A gantry type robot for ultrasonic cleaning production line and control method

Abstract

The application discloses a gantry type mechanical hand for an ultrasonic cleaning production line and a control method, wherein a Y-axis driving mechanism, a Z-direction lifting mechanism, a mother basket hanging and grabbing mechanism, a multi-stage safety protection detection device and a control center are integrated and installed through a gantry support; the Y-axis driving mechanism and the Z-direction lifting mechanism drive the mother basket hanging and grabbing mechanism to execute hooking or releasing of a mother basket tool of the ultrasonic cleaning production line, and the multi-stage safety protection detection device provides multi-stage protection; a basket pressing and inductive detection assembly inductively detects real-time in-place information and a hanging posture of the mother basket hanging and grabbing mechanism in real time; irreversible mechanical hard damage of equipment is completely avoided, production line downtime maintenance time is significantly shortened, the operation rate is improved, safety levels are clear, operation risks are greatly reduced, fault tolerance is strong, and operation is convenient.

Description

Technical Field

[0001] This invention belongs to the field of electronic device manufacturing and processing technology, specifically relating to a gantry-type robotic arm and its control method for an ultrasonic cleaning production line. Background Technology

[0002] Ultrasonic cleaning is typically required during the manufacturing and processing of electronic components. However, existing gantry cranes have limited safety features, equipped only with basic limit structures and lacking multiple protection mechanisms such as station positioning detection, graded stroke overload protection, and hook material handling status monitoring. In actual production, the following defects exist: 1. The lack of real-time detection for slot positioning, hook disengagement, and basket positioning means the equipment continues to operate even when workpieces are misaligned, baskets are not properly secured, or hooks are not fully disengaged, greatly increasing the risk of workpiece falls and mechanical collisions, causing hard mechanical damage to the baskets, gantry frame, and servo transmission mechanism; 2. Stroke protection relies solely on single-level physical limit switches. Servo encoder failure or pulse loss can cause the servo motor to overtravel and impact the column, leading to deformation and scrapping of the lead screw, guide rails, and servo reducer; 3. The lack of graded warning and shutdown logic after a fault occurs means that even minor abnormalities in a single component can directly cause the entire machine to jam, resulting in long downtime repair cycles and significantly reduced production line uptime; 4. Fault locations cannot be quickly determined, requiring time-consuming disassembly and troubleshooting, and making maintenance operations cumbersome. As automated production lines increasingly demand higher levels of equipment stability and continuous production capacity, the shortcomings of existing gantry handling robots, such as lack of protective systems, significant malfunction damage, and long downtime, can no longer meet the needs of high-precision and highly continuous production. Summary of the Invention

[0003] To address the aforementioned problems in existing technologies, this invention aims to provide a gantry-type robotic arm and its control method for ultrasonic cleaning production lines. Addressing the shortcomings of existing gantry-type robotic arms—such as insufficient safety protection, the susceptibility of single-component failures to mechanical damage to the entire machine, and long downtime for maintenance—this invention provides a gantry-type robotic arm with a fully servo motor and safety protection. It constructs a layered protection system combining multi-station positioning detection and dual-level overtravel limits, enabling early fault warning and tiered shutdown, preventing minor component failures from escalating into structural equipment damage, shortening repair time, and improving the stability of continuous equipment operation.

[0004] The technical solution adopted in this invention is as follows: The first technical solution provides a gantry robot for an ultrasonic cleaning production line, including a gantry support, a Y-axis drive mechanism, a Z-axis lifting mechanism, a basket hanging and gripping mechanism, a multi-level safety protection and detection device, and a control center; The basket hanging and gripping mechanism is used to hook the basket tooling of the ultrasonic cleaning production line; the Y-axis drive mechanism is used to drive the gantry bracket to move linearly along the Y-axis direction; and the Z-axis lifting mechanism is used to drive the basket hanging and gripping mechanism to move up and down vertically. The basket hanging and gripping mechanism is equipped with a basket pressure sensing and detection component. The basket pressure sensing and detection component is used to sense and detect in real time the real-time information of the basket hanging and gripping mechanism hooking the basket tooling, as well as the real-time suspension posture of the basket tooling. The multi-level safety protection and detection device includes a basket positioning photoelectric detection component, a slot positioning and unhooking positioning detection component, and a servo dual-level overtravel protection component. The control center is used to synchronously collect feedback signals from all detection elements and execute hierarchical control logic and alarm shutdown control logic.

[0005] In some embodiments, the gantry support is a gantry structure composed of an X-direction support beam, a left column and a right column. Lifting guide rails are symmetrically arranged on the inner surfaces of the left column and the right column. The two ends of the basket hanging and grabbing mechanism are respectively connected to the lifting guide rails through sliding fit. The Z-axis lifting mechanism is supported above the X-axis support beam and is connected to the basket hanging and grabbing mechanism via a lifting sling.

[0006] In some embodiments, the Y-axis drive mechanism includes a Y-axis servo motor, a Y-axis reducer, and a Y-axis travel axis; a pair of travel support beams are symmetrically arranged on the outer sides of both sides of the gantry support, and the length of the pair of travel support beams is greater than the thickness of the gantry support along the Y-axis direction, so that the two ends of the pair of travel support beams extend to the front and rear sides of the gantry support respectively. The two ends of the Y-axis traveling shaft are rotatably supported and connected to the front or rear of a pair of traveling support beams. The Y-axis reducer is fixedly connected to the inner side of the traveling support beams. The Y-axis servo motor is fixedly connected above the Y-axis reducer. One end of the Y-axis traveling shaft is connected to the Y-axis reducer. Both ends of the Y-axis traveling shaft pass through the traveling support beams and are respectively connected to traveling gears. The Y-axis traveling shaft is connected to the truss rack of the ultrasonic cleaning production line through the traveling gears. Each of the walking support beams is also provided with guide slides at both ends, and the walking support beams are slidably connected to the truss guide rails of the ultrasonic cleaning production line through the guide slides.

[0007] In some embodiments, an auxiliary support is provided on one outer side of the gantry bracket, and a C-type photoelectric switch is provided on the front side of the auxiliary support. The C-type photoelectric switch is used to detect and provide slot positioning and hook-off positioning protection, thus forming the slot positioning and hook-off positioning detection component.

