A precision control system and disassembly robot for high-intensity operations

Abstract

This invention provides a precision control system and disassembly robot for high-intensity operations, relating to the field of robotics. The precision control system includes a laser-based vertical tool setting module, a laser ranging module, and a parallel robotic arm linear motion module. The laser-based vertical tool setting module ensures that the cutting head is vertically aligned with the workpiece in three-dimensional space during cutting tasks. The laser ranging module dynamically monitors the cutting depth during cutting tasks. The parallel robotic arm linear motion module enables coordinated linear motion of multiple joints during cutting tasks based on the cutting depth and tool setting feedback data. This invention provides a precision control system and robot for high-intensity operations, meeting the precision control requirements of high-intensity on-site operations.

Description

Technical Field

[0001] This invention relates to the field of robotics, and in particular to a precision control system and a disassembly robot for high-intensity operations. Background Technology

[0002] Wind turbine blades that are no longer usable due to design and usage reasons are classified as retired blades. As retired blades constitute over 50% of the non-degradable composite material waste, they must be disposed of on-site efficiently, environmentally, and resourcefully; landfilling and incineration are strictly prohibited. Due to the diverse and complex environments in which wind turbines are installed and the need for on-site cutting of retired blades, existing dismantling robots cannot meet the precise control requirements of high-intensity on-site operations. Summary of the Invention

[0003] One of the objectives of this invention is to provide a precision control system and a disassembly robot for high-intensity operations, in order to solve the aforementioned technical problems.

[0004] The present invention provides a highly adaptable and high-precision disassembly control system and robot, comprising: a laser-type vertical tool setting module, a laser ranging module, and a parallel robotic arm linear travel module; Among them, the laser-type vertical tool setting module is used to ensure that the cutting head is vertically aligned with the workpiece in three-dimensional space when performing a cutting task; The laser ranging module dynamically monitors the cutting depth during the cutting task. The parallel robotic arm linear motion module is used to coordinate the control of each branch during the cutting task based on the cutting depth and tool setting feedback data, so that the cutting head moves in a straight line.

[0005] Preferably, the laser-type vertical tool setting module includes: one laser range sensor at the front and one at the back of the cutting plane of the tool structure, and / or at least two laser range sensors arranged in an array parallel to and on one side of the cutting plane of the tool structure.

[0006] Preferably, the laser ranging module includes at least one laser ranging sensor disposed on both sides of the vertical central axis of the cutting blade in the tool structure.

[0007] Preferably, the parallel robotic arm linear motion module includes: The first data acquisition unit is used to acquire the cutting depth monitored by the laser ranging module; The second data acquisition unit is used to acquire the tool setting feedback data of the laser vertical tool setting module; The current state determination unit is used to determine the current state based on the cutting depth, tool setting feedback data, and cutting task. The attitude monitoring unit is used to monitor the current attitude of the parallel robotic arm; The target state determination unit is used to determine the target state of the parallel robotic arm based on the current state and the cutting task; The control analysis unit is used to determine the set of control parameters based on the current state, target state, and current attitude. The execution unit is used to execute the control parameter set and control the actions of the parallel robotic arm.

[0008] Preferably, the parallel robotic arm linear motion module also includes: The robot status monitoring unit is used to monitor the robot's status data; The trigger judgment unit is used to analyze the status data and determine whether to trigger a correction. The correction analysis unit is used to correct the control parameter set based on the robot's state changes after correction is triggered.

[0009] Preferably, the target state determination unit determines the target state of the parallel robotic arm based on the current state and the cutting task, and performs the following operations: Analyze the cutting task to determine the cutting direction and changes in cutting depth; Analyze the current state to determine the current cutting position and current cutting depth; Determine the target position based on the current cutting position and cutting direction; The cutting depth of the target state is determined based on the current cutting depth and the change in cutting depth.

[0010] Preferably, the parallel robotic arm linear motion module also includes: The third data acquisition unit is used to acquire historical cutting trajectories; The cutting effect analysis unit determines the difference data based on a comparative analysis of historical cutting trajectories and standard trajectories. The trajectory correction control unit is used to correct the control parameter set based on the difference data.

