A rolling method, system, device and medium based on a calibration block and a calibration needle

Abstract

The application provides a rolling edge method, system, device and medium based on a calibration block and a calibration needle, and belongs to the technical field of vehicle body manufacturing. The method comprises the following steps: acquiring a simulation position point corresponding to the calibration block, and controlling the calibration needle to align with the actual position point of the calibration block according to the simulation position point; generating a bias reference based on the position point; acquiring a user coordinate system origin point and a tool coordinate system origin point to generate an initial simulation trajectory under the outer plate contour line; after the production link simulation trajectory is configured according to the initial simulation trajectory under the rolling edge process parameters, the rolling edge off-line program is acquired by virtual running; the rolling edge off-line program is offset in the coordinate of the bias reference to obtain a production site program; and the target vehicle body is rolled according to the production site program. The application does not need to set a precise measuring device, and only needs to correct the deviation between the actual position of the rolling edge tool in the actual site and the simulation position of the simulation rolling edge tool according to the calibration needle and the calibration block, so that the accuracy of the vehicle body rolling edge is improved.

Description

Technical Field

[0001] This invention relates to the field of vehicle body manufacturing technology, and in particular to a rolling edge method, system, device and medium based on calibration blocks and calibration needles. Background Technology

[0002] Currently, robotic hemming technology is widely used in the manufacturing of important exterior body panels for automobiles, such as front and rear doors, front and rear hoods, roofs, wheel arches, and fenders. However, due to differences in vehicle shape and size, as well as variations in clamping methods, upper die mechanisms, roller head structures and sizes, and part hemming layouts and application scenarios, different hemming processes and paths are required. The quality of the hemming path directly affects the actual hemming effect in vehicle body manufacturing; therefore, there is an urgent need for hemming solutions that improve the accuracy of the hemming path.

[0003] Existing technologies use coordinate measuring machines (CMMs), laser measuring machines, or photographic acquisition equipment on-site to establish the machine tooling coordinate system on the hemming fixture. Then, by measuring and using a spatial coordinate system conversion plugin, the robot's vehicle body coordinate system relative to the machine tooling coordinate system is calculated. Next, the robot's position in the simulation software is adjusted using the robot's vehicle body coordinate system to ensure that the robot's position in the simulation environment matches its actual position on-site relative to the machine tooling coordinate system. Finally, an offline hemming program is exported for hemming. However, this existing technology requires external precision measuring equipment such as CMMs or other measuring devices, and software such as spatial coordinate system conversion plugins to implement the solution. Therefore, it cannot be implemented when measuring equipment is unavailable. Furthermore, the accuracy of the hemming path is strongly correlated with the measuring equipment; the accuracy of the measuring equipment greatly affects the accuracy of the vehicle body hemming. Therefore, when the measuring equipment's accuracy decreases due to aging or other reasons, the accuracy of the vehicle body hemming will be significantly reduced. Summary of the Invention

[0004] The present invention aims to provide a rolling hem method, system, device and medium based on calibration blocks and calibration needles to solve the above-mentioned technical problems. It eliminates the need for precision measuring equipment and can correct the deviation between the actual position of the rolling hem fixture in the actual field and the simulated position of the simulated rolling hem fixture based solely on the calibration needle and calibration block, thereby improving the accuracy of vehicle body rolling hem.

[0005] To address the aforementioned technical problems, this invention provides a hemming method based on a calibration block and a calibration needle, comprising the following steps: Obtain the simulated position point corresponding to the calibration block on the cap rolling edge tool, and control the calibration point of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point; An offset reference is generated based on the simulated location point and the actual location point; Obtain the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory on the preset outer plate contour line based on the origin of the user coordinate system and the origin of the tool coordinate system. Based on the initial simulation trajectory, the production process simulation trajectory is obtained by configuring the preset hemming process parameters, and the offline hemming program is obtained by virtual operation based on the production process simulation trajectory. The offline hemming program is offset under the offset reference to obtain the production site program; The target car body is rolled according to the aforementioned production site procedures.

[0006] The above scheme first obtains the simulated position point corresponding to the calibration block on the hemming fixture, and then controls the calibration pin of the robot's rolling tool to align with the corresponding calibration block to obtain the actual position point. Based on the simulated and actual position points, without the need for precision measuring equipment, an offset reference is generated that reflects the difference between the actual position of the hemming fixture on-site and the position in the simulation environment. In the simulation environment, the above scheme obtains the origin of the user coordinate system and the origin of the tool coordinate system, generates an initial simulation trajectory under the preset outer panel contour line, configures preset hemming process parameters to obtain the production simulation trajectory, and then obtains the offline hemming program through virtual operation. Under the offset reference, the offline hemming program is used to compensate for the positional deviation between the simulation environment and the on-site environment to obtain the production site program, reducing the deviation between the simulation environment and the actual on-site hemming, thereby improving the accuracy of the body hemming. Furthermore, the above process of first exporting the offline program and then offsetting the coordinates allows the simulation trajectory generation and deviation correction to be independent of each other. Deviation correction relies solely on the calibration pin on the robot and the calibration block on the fixture, eliminating the need for external precision measuring equipment to correct the positional deviation between the simulation environment and the actual site, reducing dependence on measuring equipment and improving the accuracy of body hemming.

