A multi-vehicle type clamp quick switching and integration method and system

Abstract

The present application relates to a kind of multi-vehicle type fixture quick switching and integration method and system, it is related to automobile parts manufacturing technical field, it includes in response to connection normal signal, import target vehicle model, and obtain corresponding target vehicle parameters in fixture database;Current hardware parameters are obtained;When current hardware parameters are consistent with target vehicle parameters, output compatible signal;When current hardware parameters are inconsistent with target vehicle parameters, output incompatible signal;Incompatible signal is parsed based on HMI module, and debugging method is executed;When there is compatible signal in the process of executing debugging method, stop debugging method and record current hardware parameters and target vehicle model, to update fixture database;In response to compatible signal, execute fixture integration method;When there is no compatible signal after executing debugging method, output manual warning signal.The present application has the effect that ensures that fixture can adapt to the production needs of different vehicle types, and realizes quick switching and integration different vehicle types.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, and in particular to a method and system for rapid switching and integration of multi-vehicle model fixtures. Background Technology

[0002] Currently, with the development of new energy vehicles, the iteration speed of new energy vehicles is generally around one year, breaking the three to five-year iteration cycle of models in the era of gasoline vehicles. In order to meet the iteration speed of new energy vehicles, automakers need to provide a suitable fixture for each model, so multi-model fixtures have emerged.

[0003] Traditional fixtures can only be adapted to one vehicle model and cannot cope with scenarios where vehicle models are frequently switched on the same production line; while the core value of multi-vehicle fixtures is not only to adapt and iterate, but also to support mixed-line production.

[0004] Regarding the aforementioned technologies, the error correction for traditional multi-vehicle fixture adaptation is a post-event remedy. Engineers can only manually troubleshoot after the fixture malfunctions (such as the cylinder not clamping or the sensor not detecting) and the workpiece is scrapped. This is time-consuming and lacks a standardized error correction path, relying on experience. Summary of the Invention

[0005] To achieve rapid switching and adaptation of fixtures for multiple vehicle models, this invention provides a method and system for rapid switching and integration of fixtures for multiple vehicle models.

[0006] In a first aspect, the present invention provides a method for rapid switching and integration of multi-vehicle model clamps, employing the following technical solution: A method for rapid switching and integration of multi-vehicle model fixtures includes: Step 1: In response to a normal connection signal, import the target vehicle model and obtain the corresponding target vehicle parameters from the preset fixture database; Step 2: Call the target vehicle model parameters to the preset PLC module and obtain the current hardware parameters; Step 3: Output a preset compatibility signal when the current hardware parameters match the target vehicle model parameters; Step 4: Output a preset incompatibility signal when the current hardware parameters are inconsistent with the target vehicle parameters; Step 5: Based on the preset HMI module, parse the incompatible signal and execute the preset debugging method according to the incompatible signal; Step 6: If the compatibility signal is present during the execution of the debugging method, stop the debugging method and record the current hardware parameters and the target vehicle model to update the fixture database; Step 7: In response to the compatibility signal, execute the preset fixture insertion method based on the PLC module; Step 8: When no compatible signal is found after the debugging method has been executed, output a preset manual warning signal.

[0007] By adopting the above technical solution, rapid switching and integration of fixtures for multiple vehicle models can be achieved, effectively addressing scenarios involving frequent model changes on the same production line, improving production efficiency, and reducing workpiece scrap rates due to fixture incompatibility. Simultaneously, this method features a standardized error correction path, does not rely on engineer experience, and can identify and resolve problems in real time, further enhancing the stability and reliability of the production line. Furthermore, by updating the fixture database, the adaptability of the fixtures can be continuously optimized to meet the demands of rapid vehicle model iteration in the new energy era.

[0008] Optionally, it also includes a method for determining the target vehicle model when the target vehicle model does not exist, the method comprising: Step 9: For models that do not exist, obtain preset cylinder position sensor parameters based on the PLC module. The cylinder position sensor parameters include release position sensor parameters and clamping position sensor parameters. Step 10: Analyze the clamping position sensor parameters to determine the clamping position time; Step 11: Traverse the fixture database based on the fixture arrival time to determine the target vehicle model parameters; Step 12: If the target vehicle parameters exist, execute steps 2 to 8; Step 13: Execute the preset fixture debugging method when the target vehicle parameters do not exist.

[0009] By adopting the above technical solution, when the system does not have a preset target vehicle model, the fixture arrival time can be indirectly determined by acquiring and parsing the cylinder positioning sensor parameters. Based on this time information, the fixture database can be traversed to find potentially matching target vehicle model parameters. This process not only improves the system's adaptability and flexibility when dealing with unknown vehicle models, but also reduces production interruptions caused by vehicle model mismatch, thereby improving overall production efficiency.

[0010] Optionally, the method for performing the fixture adjustment method when the target vehicle parameters do not exist includes: Step 130: Obtain an image of the workpiece surface to obtain the workpiece contour features; Step 131: Determine the similar target vehicle model and similar target vehicle parameters based on the workpiece contour features; Step 132: Determine the clamping position of the fixture based on the similar vehicle models and the workpiece contour features; Step 133: Based on the PLC module, control the fixture to move to the fixture gripping position according to the preset standard fixture moving speed; Step 134: During the process of moving the fixture to the fixture gripping position, obtain and correct the current hardware parameters; Step 135: Determine the number of parameters that are consistent with the corrected current hardware parameters and the parameters of the similar target vehicle model; Step 136: When the number of consistent parameters exceeds a preset threshold for the number of consistent reliable parameters, determine the corrected fixture moving speed; Step 137: Based on the corrected clamping speed, control the clamp to move to the clamping position and obtain the target hardware parameters; Step 1370: When the target hardware parameters are consistent with the similar target vehicle parameters, determine the target vehicle model and output it.

[0011] By adopting the above technical solution, even without specific target vehicle model parameters, the system can acquire workpiece surface images and extract their contour features to identify target vehicle models and their parameters similar to the current workpiece. This innovative method not only expands the system's vehicle model recognition capabilities but also improves the flexibility and efficiency of the production line by adjusting the fixture position and movement speed based on parameters of similar vehicle models.