[0011] Preferably, the parallel robotic arm linear motion module also includes: The tool resetting unit is used to determine whether to reset the tool based on the difference data. When it is determined that the tool needs to be reset, the tool resetting operation is performed through the laser vertical tool setting module. The tool resetting unit determines whether to reset the tool based on the difference data, specifically including: Analyze the discrepancy data to determine the maximum deviation, average deviation, and deviation fluctuation; When the maximum deviation is greater than or equal to the pre-configured first threshold, or the average deviation is greater than or equal to the pre-configured second threshold, or the deviation fluctuation is greater than or equal to the preset third threshold, it is determined to re-set the tool.

[0012] Preferably, the precision control system for high-intensity operations also includes: The cutting head temperature monitoring module is used to monitor the temperature of the cutting head. The cooling control module is used to control the cooling mechanism to cool the cutting head based on the monitored temperature and the robot's current working status.

[0013] The present invention also provides a disassembly robot, comprising: a main body, a walking mechanism disposed below the main body, a parallel robotic arm disposed at the upper end of the main body, a cutting tool structure and laser assembly disposed at the end of the parallel robotic arm, and a controller disposed within the main body; the controller is equipped with any of the above-mentioned precision control systems for high-intensity operations.

[0014] The present invention has the following beneficial effects: This invention employs a parallel robotic arm, which achieves highly stable linear motion through a rigid structure. It is suitable for heavy or high-load dismantling operations. Furthermore, by combining the high rigidity of the parallel robotic arm with the precise measurement of laser sensing, it can maintain cutting accuracy and stability during high-intensity operations, thereby improving dismantling efficiency and quality while reducing mechanical wear and maintenance costs.

[0015] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0016] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of a precision control system for high-intensity operations according to an embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the execution steps of the target state determination unit in an embodiment of the present invention; Figure 3 This is a schematic diagram of the cooling mechanism in an embodiment of the present invention. Detailed Implementation

[0018] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0019] Example 1: This embodiment of the invention provides a precision control system for high-intensity operations, such as... Figure 1 As shown, it includes: a laser-type vertical tool setting module 1, a laser ranging module 2, and a parallel robotic arm linear travel module 3; Among them, the laser-type vertical tool setting module 1 is used to ensure that the cutting head is vertically aligned with the workpiece in three-dimensional space when performing a cutting task; the laser ranging module 2 dynamically monitors the cutting depth when performing a cutting task; and the parallel robotic arm linear walking module 3 is used to achieve coordinated control of each branch when performing a cutting task based on the cutting depth and tool setting feedback data, so that the cutting head moves in a straight line.

[0020] The laser-based vertical tool setting module includes: one laser rangefinder sensor positioned before and after the cutting plane of the tool structure, and / or at least two laser rangefinder sensors arranged in an array parallel to and on one side of the cutting plane of the tool structure. The laser rangefinder module also includes: at least one laser rangefinder sensor positioned on both sides of the vertical central axis of the cutting blade of the tool structure.