[0007] Further, the step of obtaining the simulated position point corresponding to the calibration block on the hair cap rolling edge fixture, and controlling the calibration pin of the robot rolling head tool to align with the calibration block based on the simulated position point to obtain the actual position point includes: obtaining the simulated position point corresponding to the center of the calibration block on the hair cap rolling edge fixture; selecting a calibration simulation position point based on the simulated position point under the conditions of a preset calibration quantity and a preset distance; and controlling the calibration pin of the robot rolling head tool to align with the center of the calibration block corresponding to the calibration simulation position point to obtain the actual position point.

[0008] The above scheme uses the center of the calibration block as a positional reference, providing a clear and repeatable alignment target. This allows the calibration needle to accurately reach the designated position, ensuring the precision of the actual position point. This precision relies on the mechanical contact alignment between the calibration needle and the calibration block, without requiring any external precision measuring equipment. Furthermore, the scheme selects calibration simulation position points under preset calibration quantity and distance conditions to ensure the representativeness of the selected position points. This allows the offset reference generated based on the calibration simulation position points to effectively correct the overall deviation between the actual position of the hemming fixture in the actual field and the simulated position of the simulated hemming fixture, rather than merely reflecting local positional differences. This improves the accuracy of the offset reference and thus enhances the accuracy of the vehicle body hemming.

[0009] Further, the step of obtaining the origin of the user coordinate system and the origin of the tool coordinate system, and generating an initial simulation trajectory based on the origin of the user coordinate system and the origin of the tool coordinate system along a preset outer plate contour line, includes: obtaining the center point of the robot base and using the center point of the robot base as the origin of the user coordinate system; obtaining the contact point between the robot rolling tool and the outer plate and using the contact point as the origin of the tool coordinate system; generating an original simulation trajectory based on the origin of the user coordinate system and the origin of the tool coordinate system at a preset pitch; obtaining shape features based on the preset outer plate contour line, and performing trajectory point addition and subtraction processing on the original simulation trajectory based on the shape features to obtain a controllable simulation trajectory; performing collision interference checks on the controllable simulation trajectory to obtain interference trajectory points of the interference rolling tool; adding motion transition points based on the interference trajectory points to obtain transition trajectory points, and obtaining a non-interference simulation trajectory based on the transition trajectory points and the controllable simulation trajectory; performing reachability checks on the non-interference simulation trajectory within a preset robot working range to obtain out-of-range trajectory points, and adjusting the non-interference simulation trajectory based on the out-of-range trajectory points to generate an initial simulation trajectory.

[0010] The above scheme first obtains the center point of the robot base as the origin of the user coordinate system, and then obtains the contact point between the robot's rolling tool and the outer plate as the origin of the tool coordinate system. In this way, a spatial reference system corresponding to the robot on site is established in the simulation environment. Based on the above coordinate system origin, the original simulation trajectory is generated at a preset pitch. Then, according to the shape characteristics of the preset outer plate contour, the original simulation trajectory is processed by adding or subtracting trajectory points to obtain a controllable simulation trajectory. The above process enables the obtained controllable simulation trajectory to accurately reflect the geometric change characteristics of the outer plate contour, thereby improving the matching degree with the actual vehicle body outer plate. Furthermore, the above scheme performs collision interference checks based on controllable simulation trajectories. After identifying interference trajectory points that may interfere with the hemming tooling, motion transition points are added based on the interference trajectory points to obtain transition trajectory points, thus forming an interference-free simulation trajectory. Subsequently, an accessibility check is performed on the interference-free simulation trajectory to identify out-of-range trajectory points that exceed the robot's working range. Based on this, an initial simulation trajectory is generated, thereby ensuring the accessibility of the generated offline hemming program. This ensures that the production site program obtained after offset reference correction can accurately match the actual position of the on-site tooling while also ensuring the accessibility of controlling the hemming process, thereby improving the accuracy of vehicle body hemming.

[0011] Furthermore, the step of obtaining shape features based on the preset outer panel outline and performing trajectory point addition / reduction processing on the original simulation trajectory based on the shape features to obtain a controllable simulation trajectory includes: obtaining shape features based on the preset outer panel outline and obtaining the corner positions and arc positions of the original simulation trajectory based on the shape features; adding trajectory points to the trajectory segments corresponding to the original simulation trajectory based on the corner positions and arc positions to obtain an initial controllable simulation trajectory; and adjusting the direction of all trajectory points in the initial controllable simulation trajectory to a preset direction to obtain a controllable simulation trajectory.