[0012] Optionally, it also includes a method for updating the fixture database when the target hardware parameters are inconsistent with the similar target vehicle parameters, the method comprising: Step 1371: Based on the target hardware parameters, find the number of target hardware parameters stored in the preset temporary stack; Step 1372: When the number of stored models is 0, determine the new model based on similar models; Step 1373: Record the newly added vehicle model and the target hardware parameters to the temporary storage stack; Step 1374: Accumulate the target hardware parameter storage quantity when the storage quantity is not 0; Step 1375: Update the fixture database and the temporary stack when the number of target hardware parameters exceeds the preset number of reliable target hardware parameters.

[0013] By adopting the above technical solution, when the target hardware parameters are inconsistent with the parameters of similar target vehicle models, the system can intelligently determine whether a new vehicle model needs to be added by checking the storage quantity in the preset temporary stack. This provides more reliable data support for subsequent fixture adaptation.

[0014] Optionally, the method further includes adjusting the placement angle of the clamp when the clamp cannot be moved to the clamping position, the method comprising: Step 138: During the process of the fixture moving to the fixture gripping position, the moving speed of the fixture is acquired in real time; Step 1380: Acquire workpiece image information when the clamping speed is 0; Step 1381: Analyze the workpiece image information to determine the current fixture angle deviation; Step 1382: When the fixture angle deviation exists, adjust the placement angle of the fixture according to the fixture angle deviation, and execute steps 133 to 1370.

[0015] By adopting the above technical solution, when the fixture fails to reach the preset clamping position smoothly during movement, the system can monitor the fixture's moving speed in real time and quickly acquire workpiece image information when the speed drops to zero, analyzing whether the fixture prematurely contacts the workpiece due to angular deviation. This process not only improves the positioning accuracy of the fixture but also ensures that the fixture can accurately and stably clamp the workpiece.

[0016] Optionally, it also includes a method for outputting a preset impurity-unremovable signal when the fixture angle deviation is absent, the method comprising: Step 1383: Determine the impurity contact point and the current clamp movement distance when there is no clamp angle deviation; Step 1384: Generate an impurity removal scheme based on the impurity contact point, and import the impurity removal scheme into the PLC module to execute the impurity removal operation; Step 1385: During the impurity removal operation, obtain the corrected current fixture movement distance; Step 1386: Stop performing the impurity removal operation after the corrected fixture movement distance exceeds the current fixture movement distance; Step 1387: After the impurity removal operation is completed and the moving distance of the corrected fixture is equal to the moving distance of the current fixture, output the signal that the impurity cannot be removed.

[0017] By adopting the above technical solution, when there is no fixture angle deviation in the system, the system further determines the impurity contact point and the current fixture movement distance, and generates an impurity removal plan based on this information. This plan is then imported into the PLC module to execute the impurity removal operation. During execution, the system acquires the corrected current fixture movement distance in real time and stops the impurity removal operation when the corrected fixture movement distance exceeds the initial current fixture movement distance. This design ensures the effectiveness and safety of the impurity removal process, avoiding potential damage to the workpiece from over-removal. When the impurity removal operation is completed, and the corrected fixture movement distance equals the initial current fixture movement distance, the system outputs an impurity removal failure signal, prompting the operator to perform manual intervention or check for other possible causes of failure. This process not only improves the automation level of the production line but also ensures workpiece quality and production efficiency.

[0018] Optionally, it also includes a method for determining the expected target hardware parameters and adjusting the moving speed of the standard fixture, the method comprising: Step 1330: Obtain the spot diameter during the movement of the fixture. The spot diameter is the diameter corresponding to the spot projected onto the workpiece surface by the laser projector preset on the fixture. Step 1331: Determine the interval distance based on the light spot diameter; Step 1332: Adjust the moving speed of the standard fixture in real time according to the interval distance; Step 1333: Determine the expected target hardware parameters based on the interval distance and the current hardware parameters; Step 1334: Determine the number of corrected parameters that are consistent with the expected target hardware parameters and the similar target vehicle parameters, and use this number of consistent parameters to execute steps 136 to 1370.

[0019] By adopting the above technical solution, during the fixture movement, the system can dynamically determine the distance between the fixture and the workpiece by acquiring the diameter of the laser spot formed on the workpiece surface by the preset laser projector on the fixture. This real-time acquisition of the distance allows the system to adjust the moving speed of the standard fixture in real time based on its changes, ensuring that the fixture maintains an appropriate speed when approaching or moving away from the workpiece, avoiding problems such as inaccurate clamping or workpiece damage caused by excessively fast or slow speeds. Simultaneously, the system also predicts and determines the expected target hardware parameters based on the distance and current hardware parameters. This prediction process allows the system to plan the fixture's movement and clamping more precisely in advance.

[0020] Optionally, a specific method for determining the interval distance based on the spot diameter includes: Step 13310: Obtain the light spot contour features and analyze the light spot contour features to determine the light spot contour shape; Step 13311: Obtain the long axis of the light spot when the shape of the light spot outline is not a preset circular light spot outline; Step 13312: Perform steps 1331 to 1334 based on the long axis of the light spot as the light spot radius.

[0021] By employing the above technical solution, the system first acquires the contour features of the light spot and performs detailed analysis on these features to determine the specific contour shape of the light spot. When the light spot contour is detected to be not a preset circle, the system further acquires the major axis length of the light spot and considers this major axis length as the effective radius of the light spot. Subsequently, the system uses this light spot radius information, combined with preset algorithms and models, to accurately calculate the distance between the fixture and the workpiece.

[0022] Optionally, the method further includes a method for determining the similar target vehicle model and the similar target vehicle parameters based on the light spot contour features, the method comprising: Step 13313: Determine the workpiece clamping position contour features based on the light spot contour features; Step 13314: Obtain the sensor number corresponding to the light spot contour feature and define it as the current sensor number; Step 13315: Determine the similar target vehicle model and the similar target vehicle parameters based on the current sensor number and the workpiece clamping position contour features, and output them.