[0021] The configuration of the laser-type vertical tool setting module and the laser rangefinder module can be selected independently according to the situation. Specific configurations are as follows: I. One laser rangefinder sensor is configured at the front and one at the rear of the cutting plane of the tool structure, serving as the laser-type vertical tool setting module. At least one laser rangefinder sensor is configured on both sides of the vertical central axis of the cutting blade in the tool structure. The function of the laser-type vertical tool setting module is to perform tool setting based on the workpiece position during cutting. In specific applications, tool setting is performed based on the surface of the decommissioned blade. Generally, a configuration of one sensor at the front and one at the rear of the cutting plane of the tool structure is used. By measuring the distance to the surface of the decommissioned blade, the distance is analyzed to determine whether tool setting was successful. When the workpiece surface is flat, and the distances are equal... When the laser vertical tool setting module is activated, it can be confirmed that the tool setting was successful. In addition, the laser vertical tool setting module can also use a cross laser marker to align with a cross mark pre-marked on the workpiece surface by the operator. In this case, the laser vertical tool setting module includes a cross laser emitter and an image acquisition device. When the cross laser emitted by the cross laser emitter is aligned with the cross mark by the image acquisition device, the tool setting is confirmed to be successful. The laser ranging module measures the distance from the laser ranging sensor to the workpiece surface through the laser ranging sensor. When the distance from the installation position of the laser ranging sensor to the lowest point of the tool structure is known, the difference between the two is the cutting depth. That is, during cutting, the distance to the workpiece surface is measured in real time, which enables dynamic monitoring of the cutting depth during the cutting task. II. At least two laser rangefinders are arrayed parallel to the cutting plane of the tool structure and located on one side as a laser-type vertical tool setting module; at least one laser rangefinder is arrayed on both sides of the vertical central axis of the cutting blade of the tool structure as a laser rangefinder module; III. One laser rangefinder is arrayed at the front and one at the back of the cutting plane of the tool structure, and at least two laser rangefinders are arrayed parallel to the cutting plane of the tool structure and located on one side as a laser-type vertical tool setting module; at least one laser rangefinder is arrayed on both sides of the vertical central axis of the cutting blade of the tool structure as a laser rangefinder module; the laser rangefinders can be configured to be arranged in a C-shape around the outer periphery of the tool structure. For example, the specific arrangement can be one at the front and one at the back of the tool structure, and three or more on the side. The side arrangement ensures that one is at the position corresponding to the vertical central axis of the cutting blade of the tool structure, and one at each end; taking a circular saw blade as an example, the vertical central axis of the cutting blade is a line extending outward from the end of the robotic arm and passing through the center of the circular saw blade.

[0022] The parallel robotic arm linear motion module includes: The first data acquisition unit is used to acquire the cutting depth monitored by the laser ranging module; The second data acquisition unit is used to acquire the tool setting feedback data of the laser vertical tool setting module; The current state determination unit is used to determine the current state based on the cutting depth, tool setting feedback data, and cutting task. The attitude monitoring unit is used to monitor the current attitude of the parallel robotic arm; The target state determination unit is used to determine the target state of the parallel robotic arm based on the current state and the cutting task; The control analysis unit is used to determine the set of control parameters based on the current state, target state, and current attitude. The execution unit is used to execute the control parameter set and control the actions of the parallel robotic arm.

[0023] Based on the analysis of the current state, cutting state (cutting depth and tool feedback data) and cutting task of the parallel robotic arm, the next step is to control the motion of the parallel robotic arm. This achieves highly stable linear motion through the rigid structure of the parallel robotic arm, realizing precise control under high-intensity operations. Specifically, the control analysis unit determines the control parameter set using a pre-configured control analysis library. This involves extracting features from the current state, target state, and current posture, and then using the extracted feature parameters to find the corresponding control parameter set from the control analysis library. The control analysis library is pre-configured by professionals, and the control parameter sets are associated with the feature parameters. The control parameter set includes parameters representing the rotation or movement of each joint in each branch, etc. The feature parameters include parameters representing the current rotation or movement of each joint in each branch, the current cutting depth, the target cutting depth, the current cutting position, and the target cutting position, etc.

[0024] In actual control, precise control also requires adaptation to changes in the robot's own state; therefore, the parallel robotic arm linear motion module also includes: The robot status monitoring unit is used to monitor the robot's status data; The trigger judgment unit is used to analyze the status data and determine whether to trigger a correction. The correction analysis unit is used to correct the control parameter set based on the robot's state changes after correction is triggered. Correction can be implemented using a pre-configured first correction library, which extracts features from the state data, extracts parameter features representing posture changes at various angles and displacement parameters in various directions, and then queries the first correction library based on the extracted parameter features to obtain the correction values ​​of each control parameter in the control parameter set, and then corrects the corresponding control parameters in the control parameter set.

