. Comprising the following steps: S1, encoding assembly holes in a wallboard; s2, defining a data communication format between a robot assembly system upper computer controller and a robot assembly execution part; s3, according to the data communication format defined in the S2, generating data of each assembly hole of the wallboard of the assembled model and storing the data; s4, establishing data communication between the upper computer controller and the execution part, sending the data of the assembly hole to the execution part by the upper computer controller after the communication is established, and assembling the screw at the corresponding hole position by the execution part; and S5, according to the actual quality state of the wallboard assembly process, the assembly sequence and the assembly process data are adjusted, and then assembly is conducted according to the new assembly sequence.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of wall plate screw assembly, in particular to a wall plate screw robot assembly method with flexible assembly process. BACKGROUND

[0002] The wall plate and thin-walled part with smooth surface, no obvious geometric features and large size are important components for sealing assembly of various instruments and electronic device housings.

[0003] Such thin-walled parts made of metal sheet or composite materials usually have increased shape error and appearance deformation when the length size is greater than 0.5m. The installation and assembly of such parts are currently performed manually, and the screw assembly sequence is adjusted according to the screw compression degree and the wall plate warping degree during the assembly process. For the installation of new types and specifications of wall plates, manual adjustment and optimization of the process is repeated, which gradually forms manual assembly experience. With the increasing demand for assembly of such parts, the repetitive and monotonous manual assembly process and the high labor intensity characteristics require the research and application of robot automatic assembly of wall plate parts in the industry.

[0004] The assembly pose recognition of large-size and few-feature thin-walled parts is an important link in the robot automatic assembly of such parts, which affects the accuracy of subsequent screw assembly actions. The combination of 3D point cloud scanning and 2D image recognition methods can improve the accuracy of installation hole pose recognition. In addition, the quality and efficiency of screw locking assembly affect the assembly quality and production efficiency of products. Different types of wall plates have different optimal locking parameters due to differences in material and size. The design of the robot assembly process needs to adapt to the rapid switching and automatic adjustment of different wall plate model locking process requirements, quickly match the best operation parameters for each wall plate model, and ensure the accuracy and stability of the assembly process.

[0005] The traditional robot screw assembly method relies on the pre-written program and data of the robot for process sequence, tightening torque and screw type selection. The assembly operator cannot make changes and adjustments, and only the equipment maintenance engineer can make changes and adjustments to the program data when necessary. This method is suitable for the assembly of parts with high machining precision, small shape error and small changes in assembly process parameters. For the automatic assembly of wall plates with large size, various specifications and large assembly parameter adjustments, this pre-written and fixed program robot assembly method is difficult to adapt, and requires a lot of program development and debugging time by equipment engineers.

[0006] Therefore, it is necessary to design a flexible adjustable thin-walled part robot assembly method, which can flexibly adjust the screw assembly sequence, tightening torque and screw specification according to the specification of the wall plate and the assembly process quality, so that the assembly quality of the large-format thin-walled part or wall plate part reaches the best state. SUMMARY

[0007] The present application aims to provide a wall plate screw robot assembly method with flexible adjustable assembly process, to solve the problem that the traditional robot screw assembly method is difficult to adapt to the automatic assembly of wall plate parts with large format size, various specifications and large assembly parameter adjustment.

[0008] The present application is implemented by using the following technical solutions: The present application provides a wall plate screw robot assembly method with flexible adjustable assembly process, comprising the following steps: Step S1: encode the assembly holes on the wall plate to obtain the assembly hole position code; Step S2: define the data communication format between the robot assembly system host computer controller and the robot assembly execution component; Step S3: generate and store the data of each assembly hole of the assembled model wall plate according to the data communication format defined in step S2; Step S4: establish data communication between the robot assembly system host computer controller and the robot assembly execution component, after the communication is established, the robot assembly system host computer controller sends the assembly hole data to the robot assembly execution component, and the robot assembly execution component receives the assembly hole data and performs the assembly of the corresponding hole position screw; Step S5: adjust the assembly sequence and assembly process data according to the actual quality state of the wall plate assembly process, and then perform screw assembly according to the new assembly sequence.

[0009] As a preferred technical solution: When encoding the assembly holes on the wall plate in step S1, the assembly holes around the wall plate are encoded, and the encoding can clearly indicate the position and sequence of the assembly holes around the wall plate, and the encoding data capacity can cover the maximum number of assembly hole positions of all specifications of the assembled wall plate parts.