[0012] The above scheme first obtains the shape features based on the preset outer panel outline, and then identifies the corner and arc positions in the original simulation trajectory based on these shape features. Trajectory points are then added to the corresponding trajectory segments of the original simulation trajectory at the corner and arc positions to obtain an initial controllable simulation trajectory. Subsequently, the directions of all trajectory points in the initial controllable simulation trajectory are adjusted to preset directions to obtain a controllable simulation trajectory, ensuring the consistency of the robot's motion posture. This process adds trajectory points to the trajectory segments at corner and arc positions where the shape changes significantly on the outer panel outline, making the trajectory points in the corner and arc regions of the obtained initial controllable simulation trajectory denser. This allows the obtained controllable simulation trajectory to more closely fit the outer panel outline at points of drastic shape change, improving the accuracy of the controllable simulation trajectory. This, in turn, enables the generation of a production site program that accurately matches the geometric features of the actual vehicle body outer panel after virtual operation and offset benchmark correction, thereby improving the accuracy of the vehicle body hemming.

[0013] Further, the step of configuring the initial simulation trajectory under preset hemming process parameters to obtain a production process simulation trajectory, and then performing virtual operation based on the production process simulation trajectory to obtain an offline hemming program, includes: configuring the initial simulation trajectory under preset hemming process parameters to obtain an initial production process simulation trajectory; adding path transition process points to the initial production process simulation trajectory to obtain a production process simulation trajectory; and performing virtual operation based on the production process simulation trajectory to obtain an offline hemming program.

[0014] The above scheme first configures the initial simulation trajectory under preset hemming process parameters to obtain an initial production process simulation trajectory that meets the requirements of hemming operations. Then, it adds path transition process points to the initial production process simulation trajectory to obtain a production process simulation trajectory, making the subsequent body hemming process path transition smoother and improving the continuity of the production process simulation trajectory. Finally, it performs virtual operation based on the production process simulation trajectory to verify the executability of the trajectory. This ensures that the obtained offline hemming program has eliminated potential problems such as sudden path changes and unreachable postures before being imported into the actual site. This allows the subsequent offset of the offline hemming program coordinates using an offset reference to obtain a production site program that accurately matches the actual position of the tooling on site, eliminating the need for repeated debugging and correction on the production line and improving the accuracy of body hemming.

[0015] Furthermore, the step of obtaining the offline rolling edge program by performing virtual operation based on the production process simulation trajectory includes: running the production process simulation trajectory in a preset virtual rolling edge environment, obtaining the simulation operation status, and obtaining the alarm cancellation offline program based on the simulation operation status; and performing configuration information improvement processing based on the alarm cancellation offline program to obtain the rolling edge offline program.

[0016] The above solution places the production process simulation trajectory in a virtual rolling environment. Based on the obtained simulation running status, it can provide feedback and eliminate alarm problems in the trajectory. Subsequently, the configuration information of the alarm elimination offline program is improved, and the rolling offline program is exported. The rolling offline program obtained in the above process has eliminated problems that may cause operation interruption, such as path conflict and unreachable posture, before being imported into the field. This ensures that the subsequent rolling process can run smoothly without errors and has high executability. Unlike traditional solutions, it does not require a lot of on-site inspection and correction of the program content. This solution only needs to combine the offset reference to perform coordinate offset to obtain the production field program adapted to the on-site tooling to roll the target car body, thereby improving the accuracy of car body rolling.

[0017] This invention also provides a hemming system based on a calibration block and a calibration needle, used to implement any of the hemming methods based on calibration blocks and calibration needles described above, comprising: a position point acquisition module, used to acquire the simulated position point corresponding to the calibration block on the hemming fixture, and control the calibration needle of the robot hemming tool to align with the calibration block according to the simulated position point to obtain the actual position point; an offset reference generation module, used to generate an offset reference based on the simulated position point and the actual position point; a simulation trajectory generation module, used to acquire the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory under a preset outer panel contour line according to the origin of the user coordinate system and the origin of the tool coordinate system; an offline hemming program acquisition module, used to configure the initial simulation trajectory under preset hemming process parameters to obtain a production process simulation trajectory, and perform virtual operation based on the production process simulation trajectory to obtain an offline hemming program; an offset correction module, used to offset the offline hemming program under the offset reference to obtain a production site program; and a hemming module, used to hem the target car body according to the production site program.

[0018] Furthermore, the position point acquisition module is specifically used to: acquire the simulated position point corresponding to the calibration block on the hair cap rolling edge fixture, and control the calibration pin of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point, including: acquiring the simulated position point corresponding to the center of the calibration block on the hair cap rolling edge fixture; selecting a calibration simulation position point based on the simulated position point under the conditions of a preset calibration quantity and a preset distance; and controlling the calibration pin of the robot rolling head tool to align with the center of the calibration block corresponding to the calibration simulation position point to obtain the actual position point.