[0025] Among them, such as Figure 2 As shown, the target state determination unit determines the target state of the parallel robotic arm based on the current state and the cutting task, and performs the following operations: Step 1: Analyze the cutting task and determine the cutting direction and changes in cutting depth; Step 2: Analyze the current state to determine the current cutting position and current cutting depth; Step 3: Determine the target position of the target state based on the current cutting position and cutting direction; Step 4: Determine the cutting depth of the target state based on the current cutting depth and the change in cutting depth.

[0026] The target state includes the target position and the cutting depth. The target position refers to the position of the center of the cutting body of the tool structure corresponding to the workpiece surface, and the cutting depth refers to the distance from the bottom of the cutting body to the workpiece surface when the target position is reached. The target state is analyzed by the cutting task and the current state, which provides the control basis for the control of the parallel robotic arm. This embodiment also provides a disassembly robot, including: a main body, a walking mechanism disposed below the main body, a parallel robotic arm disposed above the main body, a cutting tool structure and laser assembly disposed at the end of the parallel robotic arm, and a controller disposed within the main body; the controller is equipped with the aforementioned precision control system for high-intensity operations. The parallel robotic arm includes at least two branches, and generally uses three or six branches; each branch includes multiple links and joints; the links are rigid rods; the joints include rotary joints, sliding joints, etc.; the cutting tool structure is disposed at the end of the parallel robotic arm (moving platform), and the moving platform is the output end of the combined action of multiple branches, the position and attitude of which are determined by the cooperation of each branch.

[0027] Example 2: This embodiment of the invention provides a precision control system for high-intensity operations, including: a laser-type vertical tool setting module, a laser ranging module, and a parallel robotic arm linear travel module; Among them, the laser-type vertical tool setting module is used to ensure that the cutting head is vertically aligned with the workpiece in three-dimensional space during the cutting task; the laser ranging module dynamically monitors the cutting depth during the cutting task; and the parallel robotic arm linear movement module is used to achieve coordinated control of each branch during the cutting task based on the cutting depth and tool setting feedback data, so that the cutting head moves in a straight line.

[0028] In actual control, precise control also requires adaptation to changes in the robot's own state; therefore, the parallel robotic arm linear motion module also includes: The robot status monitoring unit is used to monitor the robot's status data; The trigger judgment unit is used to analyze the status data and determine whether to trigger a correction. The correction analysis unit is used to correct the control parameter set based on the robot's state changes after correction is triggered. Correction can be implemented using a pre-configured first correction library, which extracts features from the state data, extracts parameter features representing posture changes at various angles and displacement parameters in various directions, and then queries the first correction library based on the extracted parameter features to obtain the correction values ​​of each control parameter in the control parameter set, and then corrects the corresponding control parameters in the control parameter set.

[0029] To further improve control precision, control can also be guided by historical cutting data. Specifically, the parallel robotic arm linear motion module also includes: The third data acquisition unit is used to acquire historical cutting trajectories; The cutting effect analysis unit determines the difference data based on a comparative analysis of historical cutting trajectories and standard trajectories. The trajectory correction control unit is used to correct the control parameter set based on the difference data.

[0030] The system uses historical cutting trajectories as the basis for correction, enabling real-time adjustments based on actual cutting conditions and further improving control precision. The standard trajectory is obtained through simulation analysis of the cutting task. The difference data includes point sampling of both the historical and standard trajectories, determining the positional deviation of points on the historical trajectory relative to their corresponding standard points, and arranging the data according to point order. The trajectory correction control unit corrects the control parameter set based on this difference data by: extracting features such as average deviation, maximum deviation, and minimum deviation; querying a pre-configured second correction library using these features to obtain the corresponding correction parameter set; and using each correction parameter in the correction parameter set to correct the corresponding control parameters in the control parameter set. The second correction library is configured by professionals, with a one-to-one correspondence between feature parameters and correction parameter sets.