[0010] As a preferred technical solution: The hole position codes on the upper side of the wall plate are sequentially set as 101, 102, 103...1X from left to right, wherein the first digit 1 represents the upper side of the wall plate, the subsequent two digits represent the position of the assembly hole, and X represents the maximum number of hole positions on the upper side of the wall plate; The hole position codes on the lower side of the wall plate are sequentially set as 201, 202, 203...2Y from left to right, wherein the first digit 2 represents the lower side of the wall plate, the subsequent two digits represent the position of the assembly hole, and Y represents the maximum number of hole positions on the lower side of the wall plate; The hole position codes on the left side of the wallboard are sequentially set as 301, 302, 303,..., 3U from left to right, wherein the first digit 3 represents the left side of the wallboard, the following two digits represent the assembly hole position, and U represents the maximum number of hole positions on the left side of the wallboard. The hole position codes on the right side of the wallboard are sequentially set as 401, 402, 403,..., 4V from left to right, wherein the first digit 4 represents the right side of the wallboard, the following two digits represent the assembly hole position, and V represents the maximum number of hole positions on the right side of the wallboard.

[0011] As a preferred technical solution: The data communication format in step S2 includes a plurality of function bits, each function bit is defined as instruction identification, assembly hole position code, assembly hole coordinate data and assembly process data.

[0012] As a preferred technical solution: The instruction identification includes a function code. The assembly hole coordinate data includes assembly hole six-dimensional coordinate data or assembly hole six-dimensional photograph recognition coordinate data. The assembly process data includes robot seventh axis position data, tightening torque data, and screw specification data.

[0013] As a preferred technical solution: In step S3, according to the data communication format defined in step S2, the instruction identification, assembly hole position code, assembly hole coordinate data and assembly process data corresponding to each assembly hole are generated and stored. The data of each assembly hole specifically includes a function code, the assembly hole position code set in step S1, assembly hole six-dimensional coordinate data or assembly hole six-dimensional photograph recognition coordinate data, robot seventh axis position data, tightening torque data, and screw specification data.

[0014] As a preferred technical solution: In step S4, the robot assembly system upper computer controller sequentially sends the entire data of each assembly hole stored in step S3 to the robot assembly execution component, and the sending order is diagonal circulation or double-hole diagonal circulation.

[0015] As a preferred technical solution: In step S4, the assembly hole position codes are sequentially queried, and then the entire data of the corresponding assembly hole is sent to the robot assembly execution component according to the arrangement order of the above assembly hole position codes.

[0016] As a preferred technical solution: In step S5, when the assembly sequence and assembly process data need to be adjusted, the assembly hole position code is sequentially queried according to the new sequence, the assembly process data that needs to be modified is modified, and then the whole data of the assembly hole corresponding to the new assembly hole position code arrangement sequence is sent to the robot assembly execution component, and the robot assembly execution component performs assembly of the screw at the corresponding hole position after receiving the data of the assembly hole.

[0017] As a preferred technical solution: The wall plate screw robot assembly method with flexible assembly process further comprises S6: storing the assembly process data adjusted in step S5 in the robot assembly system upper computer controller to form the optimized assembly process data of the assembled model specification wall plate, which is used for the assembly task of the corresponding model specification wall plate in subsequent production.

[0018] As described above, due to the adoption of the above technical solution, the beneficial effects of the present application are: 1、The present application defines the data communication format between the robot assembly system upper computer controller and the robot assembly execution component (generally a mechanical arm), defines each function bit in the data communication format as an instruction identifier, an assembly hole position code, assembly hole coordinate data and assembly process data, generates and stores each item of data in this format to obtain the data corresponding to each assembly hole, sends the assembly hole data with the instruction identifier, assembly hole position code, assembly hole coordinate data and assembly process data to the robot assembly execution component through the robot assembly system upper computer controller, and the robot assembly execution component performs assembly of the screw at the corresponding hole position according to the received assembly hole data, so that the assembly sequence and assembly process data can be adjusted according to the actual quality state of the wall plate during the assembly process, and the assembly quality of large-format wall plates is greatly improved.