[0008] In some embodiments, the Z-axis lifting mechanism includes a lifting servo motor, a lifting reducer, and a lifting shaft; the lifting servo motor and the lifting reducer are fixedly installed on the top outer side of the left column or the right column; The lifting shaft is rotatably supported and installed above the X-direction support beam via a bearing seat along the X direction. One end of the lifting shaft passes through the top of the left or right column and is connected to the lifting reducer. The other end of the lifting shaft is rotatably connected to the top of the column opposite to the lifting reducer. A lifting sling is connected to the lifting shaft via a sling pulley. The lifting sling passes through the X-direction support beam, extends below the X-direction support beam, and is connected to the basket hanging and grabbing mechanism.

[0009] In some embodiments, the basket hanging and gripping mechanism includes a main boom and a hook frame. The main boom is suspended and connected to the lifting shaft by a lifting sling. The hook frame is fixedly connected to the lower part of the main boom. The hook frame is provided with downwardly extending hooks at its four corners. The basket pressure sensing and detection component is provided on one side of the hook frame. A pair of pressure basket detection supports are symmetrically arranged on one outer side of the hook frame. Each pressure basket detection support is provided with a pressure basket detection rod through a linear bearing. The top of each pressure basket detection rod is connected to a pressure basket protection sensor through a pressure basket protection plate. A pressure basket proximity switch is provided on the top surface of the hook frame at a position corresponding to each pressure basket protection sensor. Each of the pressure basket detection rods is also connected to a pressure basket protection plate at its bottom end, and each of the pressure basket detection rods is also fitted with a compression spring, the two ends of which are respectively limited by the pressure basket protection plate and the bottom surface of the linear bearing.

[0010] In some embodiments, four pulleys are connected to both ends of the main boom via pulley seats, and both ends of the main boom are slidably connected to the lifting guide rail via the four pulleys. A metal stop is also provided on the front side of the hook frame; A C-slot support is also provided on one front side of the gantry bracket. An upper limit switch and a lower limit switch are provided on the C-slot support. Each of the upper and lower limit switches is provided with a limit switch pulley. The limit switch pulley is used to cooperate with the metal stop block to trigger the internal contacts of the limit switch, so that the upper and lower limit switches provide lifting hard limit for the basket hanging and grabbing mechanism, forming a rear physical hard limit. A lifting stroke proximity switch is also provided on the C-slot support near the lower end of the upper limit switch. The lifting stroke proximity switch is used to predict and sense the proximity of the metal block and provide a pre-deceleration warning signal.

[0011] In some embodiments, the control center adopts a PLC controller, which is electrically connected to all servo drives, multi-level safety protection detection units, human-machine interaction units, and audible and visual alarm modules. The human-machine interaction units are used to set travel thresholds, view fault codes, and manually reset alarms. The audible and visual alarm module distinguishes between two types of audible and visual prompts: minor warning and emergency stop. The servo dual-stage overtravel protection component consists of two redundant protection levels: a front-end electronic soft limit and a rear-end physical hard limit. The primary electronic soft limit is achieved by having built-in absolute encoders in the horizontal and vertical servo motors, which provide real-time feedback of the running pulse coordinates to the PLC. The PLC program presets safe travel thresholds for each axis. When the servo running coordinate reaches the threshold, the controller cuts off the servo torque output, and the servo smoothly decelerates and soft-stops. The secondary physical hard limit is achieved by mechanically fixed travel switches at both ends of the gantry column and at the left and right extreme positions of the horizontal slide. When the electronic soft limit fails or the encoder malfunctions, the metal body of the slide directly touches the travel switch contacts, forcibly cutting off the main power circuit of the entire machine and locking all servo axes with brakes to prevent overtravel from impacting the frame.

[0012] In some embodiments, the X-direction support beam is a U-shaped groove structure, and a top cover is provided at the top of the X-direction support beam. The top cover and the X-direction support beam are combined to form a slot box structure. The Z-direction lifting mechanism is disposed inside the slot box structure. The tops of the left column and the right column are respectively covered and encapsulated at both ends of the slot box structure.

[0013] The second technical solution provides a control method for a gantry robot in an ultrasonic cleaning production line. Using the aforementioned gantry robot in an ultrasonic cleaning production line, the method includes the following operating steps: S1, Equipment power-on self-test; PLC automatically collects all photoelectric switches, limit switches, and servo encoder signals, and performs sensor disconnection self-test; if the detection element is disconnected, the HMI pops up a window to indicate the corresponding point and prevents the automatic cycle from starting; S2, Basic Automated Handling; After self-checking and finding no faults, it receives the production line start signal and the robot arm executes the standard handling cycle; The servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grasping mechanism as a whole along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the basket position marking information on the cleaning tank of the ultrasonic cleaning production line, confirms that the basket hanging and grasping mechanism is above the basket position of the cleaning tank, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging and gripping mechanism to descend. The basket pressure sensing and detection component senses and detects the positioning information and real-time attitude of the basket tooling. If the positioning information of the basket tooling is detected and the real-time attitude is correct, the subsequent steps are executed. If the positioning information of the basket tooling is not detected, or the real-time attitude of the basket tooling is incorrect, a fault signal is triggered. The servo module of the Z-axis drive mechanism stops; the Y-axis drive mechanism moves slightly, and the basket hanging and gripping mechanism locks and grips the basket fixture. The servo module of the Z-axis drive mechanism rises; the servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grabbing mechanism in the opposite direction along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the unloading station marking information on the cleaning tank of the ultrasonic cleaning production line, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging gripping mechanism to descend, the Y-axis drive mechanism moves slightly, and the basket hanging gripping mechanism disengages and releases the basket tooling. The servo module of the Z-axis drive mechanism rises back to the origin, completing a single transfer cycle; S3, a three-level fault classification safety control logic; the PLC controller synchronously collects all feedback signals in real time from the basket positioning photoelectric detection component, the slot positioning and hook-off positioning C-type photoelectric switches, the lifting travel proximity switch, the upper / lower travel switch, the absolute encoders of each servo motor, and the basket pressure sensing detection component. Based on the severity of the fault risk, it classifies the logic into three levels of differentiated handling, outputs alarm signals at each level, and executes corresponding shutdown control actions: S301 Level 1 Fault: Slight abnormal posture of the workstation's gripping / placement, with no risk of mechanical impact; S302 Level 2 fault: Servo axis triggers electronic soft limit warning, posing a potential risk of overtravel impact; S303 Level 3 Fault: Slide block touches physical hard limit, high-risk fault due to emergency mechanical collision; S4, graded fault reset and recovery process: S401 Level 1 Fault Reset: After manual correction of the basket posture or mechanical manual alignment, and the restoration of the positioning signals of each detection element, the human-machine interface performs a warning reset and directly restarts the automatic cycle. S402 Level 2 Fault Reset: Manually reverse the servo axis to return to the software safe travel range, clear the travel warning alarm on the human-machine interface, and restore the automatic handling mode; S403 Level 3 Fault Reset: Power off to troubleshoot mechanical, servo encoder, and circuit faults. Manually disconnect the hard limit contact, power on the entire machine to complete sensor disconnection and full stroke self-test. Only after the self-test is passed can the equipment start automatic operation.