[0023] By adopting the above technical solution, the system can fully utilize the information contained in the light spot contour features. First, the contour features of the workpiece clamping position are accurately determined based on the light spot contour features, which provides a crucial basis for subsequent vehicle model matching. Next, the sensor number corresponding to the light spot contour features is obtained and defined as the current sensor number; this step ensures accurate association of sensor data. Finally, the system combines the current sensor number and the workpiece clamping position contour features, and intelligently determines the similar target vehicle model and similar target vehicle parameters through preset algorithms and models, and outputs the results. This process not only improves the accuracy of vehicle model recognition but also provides reliable data support for subsequent fixture adjustments and workpiece clamping.

[0024] Secondly, this invention provides a multi-vehicle model clamping rapid switching and integration system, which adopts the following technical solution: A multi-vehicle model clamping rapid switching and integration system includes: The acquisition module is used to acquire current hardware parameters; The memory is used to store the program for a method of rapid switching and integration of multi-vehicle clamps as described above; The processor loads and executes programs from memory.

[0025] By adopting the above technical solution, the system acquires current hardware parameters in real time through the acquisition module, ensuring the accuracy and timeliness of the data. The memory pre-stores a program for rapid switching and integration of multi-vehicle model fixtures. This program includes all the aforementioned steps and logic, providing the processor with the execution basis. The processor is responsible for loading and executing the program in memory, outputting compatible or incompatible signals based on the comparison between the current hardware parameters and the target vehicle model parameters, and executing corresponding debugging or fixture integration methods according to the signal type. This system design not only achieves rapid switching and integration of multi-vehicle model fixtures but also improves the stability and reliability of the production line through standardized error correction paths and real-time data monitoring, meeting the needs of rapid vehicle iteration in the new energy era.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: 1. The invention uses a fixture database to directly import target vehicle parameters and automatically compare them with current hardware parameters, eliminating the need for manual parameter adjustment. During the adjustment process, when the parameter matching degree is high, the fixture movement speed can be automatically accelerated, and the adjusted data will be updated to the database. Subsequent switching of the same vehicle model can be directly called, significantly shortening the fixture switching cycle. 2. For known vehicle models, parameters are accurately matched using the database. For new vehicle models not recorded in the database, an initial clamping scheme can be determined through workpiece contour recognition and matching with similar vehicle models. Then, the movement and clamping parameters are optimized by combining spot detection. The design of the interval distance assisted by the long axis of the spot can also adapt to irregular workpiece surfaces, reduce clamping errors caused by surface morphology, and further ensure the reliability of fixture operation and workpiece clamping. 3. During debugging, the moving speed is adjusted by spot detection to avoid collision between the fixture and the workpiece. When encountering impurities or angular deviations, the system can automatically remove impurities and correct the fixture angle. If the system cannot solve the problem, it will trigger a manual warning to prevent the fault from escalating. Attached Figure Description

[0027] Figure 1 This is a flowchart of a method for rapid switching and integration of multi-vehicle model fixtures in an embodiment of this application; Figure 2 This is a schematic diagram of the system interface of the HMI module in the embodiments of this application; Figure 3 This is a schematic diagram of the fixture numbering system interface in the embodiments of this application; Figure 4 This is a schematic diagram of the interface of the clamp sensor application system in the embodiments of this application; Figure 5 This is a schematic diagram of the clamp IN signal configuration system interface in an embodiment of this application. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0029] This invention discloses a method for rapid switching and integration of multi-vehicle model clamps. (Refer to...) Figure 1 A method for rapid switching and integration of multi-vehicle model fixtures includes: Step 1: In response to a normal connection signal, import the target vehicle model and obtain the corresponding target vehicle parameters from the preset fixture database.

[0030] A normal connection signal refers to a system-ready comprehensive signal output by the PLC module, indicating that the communication link between the core control unit and the hardware execution components in a multi-vehicle fixture switching system is intact. (Refer to...) Figure 2This includes the signal connection of the cylinder assembly and the signal connection of the workpiece detection sensor. The target vehicle model refers to a structured code used to uniquely identify a specific vehicle model, and this code is bound one-to-one with the preset parameters in the fixture database within the document.

[0031] The fixture database refers to a database pre-stored in the system's storage unit, encompassing fixture parameters for various vehicle models. These parameters include, but are not limited to, key data such as fixture dimensions, clamping force, and travel range, providing a data basis for accurate fixture adaptation. After obtaining the target vehicle model parameters, the system prepares the data for subsequent fixture switching and integration operations. Target vehicle model parameters refer to the specific parameters corresponding to the target vehicle model in the fixture database. These parameters precisely define the technical specifications of the fixtures required for that vehicle model, ensuring that the fixtures can perfectly adapt to the target vehicle model.

[0032] Reference Figure 3 It displays multiple structured codes (such as A12-0P20L-M1-1, A12-0P560R-M8LR-L-31, A12-0P40L-M5-17, etc.), which are the target vehicle models. Each code uniquely corresponds to a set of preset fixture parameters.

[0033] Step 2: Call the target vehicle model parameters to the preset PLC module and obtain the current hardware parameters.

[0034] The PLC module refers to the Programmable Logic Controller module, which is the core control unit of the entire fixture switching and integration system. It is responsible for receiving, processing, and outputting various control signals to achieve precise control of the hardware actuators. Current hardware parameters refer to the real-time status data of the hardware actuators and sensor detection data directly related to fixture operation, collected by the system. (Refer to...) Figure 4 Sensor 1 displays "√", indicating that sensor 1 has detected the workpiece in the current hardware parameters.

[0035] Step 3: Output a preset compatibility signal when the current hardware parameters match the target vehicle parameters.

[0036] A compatibility signal is a system feedback signal used to indicate that the current hardware parameters are fully matched with the target vehicle model parameters, and the fixture can normally perform operations for the corresponding vehicle model. If the current hardware parameters are consistent with the target vehicle model parameters, it means that the current hardware parameters are fully matched with the target vehicle model parameters, so a compatibility signal is output.

[0037] Step 4: Output a preset incompatibility signal when the current hardware parameters are inconsistent with the target vehicle parameters.