[0019] 2、The present application encodes each assembly hole, obtains assembly hole coding, and can query the assembly hole coding through an index tool to obtain the entire data of the assembly hole, and the host computer controller of the robot assembly system sends each assembly hole data to the robot assembly execution component in turn according to the arrangement order of the assembly hole coding; when it is necessary to adjust the assembly order and the assembly process data, the assembly hole coding can still be queried through the index tool to obtain the entire data of the assembly hole, the assembly process data is adjusted, then the assembly hole coding is reordered, and the host computer controller of the robot assembly system sends each assembly hole data to the robot assembly execution component in turn according to the new arrangement order of the assembly hole coding, so that the assembly order and the assembly process data can be quickly adjusted, especially for thin-walled parts with many assembly hole positions and prone to compression deformation and warping during the assembly process, the assembly process data can be quickly modified through the query of the assembly hole coding around the wall plate, the assembly order of the screws at each assembly hole can be quickly adjusted through the modification of the query order of the assembly hole coding around the wall plate, the assembly debugging and process parameter determination of new specifications of wall plate parts are facilitated, the difficulty of modification of the assembly process program is reduced, the actual application of production operators is facilitated, the assembly order does not need to be recorded through a large amount of teaching and programming, the robot assembly program design and deployment time of new specifications of wall plate parts is greatly reduced, the high-intensity programming work of robot engineers required in the traditional method to realize the assembly of such workpieces is reduced, the programming debugging time and the failure rate are reduced, the production efficiency is improved, the advantages of automatic assembly are maximized, and the adaptability and stability of the assembly process are ensured.

[0020] 3、The flexible assembly method of the present application can flexibly adjust the screw assembly order, tightening torque and screw specification (i.e., assembly process data) according to the specifications of the wall plate and the assembly process quality, so that the assembly quality of large-area thin-walled parts or wall plate parts reaches the best state, and the assembly method also helps to improve the flexibility of the assembly line, so that when new products are introduced or old products are updated, the robot action does not need to be reprogrammed, only the corresponding parameters need to be added or modified in the database, the preparation time for product switching is greatly shortened, and the cost is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 The flowchart of the flexible and adjustable assembly process wall plate screw robot assembly method of the present application.

[0022] Figure 2 The assembly hole coding method example for the four sides of a large-area wall plate.

[0023] Figure 3 The data communication format definition between the host computer controller of the robot assembly system and the robot assembly execution component.

[0024] Figure 4The six-dimensional photographing position coordinate data of the assembly hole is stored for the controller.

[0025] Figure 5 The six-dimensional photographing position coordinate data of the assembly hole is stored for the controller. DETAILED DESCRIPTION

[0026] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0027] Embodiment 1 As shown in the figure, the embodiment provides a wallboard screw robot assembly method with flexible assembly process, comprising the following steps: Figure 1 Step S1: encoding the assembly holes on the wallboard to obtain the assembly hole position code.

[0028] Specifically, the assembly holes around the large-format wallboard are encoded. The code can clearly indicate the position and sequence of the assembly holes around the wallboard, and the code data capacity can cover the maximum number of assembly hole positions of all specifications of the assembled wallboard parts. The code form adopts Arabic numerals, which is convenient for retrieval and inquiry during assembly.

[0029] For example, as shown in the figure, the hole position codes on the upper side of the wallboard are sequentially set as 101, 102, 103...121 from left to right, wherein the first digit 1 represents the upper side of the wallboard, and the subsequent two digits represent the position of the assembly hole. The maximum number of hole positions on the upper side is 21; the hole position codes on the lower side of the wallboard are sequentially set as 201, 202, 203...221 from left to right, wherein the first digit 2 represents the lower side of the wallboard, and the subsequent two digits represent the position of the assembly hole. The maximum number of hole positions on the lower side is 21; the hole position codes on the left side of the wallboard are sequentially set as 301, 302, 303...307 from left to right, wherein the first digit 3 represents the left side of the wallboard, and the subsequent two digits represent the position of the assembly hole. The maximum number of hole positions on the left side is 7; the hole position codes on the right side of the wallboard are sequentially set as 401, 402, 403...407 from left to right, wherein the first digit 4 represents the right side of the wallboard, and the subsequent two digits represent the position of the assembly hole. The maximum number of hole positions on the right side is 7. Figure 2 Step S2: defining the data communication format between the host computer controller and the robot assembly execution component of the robot assembly system; the data communication format contains multiple function bits, and each function bit is defined as an instruction identifier, an assembly hole position code, assembly hole coordinate data, and assembly process data.

[0030]

[0031] ​​In the embodiment, the robot assembly execution component is a six-degree-of-freedom mechanical arm carried by a mobile robot.

[0032] In the embodiment, as shown in Figure 3 The data communication format includes a plurality of function bits, each of which is defined as a function code, the assembly hole position code set in step S1, assembly hole six-dimensional coordinate data or assembly hole six-dimensional photographing recognition coordinate data, robot seventh-axis position data, tightening torque data, and screw specification data. The function bits in the above format can be appropriately reduced or increased according to the actual workpiece characteristics. The function code is an instruction identifier, which is a character identification bit for communication handshake, data packet flag, and error return. The data packet flag function code is Pose. The assembly hole six-dimensional coordinate data or assembly hole six-dimensional photographing recognition coordinate data is assembly hole coordinate data. The robot seventh-axis position data, tightening torque data, and screw specification data are assembly process data.