[0014] The beneficial effects of this invention are as follows: A gantry-type robotic arm and its control method for an ultrasonic cleaning production line are disclosed. The gantry support integrates a Y-axis drive mechanism, a Z-axis lifting mechanism, a basket-hanging and gripping mechanism, a multi-level safety protection detection device, and a control center. The Y-axis drive mechanism drives the gantry support to move linearly along the Y-axis, while the Z-axis lifting mechanism drives the basket-hanging and gripping mechanism to move vertically up and down. The basket-hanging and gripping mechanism hooks onto the basket fixture of the ultrasonic cleaning production line. The multi-level safety protection detection device includes a basket-positioning photoelectric detection component, a tank-positioning and unhooking-positioning detection component, and a servo dual-level overtravel protection component. The basket-hanging and gripping mechanism is equipped with a basket-pressure sensing detection component, which detects in real-time information about the basket-hanging and gripping mechanism hooking onto the basket fixture, as well as the real-time suspension posture of the basket fixture. The control center is used to synchronously collect feedback signals from all detection elements and execute hierarchical control logic and alarm shutdown control logic. This design offers the following advantages: 1. Completely avoid irreversible mechanical damage to equipment; multi-layer hardware detection combined with dual-level stroke redundancy protection and graded shutdown control, early warning and suspension for minor workstation abnormalities, deceleration buffer for servo overtravel, and power-off and shaft locking for extreme runaway, eliminating permanent structural damage such as basket falling, lead screw bending, gantry column deformation, and servo reducer scrapping, reducing equipment overhaul frequency by more than 80%; 2. Significantly shortens production line downtime and improves uptime; traditional equipment jams due to sensor failure, and disassembling and repairing the transmission mechanism takes more than 30 minutes; the fault codes of this invention accurately locate the fault points, and the quick-connect sensor can be replaced by a single person in 5 minutes. For minor level one faults, there is no need to cut off the power. Production can be resumed by adjusting the workpiece. Equipment downtime is reduced by 70%, and the efficiency of continuous operation of the production line is greatly improved. 3. Clear safety levels significantly reduce operational risks; differentiates between three levels of fault alarms and shutdown strategies, minor workpiece deviations only pause the cycle without affecting the power supply of the whole machine; dual-stage travel double-backup protection eliminates the risk of servo encoder failure and program abnormal collisions, while protecting the safety of operators, workpieces and equipment.

[0015] 4. Low modification cost and strong versatility: The hardware safety unit of this invention can be directly installed on the existing full servo gantry handling arm without large-scale modification of the original gantry frame and servo drive body; the supporting control method only modifies the PLC program logic, which is compatible with various hanging basket transfer automation production lines in electroplating, spraying, and hardware processing, and the promotion cost is low. 5. Strong fault tolerance and convenient operation; power-on self-test to detect sensor disconnection faults in advance; graded reset logic to constrain illegal operation; human-machine interface to intuitively display fault location, reducing the operation threshold for operators and maintenance personnel. Attached Figure Description

[0016] Figures 1-2This is a three-dimensional structural diagram of a gantry-type robotic arm used in an ultrasonic cleaning production line according to Embodiment 1 of the present invention; Figure 3 yes Figure 2 A magnified schematic diagram of a local structure; Figures 4-5 This is a schematic diagram of the three-dimensional structure of the gantry-type robotic arm after dispersion in an ultrasonic cleaning production line according to Embodiment 1 of the present invention. Figure 6 This is a three-dimensional structural diagram of the basket hanging and gripping mechanism in the gantry-type robotic arm of the ultrasonic cleaning production line according to Embodiment 1 of the present invention. Detailed Implementation

[0017] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "vertical," "horizontal," "left," "right," "inner," "outer," and similar expressions used in this specification are for illustrative purposes only. In the description of the present invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating relative importance or implying the number of indicated technical features. Thus, unless otherwise stated, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; "multiple" means two or more. The term "comprising" and any variations thereof mean non-exclusive inclusion, where one or more other features, integers, steps, operations, units, components, and / or combinations thereof may be present or added.

[0018] Furthermore, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections via an intermediate medium, or internal communication between two components. All technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0019] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0020] Example 1: Example 1 of this invention provides a gantry-type manipulator and its control method for an ultrasonic cleaning production line. The overall design first analyzes the shortcomings of traditional and existing technologies, finding that existing gantry handling manipulators have limited safety protection configurations, only equipped with basic limit structures, lacking multiple protection mechanisms such as station positioning detection, graded stroke overload protection, and hook material handling status monitoring. The following defects exist in actual production: 1. Real-time detection of missing slots, disengagement, and basket positioning. If the workpiece is misaligned, the basket is not properly secured, or the hook is not completely disengaged, the equipment will continue to run, which can easily cause the workpiece to fall or the mechanism to be squeezed and collide, resulting in hard mechanical damage to the basket, gantry frame, and servo transmission mechanism. 2. The travel protection relies solely on a single-stage physical limit switch. When the servo encoder fails or pulses are lost, the servo motor goes out of control and overtravels, impacting the column and causing deformation and scrapping of the lead screw, guide rail, and servo reducer. 3. There is no graded warning and shutdown logic after a failure occurs. A slight abnormality in a single component can directly cause the entire machine to freeze and become stuck. The equipment downtime and maintenance cycle is long, which greatly reduces the production line utilization rate. 4. Fault locations cannot be quickly identified, and disassembling and troubleshooting the entire machine is time-consuming and cumbersome.

[0021] As automated production lines increasingly demand higher levels of equipment stability and continuous production capacity, the shortcomings of existing gantry handling robots, such as lack of protective systems, significant malfunction damage, and long downtime, can no longer meet the needs of high-precision and highly continuous production.

[0022] Therefore, this invention provides a gantry-type robotic arm and control method for ultrasonic cleaning production lines. Addressing the technical shortcomings of existing gantry-type robotic arms—such as insufficient safety protection, the susceptibility of single-component failures to mechanical damage to the entire machine, and long downtime maintenance cycles—this invention provides a gantry-type robotic arm with a full servo motor and safety protection. It constructs a layered protection system combining multi-station positioning detection and dual-level overtravel limit switching, enabling early fault warning and graded shutdown, preventing minor component failures from escalating into structural equipment damage, shortening fault repair time, and improving the stability of continuous equipment operation.