[0031] To avoid the risk of tool damage during disassembly, the parallel robotic arm linear motion module also includes: The tool resetting unit is used to determine whether to reset the tool based on the difference data. When it is determined that the tool needs to be reset, the tool resetting operation is performed through the laser vertical tool setting module. The tool resetting unit determines whether to reset the tool based on the difference data, specifically including: Analyze the discrepancy data to determine the maximum deviation, average deviation, and deviation fluctuation; When the maximum deviation is greater than or equal to the pre-configured first threshold (any value between 0.5mm and 2cm), or the average deviation is greater than or equal to the pre-configured second threshold (any value between 0.1mm and 1cm), or the deviation fluctuation is greater than or equal to the preset third threshold (any value between 0.1mm and 1cm), it is determined that the tool needs to be re-set.

[0032] This embodiment also provides a disassembly robot, including: a main body, a walking mechanism disposed below the main body, a parallel robotic arm disposed above the main body, a cutting tool structure and laser assembly disposed at the end of the parallel robotic arm, and a controller disposed within the main body; the controller is equipped with the aforementioned precision control system for high-intensity operations.

[0033] Example 3: This embodiment of the invention provides a precision control system for high-intensity operations, including: a laser-type vertical tool setting module, a laser ranging module, and a parallel robotic arm linear travel module; Among them, the laser-type vertical tool setting module is used to ensure that the cutting head is vertically aligned with the workpiece in three-dimensional space during the cutting task; the laser ranging module dynamically monitors the cutting depth during the cutting task; and the parallel robotic arm linear movement module is used to achieve coordinated control of each branch during the cutting task based on the cutting depth and tool setting feedback data, so that the cutting head moves in a straight line.

[0034] During high-intensity operations, the cutting head is prone to overheating due to insufficient heat dissipation, affecting working accuracy and efficiency. Therefore, a precision control system for high-intensity operations also includes: The cutting head temperature monitoring module is used to monitor the temperature of the cutting head. The cooling control module is used to control the cooling mechanism to cool the cutting head based on the monitored temperature and the robot's current working status.

[0035] Among them, such as Figure 3As shown, the cutting head temperature monitoring module includes an infrared temperature sensor 31 configured on one side of the cutting head (saw blade); the cooling mechanism includes a rotating shaft 32 and an L-shaped component 33 fixedly mounted on the rotating shaft 32; the end of the L-shaped component 33 away from the rotating shaft 32 can move to a position close to the outer periphery of the saw blade under the rotation of the rotating shaft 32; multiple air outlets or liquid outlets (not shown in the figure) are provided on the side of the L-shaped component close to the saw blade; the air outlets or liquid outlets spray cooling gas or liquid onto the cutting head under the control of the cooling control module; before the cutting head cuts, the rotating shaft rotates to move the L-shaped component to the saw blade position corresponding to the cutting depth, so that the cooling mechanism does not affect the cutting action; to further improve safety, a pressure sensor is provided on the side of the L-shaped component away from the rotating shaft and away from the cutting head; when the pressure sensor detects that the pressure is greater than a preset threshold (any value between 0 and 1 kPa), a preset alarm message is issued and the cutting head and parallel robotic arm are controlled to stop moving. In specific applications, the cooling mechanism is configured as a symmetrical pair that rotates synchronously; it can be used to cool the cutting head during the tool resetting period; during the cutting operation, the L-shaped component 33 is driven by the rotating shaft to be placed in a horizontal position or above the horizontal position to avoid interference with the cutting; in addition, the pressure sensor configured during the cutting movement can play a role in anti-collision and limit.

[0036] This embodiment also provides a disassembly robot, including: a main body, a walking mechanism disposed below the main body, a parallel robotic arm disposed above the main body, a cutting tool structure and laser assembly disposed at the end of the parallel robotic arm, and a controller disposed within the main body; the controller is equipped with the aforementioned precision control system for high-intensity operations.