[0038] An incompatibility signal is a system feedback signal used to indicate that the current hardware parameters do not match the target vehicle model parameters, and the fixture cannot perform the corresponding vehicle model operation normally, requiring debugging or correction. When the system detects a difference between the current hardware parameters and the target vehicle model parameters, it indicates a mismatch between the current hardware parameters and the target vehicle model parameters, thus triggering the output of the incompatibility signal to prompt the operator or automatic control system to make corresponding adjustments or handle the situation.

[0039] Step 5: Based on the preset HMI module, analyze the incompatible signals and execute the preset debugging method according to the incompatible signals.

[0040] Reference Figure 2 The HMI module, or Human-Machine Interface module, is a crucial interface for operators to interact with the fixture switching system. Through the HMI module, operators can visually view the specific details of incompatible signals, including which hardware parameters do not match the target vehicle model parameters, and the degree of mismatch. The debugging method refers to adjusting hardware parameters automatically or manually to match the target vehicle model parameters. Specifically, the HMI module analyzes the specific hardware components causing the parameter mismatch and the resulting parameter deviations, then adjusts these deviations. The HMI module provides detailed hardware information about the parameter mismatch, such as insufficient clamping force in a cylinder or a sensor's detection position deviation. Simultaneously, the HMI module displays the numerical values ​​of the parameter deviations caused by the mismatch, such as how many Newtons the clamping force is reduced or how many millimeters the detection position is off. Operators or the automatic control system then adjust the current hardware parameters based on this information.

[0041] Step 6: If a compatibility signal is detected during the debugging process, stop the debugging method and record the current hardware parameters and target vehicle model to update the fixture database.

[0042] When a compatibility signal appears during the adjustment process, it indicates that the current hardware parameters have achieved compatibility between the clamped workpiece and the fixture through adjustments to the target vehicle model parameters. The system records the adjusted hardware parameters and the corresponding target vehicle model, updating this information in the fixture database. This way, when encountering a vehicle model not recorded in the fixture database later, the target vehicle model parameters in the database can be directly referenced based on vehicle model similarity. It should be noted that a compatibility signal also appears during debugging when the current hardware parameters do not meet the target vehicle model parameters. This indicates that the target vehicle model has been iterated and needs to be updated by the current hardware parameters, thus requiring an update to the fixture database.

[0043] Step 7: In response to the compatibility signal, execute the preset fixture integration method based on the PLC module.

[0044] The fixture integration method refers to the method by which a fixture clamps a workpiece. When a compatibility signal is present, it indicates that the current hardware parameters are completely matched with the target vehicle model parameters. At this time, the PLC module will execute the clamping of the fixture according to the parameters corresponding to the fixture integration method.

[0045] Step 8: Output a preset manual warning signal when no compatible signal is found after the debugging method has been executed.

[0046] A manual warning signal is a signal used to indicate that there are problems that the system cannot solve during the integration of the fixture with the target vehicle model. If no compatibility signal is found after executing the debugging method, it means that the system, even after debugging, still cannot match the current hardware parameters with the target vehicle model parameters. This may indicate a hardware failure, incorrect parameter settings, or other unknown problems. In this case, a manual warning signal is output to remind the operator to intervene.

[0047] The methods for outputting a manual warning signal when no compatible signal is found after the debugging method has been executed include: Step 9: For models that do not exist, obtain the preset cylinder position sensor parameters based on the PLC module. The cylinder position sensor parameters include the release position sensor parameters and the clamping position sensor parameters.

[0048] Reference Figure 5 The cylinder position sensor parameters refer to the sensor parameters corresponding to the position where the cylinder drives the clamp to abut against the workpiece. These parameters are collected in real time by sensors installed on the cylinder and transmitted to the PLC module. The release position sensor parameters refer to the parameter information fed back by the sensor when the cylinder performs the release action, indicating that the release limit position has been reached. This parameter is used to determine whether the cylinder has fully released. The clamping position sensor parameters refer to the parameter information fed back by the sensor when the cylinder performs the clamping action, indicating that the clamping limit position has been reached. This parameter is used to confirm whether the cylinder has firmly clamped the workpiece.

[0049] Step 10: Analyze the clamping position sensor parameters to determine the clamping position time.

[0050] The fixture arrival time refers to the time required for the fixture to contact the workpiece and clamp the workpiece. This time is recorded by the system's internal clock module from the moment the cylinder begins its operation to the moment the fixture clamps the workpiece, and then the fixture arrival time is calculated.

[0051] Step 11: Traverse the fixture database based on the fixture arrival time to determine the target vehicle model parameters.

[0052] Because there is a mapping relationship between the target vehicle model in the fixture database and the fixture arrival time, the target vehicle model can be re-determined through the fixture arrival time, and the target vehicle parameters can be obtained through the re-determined target vehicle model.

[0053] Step 12: If the target vehicle model parameters exist, execute steps 2 to 8.

[0054] If the target vehicle model parameter exists, it means that the vehicle model corresponding to the currently unidentified workpiece is already recorded in the fixture database, so proceed with steps 2 to 8.

[0055] Step 13: Execute the preset fixture debugging method when the target vehicle parameters are not available.

[0056] When the target vehicle model parameter is not found, it means that the vehicle model corresponding to the currently unidentified workpiece cannot be calculated from the fixture arrival time. Therefore, the fixture debugging method is executed. The fixture debugging method refers to a method that involves manually adjusting various parameters of the fixture and performing real-time verification in conjunction with sensor feedback until the current hardware parameters are compatible with the assumed target vehicle model parameters.

[0057] The methods for performing fixture adjustment when the target vehicle model parameters are not available include: Step 130: Obtain the workpiece surface image to obtain the workpiece contour features.

[0058] A workpiece surface image refers to an image of the workpiece's appearance, acquired through a high-definition camera mounted above the workpiece.

[0059] Workpiece contour features refer to the contour of the workpiece surface, which contains key information such as the workpiece's shape, size, and surface texture. Workpiece contour features are obtained by analyzing the workpiece surface image using an image recognition algorithm. Here, the image recognition algorithm is the Canny edge detection algorithm, a common existing technology, which will not be elaborated upon here.