[0023] The first technical solution of this invention provides a gantry-type manipulator for an ultrasonic cleaning production line, specifically composed of a gantry support 1, a Y-axis drive mechanism 2, a Z-axis lifting mechanism 3, a basket-hanging and gripping mechanism 4, a multi-level safety protection and detection device 5, and a control center. The basket-hanging and gripping mechanism 4 can hook onto the basket fixture of the ultrasonic cleaning production line; the Y-axis drive mechanism drives the gantry support to move linearly along the Y-axis, and the Z-axis lifting mechanism drives the basket-hanging and gripping mechanism to move up and down vertically. The basket-hanging and gripping mechanism is equipped with a basket-pressure sensing and detection component, which is used to sense and detect in real time the real-time information of the basket-hanging and gripping mechanism hooking onto the basket fixture, as well as the real-time suspension posture of the basket fixture; the multi-level safety protection and detection device includes a basket-positioning photoelectric detection component, a slot-positioning and unhooking-positioning detection component, and a servo dual-level overtravel protection component; the control center is used to synchronously collect feedback signals from all detection elements and execute hierarchical control logic and alarm shutdown control logic.

[0024] The specific structural features of the gantry support 1 are as follows: The gantry support 1 is a gantry structure composed of an X-direction support beam 11, a left column 12 and a right column 13. Lifting guide rails 14 are symmetrically arranged on the inner sides of the left and right columns. The two ends of the basket hanging and grabbing mechanism 4 are respectively connected to the lifting guide rails 14 through sliding fit. The Z-direction lifting mechanism 3 is supported above the X-direction support beam 11 and is connected to the basket hanging and grabbing mechanism through the lifting sling 30.

[0025] The specific structural features of the Y-axis drive mechanism 2 are as follows: The Y-axis drive mechanism 2 consists of a Y-axis servo motor 21, a Y-axis reducer 22, and a Y-axis traveling shaft 23; a pair of traveling support beams 24 are symmetrically arranged on the outer sides of both sides of the gantry support, the length of the pair of traveling support beams 24 is greater than the thickness of the gantry support 1 along the Y-axis direction, so that the two ends of the pair of traveling support beams extend to the front and rear sides of the gantry support respectively; the two ends of the Y-axis traveling shaft 23 are rotatably supported and connected to the front or rear of the pair of traveling support beams, the Y-axis reducer is fixedly connected to the inner side of the traveling support beam, the Y-axis servo motor is fixedly connected above the Y-axis reducer, and one end of the Y-axis traveling shaft... The end drive is connected to the Y-axis reducer, so that the Y-axis servo motor is connected to the Y-axis travel axis via the Y-axis reducer. The two ends of the Y-axis travel axis pass through the travel support beam and are respectively connected to a travel gear 27. The Y-axis travel axis can be connected to the truss rack of the ultrasonic cleaning production line through the meshing of the travel gear. Thus, the Y-axis travel axis can be driven to rotate by the Y-axis servo motor via the Y-axis reducer, and move back and forth in a straight line along the truss rack of the ultrasonic cleaning production line through the travel gear 27. Guide slides 26 are also set below both ends of each travel support beam. The travel support beam is connected to the truss guide rail of the ultrasonic cleaning production line through the sliding engagement of the guide slide.

[0026] An auxiliary support 10 is also installed on the outer side of one side of the gantry support 1. A C-type photoelectric switch 101 is installed on the front side of the auxiliary support 10. The C-type photoelectric switch provides protection for the slot arrival and unhooking, forming a slot arrival and unhooking detection component. The C-type photoelectric switch can cooperate with the hanging basket station mark and unloading basket station mark on the cleaning tank of the ultrasonic cleaning production line to provide travel limit protection. The C-type photoelectric switch and the hanging basket station mark provide slot arrival protection, that is, when the travel reaches the hanging basket station, the mother basket fixture can be locked and gripped. The C-type photoelectric switch and the unloading basket station mark provide unhooking protection, that is, when the travel reaches the unloading basket station, the mother basket fixture can be unhooked and released. An auxiliary travel sensing plate 25 can also be installed on the rear side of the auxiliary support 10. The auxiliary travel sensing plate 25 can cooperate with the corresponding photoelectric sensor on the cleaning tank of the ultrasonic cleaning production line to provide safety limit protection, further improving the safety effect.

[0027] The specific structural features of the Z-axis lifting mechanism 3 are as follows: The main structure of the Z-axis lifting mechanism 3 consists of a lifting servo motor 31, a lifting reducer 32, and a lifting shaft 33; the lifting servo motor 31 and the lifting reducer 32 are fixedly installed on the top outer side of the left or right column; the lifting shaft 33 is rotatably supported and installed above the X-axis support beam through a bearing seat along the X direction, and one end of the lifting shaft passes through the top of the left or right column and is connected to the lifting reducer, while the other end of the lifting shaft is rotatably connected to the top of the column on the opposite side of the lifting reducer; two lifting slings 30 are connected to the lifting shaft through two lifting wheels 34, and the lifting slings pass through the X-axis support beam and extend to the bottom of the X-axis support beam and are connected to the basket hanging and grabbing mechanism.

[0028] The specific structural features of the basket hanging and gripping mechanism 4 are as follows: The main structure of the basket hanging and gripping mechanism 4 is a main boom 41 and a hook frame 42. The main boom is suspended and connected to the lifting shaft 33 via a lifting sling 30. The hook frame 42 is fixedly connected to the bottom of the main boom 41. Hooks 421 extending downwards are respectively provided at the four corners of the hook frame. A basket pressure sensing and detection component is provided on one side of the hook frame. A pair of basket pressure detection supports 43 are symmetrically arranged on the outer surface of one side of the hook frame. Each basket pressure detection support 43 is connected via... A linear bearing 44 is used to run through a pressure basket detection rod 45. Each pressure basket detection rod has a pressure basket protection sensor 46 connected to its top via a pressure basket protection plate 40. A pressure basket proximity switch 47 is installed on the top surface of the hook frame at a position corresponding to each pressure basket protection sensor 46. The bottom end of each pressure basket detection rod 45 is also connected to a pressure basket protection plate 40. A compression spring 48 is fitted onto each pressure basket detection rod, with its ends limited by the pressure basket protection plate at the lower end of the pressure basket detection rod 45 and the bottom surface of the linear bearing, respectively. Four pulleys are connected to both ends of the main boom via pulley seats 49. Both ends of the main boom 41 are slidably connected to the lifting guide rail via these four pulleys.