[0019] The present invention also provides a terminal device, including a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, it implements any of the above-described hemming methods based on calibration blocks and calibration needles.

[0020] The present invention also provides a computer-readable storage medium, comprising: a stored computer program, wherein, when the computer program is executed, it controls the device in which the computer-readable storage medium is located to perform any of the above-described edge-rolling methods based on calibration blocks and calibration needles.

[0021] The above solution eliminates the need for precision measuring equipment. It uses the simulated position points corresponding to the calibration blocks on the hemming fixture and controls the calibration pin of the robot's rolling tool to align with the corresponding calibration blocks to obtain the actual position points. Based on these simulated and actual position points, an offset reference is generated that reflects the difference between the actual position of the hemming fixture on-site and in the simulation environment. In the simulation environment, the solution obtains the origins of the user coordinate system and the tool coordinate system, generates an initial simulation trajectory along the preset outer panel contour line, and obtains the production simulation trajectory after configuring preset hemming process parameters. The offline hemming program is then obtained through virtual operation. This offline program, under the offset reference, compensates for the positional deviation between the simulation environment and the actual on-site environment. The resulting production on-site program reduces the deviation between the simulation environment and the actual on-site hemming, thereby improving the accuracy of the body hemming. Furthermore, the above process of first exporting the offline program and then offsetting the coordinates allows the simulation trajectory generation and deviation correction processes to be independent of each other. Deviation correction can be achieved solely by the calibration needle on the robot and the calibration block on the tooling, eliminating the need for external precision measuring equipment to correct the positional deviation between the simulation environment and the actual site. This reduces dependence on measuring equipment and improves the accuracy of the vehicle body hemming. Attached Figure Description

[0022] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 This is a flowchart illustrating the implementation of a rolling edge method based on a calibration block and a calibration needle, according to an embodiment of the present invention. Figure 2 A schematic diagram of the position of the calibration block on the cap rolling tooling for a rolling method based on calibration block and calibration needle provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of a calibration pin aligned with a calibration block, provided by an embodiment of the present invention, using a rolling edge method based on a calibration block and a calibration pin. Figure 4 This is a schematic diagram of a rolling edge system architecture based on a calibration block and a calibration needle, provided in an embodiment of the present invention; In the diagram: 1. Hair cap edge rolling fixture; 2. First calibration block; 3. Second calibration block; 4. Third calibration block; 5. Fourth calibration block; 6. Fifth calibration block; 7. Sixth calibration block; 8. Calibration block; 9. Calibration needle. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0026] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0027] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0028] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0029] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0030] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0031] Please see Figure 1 This embodiment provides a hemming method based on a calibration block and a calibration needle, including the following steps: Step S1: Obtain the simulated position point corresponding to the calibration block on the cap rolling edge fixture, and control the calibration point of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point; Step S2: Generate an offset reference based on the simulated position point and the actual position point; Step S3: Obtain the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory on the preset outer plate contour line based on the origin of the user coordinate system and the origin of the tool coordinate system; Step S4: Configure the initial simulation trajectory under the preset hemming process parameters to obtain the production process simulation trajectory, and perform virtual operation based on the production process simulation trajectory to obtain the offline hemming program; Step S5: The offline hemming program is offset by coordinates under the offset reference to obtain the production site program; Step S6: Roll the edge of the target car body according to the production site procedure.

[0032] The above embodiment first obtains the simulated position point corresponding to the calibration block on the hemming fixture, and controls the calibration pin of the robot's rolling tool to align with the corresponding calibration block to obtain the actual position point. Then, based on the simulated position point and the actual position point, without setting up precision measuring equipment, an offset reference reflecting the position difference between the actual position of the hemming fixture on site and the simulated environment is generated. In the simulation environment, the above embodiment obtains the origin of the user coordinate system and the origin of the tool coordinate system, generates an initial simulation trajectory under the preset outer panel contour line, configures preset hemming process parameters to obtain the production simulation trajectory, and then obtains the offline hemming program through virtual operation. Under the offset reference, the above offline hemming program compensates for the positional deviation between the simulation environment and the actual site environment to obtain the production site program, reducing the deviation between the simulation environment and the actual site hemming, thereby improving the accuracy of body hemming. Moreover, the above process first exports the offline program and then performs coordinate offset, which makes the simulation trajectory generation and deviation correction independent of each other. The deviation correction is achieved only by the calibration pin on the robot and the calibration block on the fixture, without the need for external precision measuring equipment to correct the positional deviation between the simulation environment and the actual site, reducing dependence on measuring equipment and improving the accuracy of body hemming.