[0060] Step 131: Determine the similar target vehicle model and similar target vehicle parameters based on the workpiece contour features.

[0061] The similar target vehicle model refers to the vehicle model that most closely resembles the workpiece's contour features. This determination process relies on the system's built-in similarity matching algorithm. This algorithm compares the workpiece's contour features with the contour features of various vehicle models stored in the fixture database, identifying the model with the highest similarity as the similar target vehicle model. Here, the similarity matching algorithm is the cosine similarity algorithm, a common existing technology, which will not be elaborated upon here. The similar target vehicle model parameters refer to the corresponding target vehicle model parameters in the fixture database.

[0062] Step 132: Determine the clamping position of the fixture based on similar vehicle models and workpiece contour features.

[0063] The clamping position refers to the optimal point of action of the clamp when clamping the workpiece. This position is determined first by retrieving standard clamping position parameters corresponding to the parameters of a similar target vehicle model, serving as the initial clamping position reference. Then, the initial clamping position is corrected based on the workpiece contour features. The standard clamping position parameters are reliable, practically verified, preset parameters of the clamping position used when clamping workpieces with similar target vehicle models. These parameters are stored in the clamping database, providing an accurate reference for the initial clamping position.

[0064] Step 133: Based on the PLC module, control the fixture to move to the fixture gripping position according to the preset standard fixture moving speed.

[0065] The standard fixture traverse speed refers to the preset speed value followed by the fixture during the traverse process. It is designed to ensure that the fixture can move smoothly to the clamping position and avoid clamping errors or damage to the workpiece due to excessive speed.

[0066] Step 134: Obtain and correct the current hardware parameters during the process of moving the fixture to the fixture gripping position.

[0067] Correcting the current hardware parameters means that during the process of the fixture moving to the fixture gripping position, the system will continuously collect the status data of the hardware execution components in real time through various sensors.

[0068] Step 135: Determine the number of parameters that are consistent with the current hardware parameters and the parameters of similar target vehicle models.

[0069] The parameter consistency count refers to the number of identical parameters that are corrected between the current hardware parameters and those of similar target vehicle models. The parameter consistency count helps assess the degree of matching between the current hardware parameters and those of similar target vehicle models.

[0070] Step 136: When the number of consistent parameters exceeds the preset threshold for the number of consistent reliable parameters, determine the corrected fixture movement speed.

[0071] The reliable parameter consistency threshold is a pre-set threshold used to determine whether the current hardware parameters match those of a similar target vehicle, verified through multiple experiments. The corrected fixture movement speed is an increased movement speed based on the standard fixture movement speed. When the number of consistent parameters exceeds the reliable parameter consistency threshold, it indicates a high degree of matching between the current hardware state and the similar target vehicle model. At this point, it can be determined that the fixture will not collide with the workpiece within a known range, thus allowing for the determination of the corrected fixture movement speed and increasing the fixture's debugging efficiency.

[0072] Step 137: Based on the corrected fixture moving speed, control the fixture to move to the fixture gripping position and obtain the target hardware parameters.

[0073] Target hardware parameters refer to the latest hardware data directly related to the fixture's operation and workpiece status collected by the system after the fixture has moved to the clamping position at a corrected moving speed. When the fixture moves to the clamping position, it indicates that the fixture has reached the corresponding clamping point, at which point the system will comprehensively collect the target hardware parameters.

[0074] Step 1370: When the target hardware parameters are consistent with the parameters of similar target vehicle models, determine the target vehicle model and output it.

[0075] When the target hardware parameters are consistent with the parameters of similar target models, it means that the hardware status of the current fixture is completely consistent with the parameters of similar target models recorded in the database. This indicates that the identified workpiece does indeed belong to the similar target model, so the target model number is output.

[0076] This includes a method for updating the fixture database when the target hardware parameters are inconsistent with the parameters of similar target vehicle models. This method includes: Step 1371: Find the number of target hardware parameters stored in the preset temporary stack based on the target hardware parameters.

[0077] A temporary storage stack is a temporary data storage area set up internally by the system; it is a stack in data structures. The number of target hardware parameters stored refers to the number of target hardware parameters already stored in the temporary storage stack.

[0078] Step 1372: When the number of stored models is 0, determine the new model based on similar models.

[0079] Adding a new vehicle model refers to a situation where the number of target hardware parameters stored in the temporary stack is 0, meaning the system has not yet stored target hardware parameters similar to the current situation. In this case, the system will use previously identified similar vehicle models as candidates for adding a new vehicle model. The prefix of the number corresponding to the new vehicle model is the same as that of the similar vehicle models. Therefore, the system uses the similar vehicle models and a preset incrementing function to obtain the new vehicle model. The incrementing function is a common technique and will not be elaborated on here.

[0080] Step 1373: Record the new vehicle model and target hardware parameters to the temporary stack.

[0081] When a new vehicle model and target hardware parameters are found, it means that the system has identified a new vehicle model, and this information is not yet fully recorded in the fixture database. Therefore, the new vehicle model and corresponding target hardware parameters need to be recorded in the temporary stack.

[0082] Step 1374: Accumulate the target hardware parameter storage quantity when the storage quantity is not 0.

[0083] When the number of stored parameters is not 0, it means that a certain number of target hardware parameters have been stored in the temporary stack. This means that the system has encountered a scenario similar to or the same as the current situation before. Therefore, it is not necessary to determine the new vehicle model. Instead, the number of stored target hardware parameters is accumulated.

[0084] Step 1375: Update the fixture database and temporary stack when the number of target hardware parameters exceeds the preset number of reliable target hardware parameters.

[0085] The number of reliable target hardware parameters refers to a pre-defined threshold used to determine whether the number of target hardware parameters has reached the update standard. When the number of target hardware parameters exceeds the number of reliable target hardware parameters, it means that enough target hardware parameters have accumulated in the temporary storage stack. These parameters are sufficient to reflect the appearance of a workpiece corresponding to a previously unrecorded vehicle model on the current production line. Therefore, the fixture database is updated with the target hardware parameters and the newly added vehicle model, and the target hardware parameters in the temporary storage stack are deleted.