[0029] When the Y-axis drive mechanism 2 drives the gantry bracket 1, which in turn drives the Z-axis lifting mechanism 3, the basket hanging and gripping mechanism 4, and the multi-level safety protection detection device 5 to move linearly to the corresponding position of the loading station, the Z-axis lifting mechanism 3 drives the basket hanging and gripping mechanism 4 to descend. When the two basket pressure protection plates at the lower ends of the two basket pressure detection rods 45 simultaneously touch the upper frame of the basket fixture, the two basket pressure detection rods 45 are simultaneously pushed upward, and the basket pressure protection sensing plates 46 at the top ends of the two basket pressure detection rods 45 move upward accordingly. When the basket pressure protection sensing plates 46 at the top ends of the two basket pressure detection rods 45 simultaneously disengage from the two basket pressure proximity switches 47, feedback information on the basket fixture's arrival status is sent to the control center. The Y-axis drive mechanism 2 then drives the gantry bracket 1, which in turn drives the Z-axis lifting mechanism 3, the basket hanging and gripping mechanism 4, and the multi-level safety protection detection device 5 to move linearly forward until the hook is located below the handle of the basket fixture. The Z-axis lifting mechanism 3 then drives the basket hanging and gripping mechanism 4 to descend. When the lifting mechanism 4 rises, the hook simultaneously engages the handle of the mother basket fixture, thus suspending and grabbing the mother basket fixture. If the mother basket fixture is tilted, not securely attached, or missing, the two pressure protection plates at the lower ends of the two pressure detection rods 45 cannot simultaneously touch the upper frame of the mother basket fixture, the pressure protection sensing plates 46 at the top ends of the two pressure detection rods 45 cannot simultaneously move upward, and the pressure protection sensing plates 46 at the top ends of the two pressure detection rods 45 cannot simultaneously disengage from the two pressure proximity switches 47, indicating that the mother basket fixture is in an incorrect posture and does not meet the hooking, suspension, and hoisting requirements of the production line. If no mother basket fixture is in place, neither of the two pressure protection plates at the lower ends of the two pressure detection rods 45 can touch the upper frame of the mother basket fixture, neither of the pressure protection sensing plates 46 at the top ends of the two pressure detection rods 45 moves upward, and neither of the pressure protection sensing plates 46 at the top ends of the two pressure detection rods 45 disengage from the two pressure proximity switches 47, indicating that no mother basket fixture is in place.

[0030] The control center uses a PLC controller, which is electrically connected to all servo drives, multi-level safety protection and detection units, human-machine interface units, and audible and visual alarm modules. The human-machine interface unit is used to set travel thresholds, view fault codes, and manually reset alarms. The audible and visual alarm module distinguishes between minor warnings and emergency stops. The servo dual-level overtravel protection component consists of two redundant protection levels: a front-end electronic soft limit and a rear-end physical hard limit. The primary electronic soft limit is achieved by the built-in absolute encoders of the horizontal and vertical servo motors, which provide real-time feedback of the running pulse coordinates to the PLC. The PLC program presets the safe travel threshold for each axis. When the servo running coordinate reaches the threshold, the controller cuts off the servo torque output, and the servo smoothly decelerates and soft-stops. The secondary physical hard limit is achieved by mechanical fixed travel switches at both ends of the gantry column and the left and right extreme positions of the horizontal slide. When the electronic soft limit fails or the encoder malfunctions, the metal body of the slide directly touches the travel switch contacts, forcibly cutting off the main power circuit of the entire machine and locking all servo axes to prevent overtravel impacts on the frame.

[0031] A metal stop 66 is also provided on the front side of the hook frame; a C-slot support 6 is also provided on the front side of one side of the door bracket, and an upper limit switch 61 and a lower limit switch 62 are provided on the C-slot support. The upper limit switch and the lower limit switch are respectively provided with limit switch pulleys 63. The limit switch pulleys can cooperate with the metal stop to trigger the internal contacts of the limit switch, so that the upper limit switch and the lower limit switch can provide Z-direction lifting limit for the basket hanging and grabbing mechanism; the upper limit switch and the lower limit switch provide lifting hard limit for the basket hanging and grabbing mechanism, forming a rear physical hard limit.

[0032] A lifting travel proximity switch 64 is also installed on the C-slot support near the lower end of the upper limit switch. This lifting travel proximity switch serves as a software pre-deceleration position (warning position). When the Z-axis lifting mechanism moves upward, the metal block reaches the sensing area of ​​the proximity switch first. At this time, the equipment has not yet touched the upper roller limit switch. The main controller receives the proximity switch signal and executes the upper-level software scheduling logic: the servo motor immediately decelerates, switching from high speed to low-speed crawling. If the system is normal after deceleration, it continues to move at low speed to the target position and stops. If the software fails, the servo malfunctions, and continues to move upward, the metal block will continue to move upward and collide with the roller limit switch (hardware limit), triggering the underlying hardware circuit to cut off the servo enable and perform an emergency stop to prevent overtravel collision. A lifting travel proximity switch can also be installed above the lower limit switch, near its upper end.

[0033] The lifting stroke proximity switch, together with the upper limit switch 61 and the lower limit switch 62, constitutes a two-stage limit protection for the lifting stroke of the Z-axis lifting mechanism: First stage: The proximity switch uses software pre-limiting for warning and deceleration; it is non-contact, with software intervention, and takes priority under normal operating conditions to avoid direct impact with the hard limit, reducing shock. Second stage: The roller limit switch uses mechanical contact hardware hard limiting, which is the last line of defense. In case of failure or loss of control, it forcibly cuts off power to prevent the Z-axis from overtraveling and hitting the top.

[0034] The X-direction support beam adopts a U-shaped groove structure, and a top cover 111 is set at the top of the X-direction support beam. The top cover and the X-direction support beam are combined to form a groove box structure. The Z-direction lifting mechanism is set inside the groove box structure. The tops of the left column and the right column are respectively covered and encapsulated at both ends of the groove box structure.