[0033] Step S3: According to the data communication format defined in step S2, the data of each assembly hole of the assembled model wallboard is generated, including the instruction identifier, assembly hole position code, assembly hole coordinate data, and assembly process data corresponding to each assembly hole, and these data are stored.

[0034] The data of each assembly hole specifically includes a function code, an assembly hole position code set in step S1, assembly hole six-dimensional coordinate data or assembly hole six-dimensional photographing recognition coordinate data, robot seventh-axis position data, tightening torque data, and screw specification data.

[0035] The tightening torque data and the screw specification data can be generated according to the process requirement file.

[0036] For wallboard installation with high assembly position accuracy requirements, assembly hole six-dimensional coordinate data is generated, and for wallboard installation with low assembly position accuracy requirements, assembly hole six-dimensional photographing recognition coordinate data is generated, and the robot reaches the photographing recognition position to recognize the hole position before assembly.

[0037] The teaching or offline programming method is used to generate assembly hole coordinate data according to the number of assembly holes. When the number of assembly holes is small, the teaching method is used to generate assembly hole coordinate data, and when the number of assembly holes is large (for example, more than 20), the offline programming method is used to generate assembly hole coordinate data.

[0038] As shown in Figure 4 The offline programming method is used to generate assembly hole six-dimensional photographing recognition coordinate data, Figure 4 (a), Figure 4 (b), Figure 4 (c), Figure 4 (d) are the photographing positions generated by single diagonal cycle assembly, Figure 5The six-dimensional photographing recognition coordinate data of the assembly hole stored by the host computer controller is shown.

[0039] Step S4: Establish data communication between the host computer controller of the robot assembly system and the robot assembly execution component. After the communication is established, the host computer controller of the robot assembly system sends the data of the assembly hole stored in step S3 to the robot assembly execution component. After receiving the data of the assembly hole, the execution component performs assembly of the corresponding hole position screw.

[0040] Specifically, according to the robot model, generally TCP / IP or Modbus communication mode is adopted. After the communication connection is established, the host computer controller of the robot assembly system sends the instruction identifier, assembly hole position code and assembly process data corresponding to each assembly hole stored in step S3 to the robot assembly execution component in sequence, that is, sends each complete data (such as shown) in sequence. Figure 3

[0041] In this embodiment, TCP / IP communication mode is adopted. The order of sending data is based on the diagonal cycle according to experience, for example, the assembly hole position codes 101, 221, 102, 220, 103 and 219 are queried in sequence, and then the complete data of the corresponding assembly hole is sent to the robot assembly execution component according to the arrangement order of the above assembly hole position codes.

[0042] When the six-dimensional photographing recognition coordinate data of the assembly hole is generated in step S3, after the host computer controller of the robot assembly system sends the data of the assembly hole stored in step S3 to the robot assembly execution component, the visual photographing recognition assembly hole position guides the mechanical arm to complete the final position screw assembly.

[0043] Step S5: According to the actual quality state of the wallboard assembly process, adjust the assembly sequence and assembly process data, and send the data of the assembly hole to the robot assembly execution component according to the new assembly sequence. After receiving the data of the assembly hole, the robot assembly execution component performs assembly of the corresponding hole position screw.

[0044] In this way, the assembly error can be reduced, and the assembly quality of the large-format wallboard part can be greatly improved.

[0045] Among them, the actual quality state of the wallboard assembly process includes data such as wallboard joint width, surface step difference, and pressing torque.

[0046] ​For example, it is found that the right upper corner and the left lower corner of the wallboard have corner edge warping phenomenon during assembly process. The assembly sequence and assembly process data are adjusted. The assembly hole position codes 101, 221, 121, 201, 102 and 220 are sequentially queried according to the new sequence, and the assembly process data that need to be modified are modified. Then the whole data of the assembly hole corresponding to the new assembly hole position code arrangement sequence is sequentially sent to the robot assembly execution component. After the robot assembly execution component receives the data of the assembly hole, the assembly of the corresponding hole position screw is performed. It is found that the warping of the four edges of the wallboard and the surface step difference state are obviously improved during the assembly process. Finally, the assembly quality of the large-size wallboard is greatly improved, and the quality specification requirements are met.

[0047] Step S6: store the assembly process data adjusted in step S5 in the robot assembly system host computer controller, form the optimized assembly process data of the assembled model specification wallboard, and use it for the assembly task of the corresponding model specification wallboard in subsequent production.