[0086] This also includes a method for adjusting the placement angle of the clamp when the clamp cannot be moved to the clamping position, the method comprising: Step 138: Acquire the clamping speed in real time during the clamping process.

[0087] The fixture movement speed refers to the real-time speed value of the fixture as it moves to the gripping position. This speed value is collected in real time by sensors installed on the fixture and transmitted to the system control module. Specifically, the fixture movement speed is obtained by dividing the distance the fixture moves by the time it takes to move that distance.

[0088] Step 1380: Obtain workpiece image information when the fixture moving speed is 0.

[0089] Workpiece image information refers to the image data presented by the workpiece when its movement is obstructed by the fixture. This data is captured in real time by a high-definition camera. The workpiece image information includes key information such as the workpiece's current posture, position, and any obstacles that may be hindering the fixture's movement. By analyzing the workpiece image information, the system can further determine the specific reason why the fixture cannot move to the gripping position.

[0090] Step 1381: Analyze the workpiece image information to determine the current fixture angle deviation.

[0091] The fixture angle deviation refers to the difference between the actual placement angle of the current fixture and the preset ideal clamping angle. Specifically, Canny edge detection is used to extract key feature lines of the workpiece from the workpiece image information, calculate the actual angle reflecting the current posture of the workpiece, and obtain the ideal fixture angle by subtracting the actual angle from the ideal clamping angle corresponding to a similar target vehicle model. The ideal fixture angle refers to the optimal clamping angle of the fixture corresponding to a similar target vehicle model, obtained through extensive experimental analysis.

[0092] Step 1382: When there is a fixture angle deviation, adjust the placement angle of the fixture according to the fixture angle deviation, and execute steps 133 to 1370.

[0093] The fixture's placement angle refers to the rotation angle of the fixture relative to the workpiece in space. The fixture must be parallel to the workpiece, and both must be on the same horizontal plane. Only angular deviations on the horizontal plane will occur; there will be no tilting angular deviations. When a fixture angular deviation exists, it indicates a difference between the actual placement angle and the ideal clamping angle. Therefore, the angle needs to be adjusted according to the fixture's placement angle, and steps 133 to 1370 should be repeated to ensure the fixture can be accurately moved to the clamping position.

[0094] This also includes a method for outputting a preset signal indicating that impurities cannot be removed when there is no fixture angle deviation, the method comprising: Step 1383: Determine the impurity contact point and the current clamp movement distance when there is no clamp angle deviation.

[0095] The impurity contact point refers to the specific location where the clamp first comes into contact with a potential obstacle during its movement. This location is determined by the system's real-time monitoring of the clamp's movement distance and data from sensor feedback. The current clamp movement distance refers to the total distance traveled by the clamp from the start of its movement until it is found that it cannot move further. This data is measured by a linear displacement sensor within the system. When there is no clamp angle deviation, it means that the clamp's inability to move to the clamping position is not caused by angle deviation. Therefore, the system needs to further investigate other potential obstacles. Determining the impurity contact point and the current clamp movement distance is to locate the source of the obstacle and determine the reason why the clamp cannot move to the clamping position.

[0096] Step 1384: Generate an impurity removal plan based on the impurity contact point, and import the impurity removal plan into the PLC module to execute the impurity removal operation.

[0097] An impurity removal plan refers to a specific removal strategy tailored to the impurity contact point, ensuring that impurities are removed without damaging the workpiece. Specifically, the plan uses vibration at a specific frequency to loosen impurities adhering to the workpiece and then uses a gentle airflow to remove them. Upon receiving the impurity removal plan, the PLC module precisely controls the preset vibrator and air pump to execute the impurity removal operation according to preset impurity removal parameters. These parameters include the vibration frequency and intensity, as well as the airflow pressure and flow rate. The impurity removal operation refers to the process where the PLC module controls the vibrator and air pump to loosen the impurities at the contact point through vibration and purge them with airflow, according to the impurity removal plan.

[0098] Step 1385: Obtain the corrected current fixture movement distance during the impurity removal operation.

[0099] Corrected fixture movement distance refers to the actual distance the fixture has moved from the starting point to the current moment during the impurity removal operation. The starting point refers to the position of the fixture before the PLC module starts controlling the fixture.

[0100] Step 1386: Stop the impurity removal operation after the corrected fixture movement distance exceeds the current fixture movement distance.

[0101] When the corrected fixture travel distance exceeds the current fixture travel distance, it indicates that the fixture has successfully overcome the original obstacle point during the impurity removal operation. Continuing the impurity removal operation is unnecessary and may cause unnecessary damage to the workpiece or fixture. Therefore, the impurity removal operation should be stopped to avoid over-processing.

[0102] Step 1387: After the impurity removal operation is completed and the corrected clamp movement distance is equal to the current clamp movement distance, output an impurity cannot be removed signal.

[0103] The "Impurity Unremovable" signal indicates that there is currently an impurity that cannot be removed. After performing the impurity removal operation, if the corrected clamp movement distance is exactly equal to the current clamp movement distance, it indicates that although the removal operation was attempted, the clamp still failed to move to the predetermined clamping position. At this time, the system determines that there is an obstacle that cannot be removed by conventional means, and therefore outputs the "Impurity Unremovable" signal.

[0104] This also includes a method for determining the expected target hardware parameters and adjusting the standard fixture's moving speed, the method comprising: Step 1330: Obtain the spot diameter during the movement of the fixture. The spot diameter is the diameter corresponding to the spot projected onto the workpiece surface by the laser projector preset on the fixture.

[0105] The spot diameter refers to the size of the spot formed on the workpiece surface by the laser projector preset on the fixture. This data is measured in real time by a high-precision optical sensor mounted on the fixture and fed back to the system. The size of the spot diameter directly reflects the distance between the laser projector and the workpiece surface.

[0106] Step 1331: Determine the interval distance based on the spot diameter.