[0035] The second technical solution provides a control method for a gantry robot in an ultrasonic cleaning production line. Using the aforementioned gantry robot in an ultrasonic cleaning production line, the method includes the following operating steps: S1, Equipment power-on self-test; PLC automatically collects all photoelectric switches, limit switches, and servo encoder signals, and performs sensor disconnection self-test; if the detection element is disconnected, the HMI pops up a window to indicate the corresponding point and prevents the automatic cycle from starting; S2, Basic Automated Handling; After self-checking and finding no faults, it receives the production line start signal and the robot arm executes the standard handling cycle; The servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grasping mechanism as a whole along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the basket position marking information on the cleaning tank of the ultrasonic cleaning production line, confirms that the basket hanging and grasping mechanism is above the basket position of the cleaning tank, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging and gripping mechanism to descend. The basket pressure sensing and detection component senses and detects the positioning information and real-time attitude of the basket tooling. If the positioning information of the basket tooling is detected and the real-time attitude is correct, the subsequent steps are executed. If the positioning information of the basket tooling is not detected, or the real-time attitude of the basket tooling is incorrect, a fault signal is triggered. The servo module of the Z-axis drive mechanism stops; the Y-axis drive mechanism moves slightly, and the basket hanging and gripping mechanism locks and grips the basket fixture. The servo module of the Z-axis drive mechanism rises; the servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grabbing mechanism in the opposite direction along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the unloading station marking information on the cleaning tank of the ultrasonic cleaning production line, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging gripping mechanism to descend, the Y-axis drive mechanism moves slightly, and the basket hanging gripping mechanism disengages and releases the basket tooling. The servo module of the Z-axis drive mechanism rises back to the origin, completing a single transfer cycle; S3, a three-level fault classification safety control logic; the PLC controller synchronously collects all feedback signals in real time from the basket positioning photoelectric detection component, the slot positioning and hook-off positioning C-type photoelectric switches, the lifting travel proximity switch, the upper / lower travel switch, the absolute encoders of each servo motor, and the basket pressure sensing detection component. Based on the severity of the fault risk, it classifies the logic into three levels of differentiated handling, outputs alarm signals at each level, and executes corresponding shutdown control actions: S301 Level 1 Fault: Slight abnormal posture of the gripper / placement at the workstation (no risk of mechanical impact). A Level 1 fault is triggered if any one of the following conditions is met: 1) The C-type photoelectric switch failed to collect the light-blocking mark signal of the basket loading / basket placing station, causing the robot arm to be misaligned; 2) The basket pressure sensor detection component does not give a signal that the basket is properly pressed in place, indicating that the basket is not securely attached, is tilted, or is missing; 3) The hook release action was not confirmed by the detection component; Control the execution of actions: ① The equipment immediately pauses all automatic cycle processes, the Y-axis and Z-axis servo motors remain in position lock, and the servo brake maintains the current posture; ② When the audible and visual alarm module is activated, a solid yellow light illuminates and an intermittent buzzing provides a mild warning. The human-machine interface unit pop-up window accurately displays the fault location and fault type. ③ The main power circuit of the whole machine is continuously powered, only locking the automatic handling process. After the operator adjusts the placement of the basket tooling and corrects the alignment of the robot arm, he can click the warning reset on the human-machine interface. Once the signal returns to normal, the automatic cycle can be restarted directly without powering off the whole machine to restart. S302 Level 2 Fault: Servo axis triggers electronic soft limit warning (potential risk of overtravel impact). Judgment criteria: The absolute encoders of the Y-axis translation servo and Z-axis lifting servo provide real-time feedback on the running coordinates, which reach the software safety travel threshold preset by the PLC program, and the metal stop block does not contact the upper / lower limit switch or the limit switch pulley; Control the execution of actions: ① The PLC controller immediately sends a deceleration command to the corresponding servo driver. The servo motor decelerates smoothly until it comes to a complete stop and locks the shaft, preventing the equipment from continuing to move in the direction of overtravel danger. Only manual reverse jogging permission is allowed. ② The sound and light alarm module is activated by flashing yellow and red alternately and sounding a continuous buzzer alarm. A pop-up window on the human-machine interface prompts a warning of excessive travel of the corresponding motion axis. ③ Manually reverse the servo axis to return it to the safe travel range in the software using manual mode. After eliminating the travel error, clear the travel alarm in the human-machine interface before restoring the automatic handling mode. S303 Level 3 Fault: Slide block touches physical hard limit (high-risk emergency mechanical collision fault) A Level 3 fault is triggered if any one of the following conditions is met: 1) The metal stop of the Z-axis lifting mechanism touches the limit switch pulley of the upper or lower limit switch; 2) Limit switches are provided at both ends of the Y-axis drive mechanism contact truss; Control the execution of actions: ① The hardware safety circuit directly cuts off the main power circuit of the whole machine, forces the enable signals of all servo drives to disconnect, and locks all servo axes of Y and Z, completely blocking the motion trend; ② The sound and light alarm module activates a red high-frequency flashing and a continuous high-decibel emergency alarm. The human-machine interaction unit locks all automatic operation functions, retaining only the access to view fault codes and historical fault records. ③ Operators must power off and stop the machine to troubleshoot the root cause of the fault (encoder damage, program parameter errors, mechanical jamming, tooling deformation, etc.), manually jog the servo axis to disengage the metal stop from the contact area of ​​the limit switch pulley, complete the machine's power-on initialization and full sensor self-test, and only after all self-tests pass can the equipment be unlocked and the automatic transfer cycle started.

[0036] S4, graded fault reset and recovery process: S401 Level 1 Fault Reset: After manual correction of the basket posture or mechanical manual alignment, and the restoration of the positioning signals of each detection element, the human-machine interface performs a warning reset and directly restarts the automatic cycle. S402 Level 2 Fault Reset: Manually reverse the servo axis to return to the software safe travel range, clear the travel warning alarm on the human-machine interface, and restore the automatic handling mode; S403 Level 3 Fault Reset: Power off to troubleshoot mechanical, servo encoder, and circuit faults. Manually disconnect the hard limit contact, power on the entire machine to complete sensor disconnection and full stroke self-test. Only after the self-test is passed can the equipment start automatic operation.