[0033] In one embodiment, the calibration block mounted on the cap rolling edge tooling is as follows: Figure 2 As shown, Figure 2 The device includes a tooling 1 for rolling the edge of the membrane cap. Six calibration blocks are evenly distributed around the outer periphery of the tooling 1, including a first calibration block 2, a second calibration block 3, a third calibration block 4, a fourth calibration block 5, a fifth calibration block 6, and a sixth calibration block 7. All of the calibration blocks are stainless steel cuboids of 50mm × 50mm × 10mm.

[0034] Please see as follows Figure 3 The diagram shown illustrates the alignment of the calibration pin with the calibration block, including calibration block 8 and calibration pin 9. Each calibration block has a 0.1mm deep, 45° taper crosshair on its upper surface, and is mounted to the cap edge-rolling fixture 1 via two locating pins. Furthermore, as... Figure 3 As shown, the center point of the cross on the calibration block 8 serves as the calibration point for the program. The calibration needle 9 is mounted on the rolling head tool at the end of the robot's six axes. The calibration needle 9 is a stainless steel cylindrical body with a diameter of 6mm and a length of 130mm. One end is pointed, and the other end has an M5 external thread. It is used to mount on the rolling head tool that the robot grips. One end of the rolling head tool has an M5 internal thread. When controlling the calibration needle to align with the calibration block, it is necessary to ensure that the robot's six axes and the orientation of the calibration needle are completely perpendicular to the calibration block and aligned with the center point of the calibration block.

[0035] In one embodiment, the position of the center point of the cross on the calibration block of the cover rolling tool is obtained as the corresponding simulation position point. The actual position point is obtained by aligning the calibration point of the control robot rolling tool with the center point of the calibration block corresponding to the simulation position point. Then, an offset reference is generated based on the simulation position point and the actual position point. This offset reference is used to offset the coordinates of the offline rolling program obtained in the simulation environment under the offset reference to obtain the production site program for rolling the target car body.

[0036] Further, the step of obtaining the simulated position point corresponding to the calibration block on the hair cap rolling edge fixture, and controlling the calibration pin of the robot rolling head tool to align with the calibration block based on the simulated position point to obtain the actual position point includes: obtaining the simulated position point corresponding to the center of the calibration block on the hair cap rolling edge fixture; selecting a calibration simulation position point based on the simulated position point under the conditions of a preset calibration quantity and a preset distance; and controlling the calibration pin of the robot rolling head tool to align with the center of the calibration block corresponding to the calibration simulation position point to obtain the actual position point.

[0037] The above embodiments use the center of the calibration block as a position reference, providing a clear and repeatable alignment target. This allows the calibration needle to accurately reach the designated position, ensuring the accuracy of the actual position point. This accuracy relies on the mechanical contact alignment between the calibration needle and the calibration block, without requiring any external precision measuring equipment. Furthermore, the above embodiments select calibration simulation position points under preset calibration quantity and preset distance conditions to ensure the representativeness of the selected position points. This allows the offset reference generated based on the calibration simulation position points to effectively correct the overall deviation between the actual position of the hemming fixture in the actual field and the simulated position of the simulated hemming fixture, rather than merely reflecting local positional differences. This improves the accuracy of the offset reference and thus enhances the accuracy of the vehicle body hemming.

[0038] In one embodiment, based on the simulation position points of each calibration block, under the conditions of a preset calibration quantity of 3 and a preset distance, calibration simulation position points corresponding to 3 calibration blocks that are far apart are obtained. Specifically, the first calibration block 2, the third calibration block 4 and the fifth calibration block 6 are grouped together, and the second calibration block 3, the fourth calibration block 5 and the sixth calibration block 7 are grouped together.

[0039] Taking the first calibration block 2, the third calibration block 4, and the fifth calibration block 6 as an example, in the simulation environment, the crosshair center positions of the first calibration block 2, the third calibration block 4, and the fifth calibration block 6 are recorded as calibration simulation position points [P1;P2;P3] through the teach pendant. Among them, P1 is the calibration simulation position point corresponding to the first calibration block 2, P2 is the calibration simulation position point corresponding to the third calibration block 4, and P3 is the calibration simulation position point corresponding to the fifth calibration block 6. Each calibration simulation position point includes three-dimensional position coordinate information and attitude information. The attitude information may include the yaw angle of rotation around the Z-axis of the three-dimensional position coordinate, the pitch angle of rotation around the Y-axis of the three-dimensional position coordinate, and the roll angle of rotation around the X-axis of the three-dimensional position coordinate.

[0040] In the actual production environment, the robot is precisely aligned with the positions of the crosshair centers of the three calibration blocks corresponding to the calibration simulation position points, i.e., the positions of the crosshair centers of the first calibration block 2, the third calibration block 4, and the fifth calibration block 6, and the actual position points [Q1;Q2;Q3] are recorded. Among them, Q1 is the actual position point corresponding to the first calibration block 2, Q2 is the actual position point corresponding to the third calibration block 4, and Q3 is the actual position point corresponding to the fifth calibration block 6. Each actual position point includes three-dimensional position coordinate information and attitude information. The attitude information may include the yaw angle of rotation around the Z-axis of the three-dimensional position coordinates, the pitch angle of rotation around the Y-axis of the three-dimensional position coordinates, and the roll angle of rotation around the X-axis of the three-dimensional position coordinates.