[0107] The interval distance refers to the vertical distance between the current laser projector and the workpiece surface. The specific calculation method is to obtain the preset reference distance and the preset reference spot diameter. The reference distance is the vertical distance between the laser projector and the standard planar workpiece corresponding to the reference spot diameter. Here, the interval distance is set as H, the reference distance is set as h, the reference spot diameter is set as d, and the spot diameter is set as D. The specific calculation formula for the interval distance is H=h×d / D.

[0108] Step 1332: Adjust the moving speed of the standard fixture in real time according to the interval distance.

[0109] Because the distance between the fixture and the workpiece can be determined, when the distance is long, the fixture can be moved quickly. Since the position of the workpiece is known, the rapid movement of the fixture will not collide with the workpiece and cause damage to it.

[0110] Step 1333: Determine the expected target hardware parameters based on the interval distance and current hardware parameters.

[0111] The projected target hardware parameters refer to the ideal state parameters that each hardware component should reach when the fixture reaches the clamping position, calculated based on the current distance between the fixture and the workpiece surface, combined with the current hardware parameters of the fixture, and using a preset projected target hardware parameter calculation model. The projected target hardware parameter calculation model is a mathematical model built based on a large amount of experimental data and theoretical analysis. This model comprehensively considers the distance between the fixture and the workpiece surface, the current hardware parameters of the fixture, and similar scenarios in historical debugging data to accurately calculate the projected target hardware parameters.

[0112] Step 1334: Determine the number of corrected parameters that are consistent with the expected target hardware parameters and similar target vehicle parameters, and use this number of parameters to execute steps 136 to 1370.

[0113] The number of corrected parameter consistency parameters refers to the number of parameters that are identical between the expected target hardware parameters and the parameters of similar target vehicle models. Similar to the concept of parameter consistency parameters mentioned earlier, the corrected parameter consistency parameter number here is used to evaluate the degree of matching between the expected target hardware parameters and the parameters of similar target vehicle models.

[0114] Specific methods for determining the interval distance based on the spot diameter include: Step 13310: Obtain the light spot contour features and analyze the light spot contour features to determine the shape of the light spot contour.

[0115] Light spot contour features refer to the geometric characteristics exhibited by the edge of a light spot. These features are extracted and analyzed using edge recognition algorithms after the light spot image is captured by a high-precision optical sensor. The shape of the light spot contour describes the overall morphology of the light spot edge. Common light spot contour shapes include circles, ellipses, or other irregular shapes.

[0116] Step 13311: Obtain the long axis of the light spot when the shape of the light spot outline is not a preset circular light spot outline.

[0117] A circular light spot outline refers to a pre-defined ideal light spot shape used as a judgment standard. The major axis of the light spot refers to the longest diameter line segment of an elliptical or other irregularly shaped light spot, determined by analyzing the light spot image using image processing algorithms. When the light spot outline shape is not the pre-defined circular light spot outline, it indicates that the light spot is deformed. In this case, it is necessary to obtain the major axis of the light spot because the upper limit of the projected size is determined by the original shape. The direction of parallel light rays is fixed; it only projects the original shape onto the receiving surface proportionally and does not add any extra length. The light spot formed by parallel light will never be elongated; only compression will cause shape changes. Based on the above principle, the radius of the circular light plate, that is, the radius of the light spot on a regular plane, can be directly restored from the major axis of the light spot.

[0118] Step 13312: Execute steps 1331 to 1334 based on the long axis of the light spot as the light spot radius.

[0119] This also includes a method for determining similar target vehicle models and similar target vehicle parameters based on light spot contour features, the method comprising: Step 13313: Determine the workpiece clamping position contour features based on the light spot contour features.

[0120] The workpiece clamping position contour feature refers to the analysis of the contour characteristics of the light spot projected onto the workpiece surface, combined with a pre-set vehicle model feature database for matching. This contour feature includes the workpiece edge geometry, curvature variations, and local detail features. This information is acquired by a high-precision optical sensor, and key feature points are extracted using an edge recognition algorithm. These key feature points are then compared with the vehicle model feature database to determine the workpiece clamping position contour feature. The vehicle model feature database is a pre-established database that stores the clamping position contour features and related parameters of workpieces from various vehicle models. This database was built through extensive experiments and actual production data, covering the clamping position contour feature information of workpieces from different vehicle models under various conditions.

[0121] Step 13314: Obtain the sensor number corresponding to the light spot contour feature and define it as the current sensor number.

[0122] The current sensor number refers to the unique identifier of the high-precision optical sensor associated with the current light spot contour feature acquisition. This number is set during system initialization and is used to track and identify the data source of a specific sensor during data processing and vehicle model matching. Through the current sensor number, the system can ensure a one-to-one correspondence between the light spot contour feature and the sensor that acquired that feature, avoiding data confusion or incorrect association.

[0123] Step 13315: Determine the similar target vehicle model and similar target vehicle parameters based on the current sensor number and workpiece clamping position contour features, and output them.

[0124] When it is impossible to determine the similar target vehicle model and similar target vehicle parameters through the workpiece contour features, or when the workpiece contour features are not identified, but there are current sensor numbers and workpiece clamping position contour features, the target vehicle model and target vehicle parameters corresponding to the current sensor number and workpiece clamping position contour features can be obtained from the sensor position and workpiece contour mapping table in the fixture database, and output as similar vehicle models and similar target vehicle parameters.

[0125] Based on the same inventive concept, embodiments of the present invention provide a system for rapid switching and integration of clamps for multiple vehicle models.

[0126] One of the systems for rapid switching and integration of multi-vehicle clamps includes: The acquisition module is used to acquire current hardware parameters; The memory is used to store the program of a control method for a method of rapid switching and integration of multi-vehicle clamps; The processor loads and executes programs from memory.