[0048] In summary, the method proposed by the present application is suitable for the robot automatic assembly process of the large-size wallboard with fast and flexible adjustable assembly process, and meets the requirements of robot assembly production.

[0049] The above only describes the preferred embodiments of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A robot assembly method for wall panel screws with flexible and adjustable assembly process, characterized in that: Includes the following steps: Step S1: Encode the assembly holes on the wall panel to obtain the assembly hole position code; Step S2: Define the data communication format between the host computer controller of the robot assembly system and the robot assembly execution components; Step S3: Generate and store the data of each assembly hole of the assembled model wall panel according to the data communication format defined in step S2; Step S4: Establish data communication between the host computer controller of the robot assembly system and the robot assembly execution component. After the communication is established, the host computer controller of the robot assembly system sends the data of the assembly holes to the robot assembly execution component. After receiving the data of the assembly holes, the robot assembly execution component assembles the screws at the corresponding hole positions. Step S5: Adjust the assembly sequence and assembly process data according to the actual quality status of the wall panel assembly process, and then assemble the screws according to the new assembly sequence.

2. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 1, characterized in that: In step S1, when encoding the mounting holes on the wall panel, the mounting holes around the wall panel are encoded so that the encoding can clearly indicate the position and order of the mounting holes around the wall panel, and the encoding data capacity can cover the maximum number of mounting holes for all specifications of the assembled wall panel parts.

3. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 2, characterized in that: The hole positions on the upper side of the panel are numbered from left to right as 101, 102, 103...1X, where the first '1' indicates the upper side of the panel, the next two '2' indicate the position of the assembly hole, and 'X' indicates the maximum number of holes on the upper side of the panel. The hole positions on the lower side of the wall panel are numbered from left to right as 201, 202, 203...2Y, where the first digit 2 indicates the lower side of the wall panel, the following two digits indicate the position of the assembly hole, and Y indicates the maximum number of holes on the lower side of the wall panel. The hole positions on the left side of the wall panel are numbered from left to right as 301, 302, 303...3U, where the first '3' indicates the left side of the wall panel, the next two '2's indicate the position of the assembly hole, and 'U' indicates the maximum number of holes on the left side of the wall panel. The hole positions on the right side of the wall panel are numbered from left to right as 401, 402, 403...4V. The first digit, 4, indicates the right side of the wall panel, the next two digits indicate the position of the assembly hole, and V indicates the maximum number of holes on the right side of the wall panel.

4. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 1, characterized in that: The data communication format in step S2 includes multiple function bits, each defined as instruction identifier, assembly hole position code, assembly hole coordinate data, and assembly process data.

5. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 4, characterized in that: Instruction identifiers include function codes; Assembly hole coordinate data includes six-dimensional coordinate data of the assembly hole or six-dimensional photo recognition coordinate data of the assembly hole; Assembly process data includes robot seventh axis position data, tightening torque data, and screw specification data.

6. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 5, characterized in that: In step S3, according to the data communication format defined in step S2, the instruction identifier, assembly hole position code, assembly hole coordinate data and assembly process data corresponding to each assembly hole are generated and stored. The data for each assembly hole specifically includes the function code, the assembly hole position code set in step S1, the six-dimensional coordinate data of the assembly hole or the six-dimensional photo recognition coordinate data of the assembly hole, the position data of the robot's seventh axis, the tightening torque data, and the screw specification data.

7. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 6, characterized in that: In step S4, the host computer controller of the robot assembly system sequentially sends the complete data of each assembly hole stored in step S3 to the robot assembly execution component. The order of sending the data is either diagonal loop or double hole diagonal loop.

8. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 7, characterized in that: In step S4, the assembly hole position codes are queried sequentially, and then the complete data of the corresponding assembly holes is sent to the robot assembly execution component according to the arrangement order of the assembly hole position codes.

9. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 8, characterized in that: In step S5, when it is necessary to adjust the assembly sequence and assembly process data, the assembly hole position codes are queried in the new order, and the assembly process data that needs to be modified is modified. Then, the entire data of the corresponding assembly hole is sent to the robot assembly execution component according to the new assembly hole position code arrangement order. After receiving the assembly hole data, the robot assembly execution component assembles the screws at the corresponding hole positions.

10. The wall panel screw robot assembly method with flexible and adjustable assembly process according to claim 9, characterized in that: It also includes S6: storing the assembly process data adjusted in step S5 in the host computer controller of the robot assembly system to form optimized assembly process data for the assembled model and specification wall panel, which is used for the assembly tasks of the corresponding model and specification wall panel in subsequent production.

Images