[0041] In one embodiment, the position information of the calibrated simulation position points [P1;P2;P3] based on the simulation position points is compared with the position information of the actual position points [Q1;Q2;Q3] to determine the spatial error between the simulation environment and the actual production environment. That is, a relative coordinate transformation relationship such as offset is formed in the robot space coordinate system to generate an offset reference.

[0042] Further, the step of obtaining the origin of the user coordinate system and the origin of the tool coordinate system, and generating an initial simulation trajectory based on the origin of the user coordinate system and the origin of the tool coordinate system along a preset outer plate contour line, includes: obtaining the center point of the robot base and using the center point of the robot base as the origin of the user coordinate system; obtaining the contact point between the robot rolling tool and the outer plate and using the contact point as the origin of the tool coordinate system; generating an original simulation trajectory based on the origin of the user coordinate system and the origin of the tool coordinate system at a preset pitch; obtaining shape features based on the preset outer plate contour line, and performing trajectory point addition and subtraction processing on the original simulation trajectory based on the shape features to obtain a controllable simulation trajectory; performing collision interference checks on the controllable simulation trajectory to obtain interference trajectory points of the interference rolling tool; adding motion transition points based on the interference trajectory points to obtain transition trajectory points, and obtaining a non-interference simulation trajectory based on the transition trajectory points and the controllable simulation trajectory; performing reachability checks on the non-interference simulation trajectory within a preset robot working range to obtain out-of-range trajectory points, and adjusting the non-interference simulation trajectory based on the out-of-range trajectory points to generate an initial simulation trajectory.

[0043] The above embodiment first obtains the center point of the robot base as the origin of the user coordinate system, and then obtains the contact point between the robot rolling tool and the outer plate as the origin of the tool coordinate system. In this way, a spatial reference system corresponding to the robot on site is established in the simulation environment. Based on the above coordinate system origin, the original simulation trajectory is generated at a preset pitch. Then, according to the shape characteristics of the preset outer plate contour, the original simulation trajectory is processed by adding or subtracting trajectory points to obtain a controllable simulation trajectory. The above process enables the obtained controllable simulation trajectory to accurately reflect the geometric change characteristics of the outer plate contour, thereby improving the matching degree with the actual vehicle body outer plate. Furthermore, the above embodiments perform collision interference checks based on controllable simulation trajectories. After identifying interference trajectory points that may interfere with the hemming tooling, motion transition points are added based on the interference trajectory points to obtain transition trajectory points, thus forming an interference-free simulation trajectory. Subsequently, an accessibility check is performed on the interference-free simulation trajectory to identify out-of-range trajectory points that exceed the robot's working range. Based on this, an initial simulation trajectory is generated, thereby ensuring the accessibility of the generated offline hemming program. This ensures that the production site program obtained after offset reference correction can accurately match the actual position of the on-site tooling while also ensuring the accessibility of controlling the hemming process, thereby improving the accuracy of vehicle body hemming.

[0044] Furthermore, the step of obtaining shape features based on the preset outer panel outline and performing trajectory point addition / reduction processing on the original simulation trajectory based on the shape features to obtain a controllable simulation trajectory includes: obtaining shape features based on the preset outer panel outline and obtaining the corner positions and arc positions of the original simulation trajectory based on the shape features; adding trajectory points to the trajectory segments corresponding to the original simulation trajectory based on the corner positions and arc positions to obtain an initial controllable simulation trajectory; and adjusting the direction of all trajectory points in the initial controllable simulation trajectory to a preset direction to obtain a controllable simulation trajectory.

[0045] In the above embodiment, the shape features are first obtained based on the preset outer panel outline. Then, the corner and arc positions in the original simulation trajectory are identified based on the shape features. Trajectory points are added to the trajectory segments corresponding to the corner and arc positions in the original simulation trajectory to obtain an initial controllable simulation trajectory. Subsequently, the direction of all trajectory points in the initial controllable simulation trajectory is adjusted to a preset direction to obtain a controllable simulation trajectory, ensuring the consistency of the robot's motion posture. The above process adds trajectory points to the trajectory segments of corner and arc positions where the shape changes significantly on the outer panel outline, making the trajectory points of the obtained initial controllable simulation trajectory in the corner and arc regions denser. This allows the obtained controllable simulation trajectory to fit the outer panel outline more closely in areas of drastic shape changes, improving the accuracy of the controllable simulation trajectory. This, in turn, enables the generation of a production site program that accurately matches the geometric features of the actual vehicle body outer panel after virtual operation and offset benchmark correction, thereby improving the accuracy of the vehicle body hemming.