[0127] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0128] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for rapid switching and integration of multi-vehicle model fixtures, characterized in that: include Step 1: In response to a normal connection signal, import the target vehicle model and obtain the corresponding target vehicle parameters from the preset fixture database; Step 2: Call the target vehicle model parameters to the preset PLC module and obtain the current hardware parameters; Step 3: Output a preset compatibility signal when the current hardware parameters match the target vehicle model parameters; Step 4: Output a preset incompatibility signal when the current hardware parameters are inconsistent with the target vehicle parameters; Step 5: Based on the preset HMI module, parse the incompatible signal and execute the preset debugging method according to the incompatible signal; The debugging method refers to adjusting the current hardware parameters automatically or manually to match the target vehicle parameters. Step 6: If the compatibility signal is present during the execution of the debugging method, stop the debugging method and record the current hardware parameters and the target vehicle model to update the fixture database; Step 7: In response to the compatibility signal, execute the preset fixture insertion method based on the PLC module; Step 8: When no compatible signal is found after the debugging method has been executed, output a preset manual warning signal.

2. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 1 is characterized in that, It also includes a method for determining the target vehicle model when the target vehicle model does not exist, the method comprising: Step 9: For models that do not exist, obtain preset cylinder position sensor parameters based on the PLC module. The cylinder position sensor parameters include release position sensor parameters and clamping position sensor parameters. Step 10: Analyze the clamping position sensor parameters to determine the clamping position time; Step 11: Traverse the fixture database based on the fixture arrival time to determine the target vehicle model parameters; Step 12: If the target vehicle parameters exist, execute steps 2 to 8; Step 13: Execute the preset fixture debugging method when the target vehicle parameters do not exist.

3. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 2 is characterized in that, The method for performing the fixture adjustment method when the target vehicle parameters do not exist includes: Step 130: Obtain an image of the workpiece surface to obtain the workpiece contour features; Step 131: Determine the similar target vehicle model and similar target vehicle parameters based on the workpiece contour features; Step 132: Determine the clamping position of the fixture based on the similar target vehicle model and the workpiece contour features; Step 133: Based on the PLC module, control the fixture to move to the fixture gripping position according to the preset standard fixture moving speed; Step 134: During the process of moving the fixture to the fixture gripping position, obtain and correct the current hardware parameters; Step 135: Determine the number of parameters that are consistent with the corrected current hardware parameters and the parameters of the similar target vehicle model; Step 136: When the number of consistent parameters exceeds a preset threshold for the number of consistent reliable parameters, determine the corrected fixture moving speed; Step 137: Based on the corrected clamping speed, control the clamp to move to the clamping position and obtain the target hardware parameters; Step 1370: When the target hardware parameters are consistent with the similar target vehicle parameters, determine the target vehicle model and output it.

4. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 3 is characterized in that, It also includes a method for updating the fixture database when the target hardware parameters are inconsistent with the similar target vehicle parameters, the method comprising: Step 1371: Based on the target hardware parameters, find the number of target hardware parameters stored in the preset temporary stack; Step 1372: When the number of stored models is 0, determine the new model based on the similar target model models; Step 1373: Record the newly added vehicle model and the target hardware parameters to the temporary storage stack; Step 1374: Accumulate the target hardware parameter storage quantity when the storage quantity is not 0; Step 1375: Update the fixture database and the temporary stack when the number of target hardware parameters exceeds the preset number of reliable target hardware parameters.

5. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 3 is characterized in that, It also includes a method for adjusting the placement angle of the clamp when the clamp cannot be moved to the clamping position, the method comprising: Step 138: During the process of the fixture moving to the fixture gripping position, the moving speed of the fixture is acquired in real time; Step 1380: Acquire workpiece image information when the clamping speed is 0; Step 1381: Analyze the workpiece image information to determine the current fixture angle deviation; Step 1382: When the fixture angle deviation exists, adjust the placement angle of the fixture according to the fixture angle deviation, and execute steps 133 to 1370.

6. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 5 is characterized in that, It also includes a method for outputting a preset impurity-unremovable signal when the fixture angle deviation is absent, the method comprising: Step 1383: Determine the impurity contact point and the current clamp movement distance when there is no clamp angle deviation; Step 1384: Generate an impurity removal scheme based on the impurity contact point, and import the impurity removal scheme into the PLC module to execute the impurity removal operation; Step 1385: During the impurity removal operation, obtain the corrected current fixture movement distance; Step 1386: Stop performing the impurity removal operation after the corrected fixture movement distance exceeds the current fixture movement distance; Step 1387: After the impurity removal operation is completed and the moving distance of the corrected fixture is equal to the moving distance of the current fixture, output the signal that the impurity cannot be removed.

7. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 3 is characterized in that, It also includes a method for determining the expected target hardware parameters and adjusting the moving speed of the standard fixture, the method comprising: Step 1330: Obtain the spot diameter during the movement of the fixture. The spot diameter is the diameter corresponding to the spot projected onto the workpiece surface by the laser projector preset on the fixture. Step 1331: Determine the interval distance based on the light spot diameter; Step 1332: Adjust the moving speed of the standard fixture in real time according to the interval distance; Step 1333: Determine the expected target hardware parameters based on the interval distance and the current hardware parameters; Step 1334: Determine the number of corrected parameters that are consistent with the expected target hardware parameters and the similar target vehicle parameters, and use this number of consistent parameters to execute steps 136 to 1370.

8. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 7, characterized in that, Specific methods for determining the interval distance based on the light spot diameter include: Step 13310: Obtain the light spot contour features and analyze the light spot contour features to determine the light spot contour shape; Step 13311: Obtain the long axis of the light spot when the shape of the light spot outline is not a preset circular light spot outline; Step 13312: Perform steps 1331 to 1334 based on the long axis of the light spot as the light spot radius.

9. The method for rapid switching and integration of multi-vehicle model fixtures according to claim 8, characterized in that, It also includes a method for determining the similar target vehicle model and the similar target vehicle parameters based on the light spot contour features, the method comprising: Step 13313: Determine the workpiece clamping position contour features based on the light spot contour features; Step 13314: Obtain the sensor number corresponding to the light spot contour feature and define it as the current sensor number; Step 13315: Determine the similar target vehicle model and the similar target vehicle parameters based on the current sensor number and the workpiece clamping position contour features, and output them.

10. A system for rapid switching and integration of multi-vehicle model clamps, characterized in that, include: The acquisition module is used to acquire current hardware parameters; A memory for storing a program of a control method for a multi-vehicle clamping rapid switching and integration method as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

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