[0037] This invention relates to a gantry-type robotic arm and control method for an ultrasonic cleaning production line. The gantry support integrates a Y-axis drive mechanism, a Z-axis lifting mechanism, a basket-hanging and gripping mechanism, a multi-level safety protection detection device, and a control center. The Y-axis drive mechanism drives the gantry support to move linearly along the Y-axis, while the Z-axis lifting mechanism drives the basket-hanging and gripping mechanism to move vertically up and down. The basket-hanging and gripping mechanism hooks onto the basket fixture of the ultrasonic cleaning production line. The multi-level safety protection detection device includes a basket-positioning photoelectric detection component, a tank-positioning and unhooking-positioning detection component, and a servo dual-level overtravel protection component. The basket-hanging and gripping mechanism is equipped with a basket-pressure sensing detection component, which detects in real-time information about the basket-hanging and gripping mechanism hooking onto the basket fixture, as well as the real-time suspension posture of the basket fixture. The control center is used to synchronously collect feedback signals from all detection elements and execute hierarchical control logic and alarm shutdown control logic. This invention offers the following advantages: 1. Completely avoid irreversible mechanical damage to equipment; multi-layer hardware detection combined with dual-level stroke redundancy protection and graded shutdown control, early warning and suspension for minor workstation abnormalities, deceleration buffer for servo overtravel, and power-off and shaft locking for extreme runaway, eliminating permanent structural damage such as basket falling, lead screw bending, gantry column deformation, and servo reducer scrapping, reducing equipment overhaul frequency by more than 80%; 2. Significantly shortens production line downtime and improves uptime; traditional equipment jams due to sensor failure, and disassembling and repairing the transmission mechanism takes more than 30 minutes; the fault codes of this invention accurately locate the fault points, and the quick-connect sensor can be replaced by a single person in 5 minutes. For minor level one faults, there is no need to cut off the power. Production can be resumed by adjusting the workpiece. Equipment downtime is reduced by 70%, and the efficiency of continuous operation of the production line is greatly improved. 3. Clear safety levels significantly reduce operational risks; differentiates between three levels of fault alarms and shutdown strategies, minor workpiece deviations only pause the cycle without affecting the power supply of the whole machine; dual-stage travel double-backup protection eliminates the risk of servo encoder failure and program abnormal collisions, while protecting the safety of operators, workpieces and equipment.

[0038] 4. Low modification cost and strong versatility: The hardware safety unit of this invention can be directly installed on the existing full servo gantry handling arm without large-scale modification of the original gantry frame and servo drive body; the supporting control method only modifies the PLC program logic, which is compatible with various hanging basket transfer automation production lines in electroplating, spraying, and hardware processing, and the promotion cost is low. 5. Strong fault tolerance and convenient operation; power-on self-test to detect sensor disconnection faults in advance; graded reset logic to constrain illegal operation; human-machine interface to intuitively display fault location, reducing the operation threshold for operators and maintenance personnel.

[0039] This invention is not limited to the above-described optional embodiments. Anyone can derive other various forms of products under the guidance of this invention. However, regardless of any changes made in their shape or structure, any technical solution that falls within the scope of the claims of this invention shall be protected by this invention.

Claims

1. A gantry-type robotic arm for an ultrasonic cleaning production line, characterized in that: It includes a gantry support, a Y-axis drive mechanism, a Z-axis lifting mechanism, a basket hanging and grabbing mechanism, multi-level safety protection and detection devices, and a control center; The basket hanging and gripping mechanism is used to hook the basket tooling of the ultrasonic cleaning production line; the Y-axis drive mechanism is used to drive the gantry bracket to move linearly along the Y-axis direction; and the Z-axis lifting mechanism is used to drive the basket hanging and gripping mechanism to move up and down vertically. The basket hanging and gripping mechanism is equipped with a basket pressure sensing and detection component. The basket pressure sensing and detection component is used to sense and detect in real time the real-time information of the basket hanging and gripping mechanism hooking the basket tooling, as well as the real-time posture of the basket tooling. The multi-level safety protection and detection device includes a basket positioning photoelectric detection component, a slot positioning and unhooking positioning detection component, and a servo dual-level overtravel protection component. The control center is used to synchronously collect feedback signals from all detection elements and execute hierarchical control logic and alarm shutdown control logic.

2. The gantry robot for an ultrasonic cleaning production line according to claim 1, characterized in that: The gantry support is a gantry structure composed of an X-direction support beam, a left column and a right column. Lifting guide rails are symmetrically arranged on the inner sides of the left column and the right column. The two ends of the basket hanging and grabbing mechanism are respectively connected to the lifting guide rails through sliding fit. The Z-axis lifting mechanism is supported above the X-axis support beam and is connected to the basket hanging and grabbing mechanism via a lifting sling.

3. The gantry-type robotic arm for an ultrasonic cleaning production line according to claim 1, characterized in that: The Y-axis drive mechanism includes a Y-axis servo motor, a Y-axis reducer, and a Y-axis travel axis; a pair of travel support beams are symmetrically arranged on the outer sides of both sides of the gantry support, and the length of the pair of travel support beams is greater than the thickness of the gantry support along the Y-axis direction, so that the two ends of the pair of travel support beams extend to the front and rear sides of the gantry support respectively. The two ends of the Y-axis traveling shaft are rotatably supported and connected to the front or rear of a pair of traveling support beams. The Y-axis reducer is fixedly connected to the inner side of the traveling support beams. The Y-axis servo motor is fixedly connected above the Y-axis reducer. One end of the Y-axis traveling shaft is connected to the Y-axis reducer. Both ends of the Y-axis traveling shaft pass through the traveling support beams and are respectively connected to traveling gears. The Y-axis traveling shaft is connected to the truss rack of the ultrasonic cleaning production line through the traveling gears. Each of the walking support beams is also provided with guide slides at both ends, and the walking support beams are slidably connected to the truss guide rails of the ultrasonic cleaning production line through the guide slides.

4. The gantry robot for an ultrasonic cleaning production line according to claim 1, characterized in that: An auxiliary support is also provided on one outer side of the gantry support. A C-type photoelectric switch is provided on the front side of the auxiliary support. The C-type photoelectric switch is used to detect and provide slot positioning and hook-off positioning protection, thus forming the slot positioning and hook-off positioning detection component.

5. The gantry robot for an ultrasonic cleaning production line according to claim 2, characterized in that: The Z-axis lifting mechanism includes a lifting servo motor, a lifting reducer, and a lifting shaft; the lifting servo motor and the lifting reducer are fixedly installed on the top outer side of the left column or the right column; The lifting shaft is rotatably supported and installed above the X-direction support beam via a bearing seat along the X direction. One end of the lifting shaft passes through the top of the left or right column and is connected to the lifting reducer. The other end of the lifting shaft is rotatably connected to the top of the column opposite to the lifting reducer. A lifting sling is connected to the lifting shaft via a sling pulley. The lifting sling passes through the X-direction support beam, extends below the X-direction support beam, and is connected to the basket hanging and grabbing mechanism.

6. The gantry robot for an ultrasonic cleaning production line according to claim 5, characterized in that: The basket hanging and grabbing mechanism includes a main boom and a hook frame. The main boom is suspended and connected to the lifting shaft by a lifting sling. The hook frame is fixedly connected to the bottom of the main boom. The hook frame has downward-extending hooks at its four corners. The basket pressure sensing and detection component is located on one side of the hook frame. A pair of pressure basket detection supports are symmetrically arranged on one outer side of the hook frame. Each pressure basket detection support is provided with a pressure basket detection rod through a linear bearing. The top of each pressure basket detection rod is connected to a pressure basket protection sensor through a pressure basket protection plate. A pressure basket proximity switch is provided on the top surface of the hook frame at a position corresponding to each pressure basket protection sensor. Each of the pressure basket detection rods is also connected to a pressure basket protection plate at its bottom end, and each of the pressure basket detection rods is also fitted with a compression spring, the two ends of which are respectively limited by the pressure basket protection plate and the bottom surface of the linear bearing.