[0046] In one embodiment, ROBCAD simulation software is used to complete controllable simulation trajectories such as pre-compression simulation trajectory, main pressure simulation trajectory, transportation simulation trajectory and switching simulation trajectory in different virtual simulation environments. Then, the controllable simulation trajectories are subjected to collision interference checks and accessibility checks in the virtual environment to reduce the collision risk during on-site debugging.

[0047] In the above embodiment, the center point of the robot base is used as the origin of the user coordinate system; the contact point between the robot's rolling tool and the outer plate is obtained, and this contact point is defined as the origin of the robot's tool coordinate system, with the Y-axis of the tool coordinate system (ToolCenter Position, TCP) aligned with the central axis of the roller. It should be noted that different rolling head dimensions correspond to different TCPs; that is, different TCPs need to be set when generating pre-pressure, main pressure, and transport trajectories for the same robot. A series of trajectory points are generated using simulation software according to the set pitch to obtain the original simulation trajectory. After selecting the outer plate contour line, the corresponding shape features are obtained, and the trajectory points of the original simulation trajectory are appropriately added or subtracted. Trajectory points are added to the corner and arc positions of the original simulation trajectory to allow for more constraints on the trajectory, making the robot's motion position accuracy controllable, thus obtaining the initial controllable simulation trajectory. The directions of all trajectory points in the initial controllable simulation trajectory are adjusted to preset directions, ensuring that all trajectory points have the same direction, allowing for reasonable segmentation of the controllable simulation trajectory.

[0048] Subsequently, collision interference checks are performed based on the controllable simulation trajectory to obtain the interference trajectory points of the interference hemming fixture. Motion transition points are added to these interference trajectory points to obtain transition trajectory points. Based on the transition trajectory points and the controllable simulation trajectory, an interference-free simulation trajectory is obtained. During this process, the robot's posture is adjusted to correspond to the trajectory points of the interference hemming fixture and the workpiece, and motion transition points are added to resolve the interference. Within a preset robot working range, an accessibility check is performed on the interference-free simulation trajectory to obtain out-of-range trajectory points. Based on these out-of-range trajectory points, the interference-free simulation trajectory is adjusted to generate an initial simulation trajectory, ensuring that all trajectory points are within the robot's working range and that the robot's joint axes do not reach their limits or exhibit singularities.

[0049] Further, the step of configuring the initial simulation trajectory under preset hemming process parameters to obtain a production process simulation trajectory, and then performing virtual operation based on the production process simulation trajectory to obtain an offline hemming program, includes: configuring the initial simulation trajectory under preset hemming process parameters to obtain an initial production process simulation trajectory; adding path transition process points to the initial production process simulation trajectory to obtain a production process simulation trajectory; and performing virtual operation based on the production process simulation trajectory to obtain an offline hemming program.

[0050] The above embodiment first configures the initial simulation trajectory under preset hemming process parameters to obtain an initial production process simulation trajectory that meets the requirements of hemming operation; then, it adds path transition process points to the initial production process simulation trajectory to obtain a production process simulation trajectory, making the subsequent body hemming process path transition smoother and improving the continuity of the production process simulation trajectory; finally, it performs virtual operation based on the production process simulation trajectory to verify the executability of the trajectory, so that the obtained offline hemming program has eliminated potential problems such as sudden path changes and unreachable posture before being imported into the actual site, so that after offsetting the coordinates of the offline hemming program by the offset reference, an accurate production site program matching the actual position of the tooling is obtained, without the need for repeated debugging and correction on the production line, thus improving the accuracy of body hemming.

[0051] In one embodiment, an initial production simulation trajectory is obtained by configuring appropriate hemming process parameters on the initial simulation trajectory. These hemming process parameters include hemming angle, hemming speed, joint curvature, and motion modes such as LIN linear motion or PTP joint motion. Furthermore, a production simulation trajectory is obtained by adding path transition process points to the initial production simulation trajectory. These path transition process points include an approach point, an asymptotic point, and a pressure-free contact point. The approach point controls the robot tool to slowly and smoothly approach the workpiece from a safe distance. The asymptotic point controls the robot tool to slowly and smoothly leave the workpiece after completing the task. The pressure-free contact point controls the robot to maintain positional contact without applying additional pressure when contacting the workpiece, thus preventing workpiece deformation.

[0052] Furthermore, the step of obtaining the offline rolling edge program by performing virtual operation based on the production process simulation trajectory includes: running the production process simulation trajectory in a preset virtual rolling edge environment, obtaining the simulation operation status, and obtaining the alarm cancellation offline program based on the simulation operation status; and performing configuration information improvement processing based on the alarm cancellation offline program to obtain the rolling edge offline program.