[0037] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A precision control system for high intensity work, characterized by, include: Laser-type vertical tool setting module, laser ranging module, and parallel robotic arm linear travel module; Among them, the laser-type vertical tool setting module is used to ensure that the cutting head is vertically aligned with the workpiece in three-dimensional space when performing a cutting task; The laser ranging module dynamically monitors the cutting depth during the cutting task. The parallel robotic arm linear motion module is used to coordinate the control of each branch during the cutting task based on the cutting depth and tool setting feedback data, so that the cutting head moves in a straight line.

2. The precision control system for high strength tasks of claim 1, wherein, The laser-based vertical tool setting module includes: one laser rangefinder sensor positioned before and after the cutting plane of the tool structure, and / or at least two laser rangefinder sensors arranged in an array parallel to and on one side of the cutting plane of the tool structure.

3. The precision control system for high-intensity operations as described in claim 1, characterized in that, The laser ranging module includes at least one laser ranging sensor disposed on both sides of the vertical central axis of the cutting blade in the tool structure.

4. The precision control system for high-intensity operations as described in claim 1, characterized in that, The parallel robotic arm linear motion module includes: The first data acquisition unit is used to acquire the cutting depth monitored by the laser ranging module; The second data acquisition unit is used to acquire the tool setting feedback data of the laser vertical tool setting module; The current state determination unit is used to determine the current state based on the cutting depth, tool setting feedback data, and cutting task. The attitude monitoring unit is used to monitor the current attitude of the parallel robotic arm; The target state determination unit is used to determine the target state of the parallel robotic arm based on the current state and the cutting task; The control analysis unit is used to determine the set of control parameters based on the current state, target state, and current attitude. The execution unit is used to execute the control parameter set and control the actions of the parallel robotic arm.

5. The precision control system for high-intensity operations as described in claim 4, characterized in that, The parallel robotic arm linear motion module also includes: The robot status monitoring unit is used to monitor the robot's status data; The trigger judgment unit is used to analyze the status data and determine whether to trigger a correction. The correction analysis unit is used to correct the control parameter set based on the robot's state changes after correction is triggered.

6. The precision control system for high-intensity operations as described in claim 4, characterized in that, Based on the current state and the cutting task, the target state determination unit determines the target state of the parallel robotic arm and performs the following operations: Analyze the cutting task to determine the cutting direction and changes in cutting depth; Analyze the current state to determine the current cutting position and current cutting depth; Determine the target position based on the current cutting position and cutting direction; The cutting depth of the target state is determined based on the current cutting depth and the change in cutting depth.

7. The adaptable and high-precision disassembly control system as described in claim 4, characterized in that, The parallel robotic arm linear motion module also includes: The third data acquisition unit is used to acquire historical cutting trajectories; The cutting effect analysis unit determines the difference data based on a comparative analysis of historical cutting trajectories and standard trajectories. The trajectory correction control unit is used to correct the control parameter set based on the difference data.

8. The precision control system for high-intensity operations as described in claim 7, characterized in that, The parallel robotic arm linear motion module also includes: The tool resetting unit is used to determine whether to reset the tool based on the difference data. When it is determined that the tool needs to be reset, the tool resetting operation is performed through the laser vertical tool setting module. The tool resetting unit determines whether to reset the tool based on the difference data, specifically including: Analyze the discrepancy data to determine the maximum deviation, average deviation, and deviation fluctuation; When the maximum deviation is greater than or equal to the pre-configured first threshold, or the average deviation is greater than or equal to the pre-configured second threshold, or the deviation fluctuation is greater than or equal to the preset third threshold, it is determined to re-set the tool.

9. The precision control system for high-intensity operations as described in claim 1, characterized in that, Also includes: The cutting head temperature monitoring module is used to monitor the temperature of the cutting head. The cooling control module is used to control the cooling mechanism to cool the cutting head based on the monitored temperature and the robot's current working status.

10. A disassembly robot, comprising: The main body, a walking mechanism disposed below the main body, a parallel robotic arm disposed at the upper end of the main body, a tool structure and laser assembly disposed at the end of the parallel robotic arm, and a controller disposed within the main body; characterized in that the controller is equipped with a precision control system for high-intensity operations as described in any one of claims 1 to 9.

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