7. The gantry robot for an ultrasonic cleaning production line according to claim 6, characterized in that: The two ends of the main boom are each connected to four pulleys via pulley seats, and the two ends of the main boom are slidably connected to the lifting guide rail via the four pulleys. A metal stop is also provided on the front side of the hook frame; A C-slot support is also provided on one front side of the gantry bracket. An upper limit switch and a lower limit switch are provided on the C-slot support. Each of the upper and lower limit switches is provided with a limit switch pulley. The limit switch pulley is used to cooperate with the metal stop block to trigger the internal contacts of the limit switch, so that the upper and lower limit switches can provide Z-axis lifting limit for the basket hanging and grabbing mechanism. A lifting stroke proximity switch is also provided on the C-slot support near the lower end of the upper limit switch. The lifting stroke proximity switch is used to predict and sense the proximity of the metal block and provide a pre-deceleration warning signal.

8. The gantry robot for an ultrasonic cleaning production line according to claim 1, characterized in that: The control center uses a PLC controller, which is electrically connected to all servo drives, multi-level safety protection and detection units, human-machine interface units, and audible and visual alarm modules. The human-machine interface units are used to set travel thresholds, view fault codes, and manually reset alarms. The audible and visual alarm module distinguishes between two types of audible and visual prompts: minor warning and emergency stop. The servo dual-stage overtravel protection component consists of two redundant protection levels: a front-end electronic soft limit and a rear-end physical hard limit. The primary electronic soft limit is achieved by having built-in absolute encoders in the horizontal and vertical servo motors, which provide real-time feedback of the running pulse coordinates to the PLC. The PLC program presets safe travel thresholds for each axis. When the servo running coordinate reaches the threshold, the controller cuts off the servo torque output, and the servo smoothly decelerates and soft-stops. The secondary physical hard limit is achieved by mechanically fixed travel switches at both ends of the gantry column and at the left and right extreme positions of the horizontal slide. When the electronic soft limit fails or the encoder malfunctions, the metal body of the slide directly touches the travel switch contacts, forcibly cutting off the main power circuit of the entire machine and locking all servo axes with brakes to prevent overtravel from impacting the frame.

9. The gantry robot for an ultrasonic cleaning production line according to claim 2, characterized in that: The X-direction support beam is a U-shaped groove structure, and a top cover is provided at the top of the X-direction support beam. The top cover and the X-direction support beam are combined to form a groove box structure. The Z-direction lifting mechanism is located inside the groove box structure. The tops of the left column and the right column are respectively covered and encapsulated at both ends of the groove box structure.

10. The gantry robot control method for an ultrasonic cleaning production line according to claim 1, characterized in that: Using the gantry-type robotic arm for an ultrasonic cleaning production line as described in any one of claims 1 to 1, the following operating steps are included: S1, Equipment power-on self-test; PLC automatically collects all photoelectric switches, limit switches, and servo encoder signals, and performs sensor disconnection self-test; if the detection element is disconnected, the HMI pops up a window to indicate the corresponding point and prohibits the start of automatic cycle; S2, Basic Automated Handling; After self-checking and finding no faults, it receives the production line start signal and the robot arm executes the standard handling cycle; The servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grasping mechanism as a whole along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the basket position marking information on the cleaning tank of the ultrasonic cleaning production line, confirms that the basket hanging and grasping mechanism is above the basket position of the cleaning tank, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging and gripping mechanism to descend. The basket pressure sensing and detection component senses and detects the positioning information and real-time attitude of the basket tooling. If the positioning information of the basket tooling is detected and the real-time attitude is correct, the subsequent steps are executed. If the positioning information of the basket tooling is not detected, or the real-time attitude of the basket tooling is incorrect, a fault signal is triggered. The servo module of the Z-axis drive mechanism stops; the Y-axis drive mechanism moves slightly, and the basket hanging and gripping mechanism locks and grips the basket fixture. The servo module of the Z-axis drive mechanism rises; the servo translation module of the Y-axis drive mechanism drives the gantry bracket to move the Z-axis lifting mechanism and the basket hanging and grabbing mechanism in the opposite direction along the truss of the ultrasonic cleaning production line. The C-type photoelectric switch detects the unloading station marking information on the cleaning tank of the ultrasonic cleaning production line, and the servo translation module of the Y-axis drive mechanism stops. The servo module of the Z-axis drive mechanism drives the basket hanging gripping mechanism to descend, the Y-axis drive mechanism moves slightly, and the basket hanging gripping mechanism disengages and releases the basket tooling. The servo module of the Z-axis drive mechanism rises back to the origin, completing a single transfer cycle; S3, a three-level fault classification safety control logic; the PLC controller synchronously collects all feedback signals in real time from the basket positioning photoelectric detection component, the slot positioning and hook-off positioning C-type photoelectric switches, the lifting travel proximity switch, the upper / lower travel switch, the absolute encoders of each servo motor, and the basket pressure sensing detection component. Based on the severity of the fault risk, it classifies the logic into three levels of differentiated handling, outputs alarm signals at each level, and executes corresponding shutdown control actions: S301 Level 1 Fault: Slight abnormal posture of the workstation's gripping / placement, with no risk of mechanical impact; S302 Level 2 fault: Servo axis triggers electronic soft limit warning, posing a potential risk of overtravel impact; S303 Level 3 Fault: Slide block touches physical hard limit, high-risk fault due to emergency mechanical collision; S4, graded fault reset and recovery process: S401 Level 1 Fault Reset: After manual correction of the basket posture or mechanical manual alignment, and the restoration of the positioning signals of each detection element, the human-machine interface performs a warning reset and directly restarts the automatic cycle. S402 Level 2 Fault Reset: Manually reverse the servo axis to return to the software safe travel range, clear the travel warning alarm on the human-machine interface, and restore the automatic handling mode; S403 Level 3 Fault Reset: Power off to troubleshoot mechanical, servo encoder, and circuit faults. Manually disconnect the hard limit contact, power on the entire machine to complete sensor disconnection and full stroke self-test. Only after the self-test is passed can the equipment start automatic operation.

Images