[0053] The above embodiment places the production process simulation trajectory in the rolling virtual environment and can provide feedback and eliminate alarm problems in the trajectory based on the obtained simulation running status. Then, the configuration information of the alarm elimination offline program is improved and the rolling offline program is exported. The rolling offline program obtained in the above process has eliminated problems that may cause operation interruption, such as path conflict and unreachable posture, before being imported into the field, so that the subsequent rolling process can run smoothly without errors and has high executability. Unlike traditional solutions, it does not require a lot of on-site investigation and correction of the program content. In this embodiment, only the coordinate offset is combined with the offset reference to obtain the production field program adapted to the on-site tooling to roll the target car body, thereby improving the accuracy of car body rolling.

[0054] In one embodiment, the robot runs a simulated production trajectory in a virtual edge-rolling environment to obtain the simulation running status. If the simulation runs smoothly without errors, the simulated production trajectory is usable. If an alarm occurs during the simulation, it needs to be cleared. After the alarm is cleared, the alarm clearing offline program is exported from the roboguide software. The configuration information of the alarm clearing offline program is improved, specifically by improving the configuration information including trajectory point velocity values, CNT values, and PR offset values, to obtain the edge-rolling offline program. It should be noted that the above information improvement process can be completed on-site, but since it requires manual improvement of the configuration information for each trajectory point, it will result in a huge workload, so on-site implementation is not recommended.

[0055] In one embodiment, after obtaining the offline hemming program, the offline hemming program is combined with an offset reference to perform coordinate offset conversion and transform it into a production site program, so as to eliminate the positional deviation of the hemming tooling relative to the robot user coordinates in the actual environment and the simulation environment. The finally obtained production site program is imported into the robot control cabinet in the production site. The robot calls the corresponding production site program as needed according to the set drive file to run and hem the target car body.

[0056] Please see Figure 4 This embodiment also provides a hemming system based on calibration blocks and calibration needles, used to implement any of the hemming methods based on calibration blocks and calibration needles as described above, including: a position point acquisition module, used to acquire the simulated position point corresponding to the calibration block on the hemming fixture, and control the calibration needle of the robot hemming tool to align with the calibration block according to the simulated position point to obtain the actual position point; an offset reference generation module, used to generate an offset reference based on the simulated position point and the actual position point; a simulation trajectory generation module, used to acquire the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory under a preset outer panel contour line according to the origin of the user coordinate system and the origin of the tool coordinate system; an offline hemming program acquisition module, used to configure under preset hemming process parameters according to the initial simulation trajectory to obtain a production process simulation trajectory, and perform virtual operation based on the production process simulation trajectory to obtain an offline hemming program; an offset correction module, used to offset the offline hemming program under the offset reference to obtain a production site program; and a hemming module, used to hem the target car body according to the production site program.

[0057] Furthermore, the position point acquisition module is specifically used to: acquire the simulated position point corresponding to the calibration block on the hair cap rolling edge fixture, and control the calibration pin of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point, including: acquiring the simulated position point corresponding to the center of the calibration block on the hair cap rolling edge fixture; selecting a calibration simulation position point based on the simulated position point under the conditions of a preset calibration quantity and a preset distance; and controlling the calibration pin of the robot rolling head tool to align with the center of the calibration block corresponding to the calibration simulation position point to obtain the actual position point.

[0058] It is understood that the above system embodiments correspond to the method embodiments of the present invention, and can implement the hemming method based on calibration block and calibration needle provided by any of the above method embodiments of the present invention.

[0059] It should be noted that the system embodiments described above are merely illustrative, and some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Furthermore, in the accompanying drawings of the system embodiments provided by this invention, the connection relationships between modules indicate that they have communication connections, which can be specifically implemented as one or more communication buses or signal lines. Those skilled in the art can understand and implement this without any creative effort.

[0060] The present invention also provides a terminal device, including a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, it implements any of the above-described hemming methods based on calibration blocks and calibration needles.

[0061] The terminal device may be a desktop computer, laptop, handheld computer, or cloud server, etc. The terminal device may include, but is not limited to, a processor and a memory.

[0062] The processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor. The processor is the control center of the terminal device, connecting all parts of the terminal device via various interfaces and lines.

[0063] The present invention also provides a computer-readable storage medium, comprising: a stored computer program, wherein, when the computer program is executed, it controls the device in which the computer-readable storage medium is located to perform any of the above-described edge-rolling methods based on calibration blocks and calibration needles.

[0064] The above embodiments do not require the use of precision measuring equipment. They rely on the simulated position points corresponding to the calibration blocks on the hemming fixture, and control the calibration pin of the robot's rolling tool to align with the corresponding calibration blocks to obtain the actual position points. Based on these simulated and actual position points, an offset reference is generated that reflects the difference between the actual position of the hemming fixture on-site and in the simulation environment. In the simulation environment, the above embodiments obtain the origin of the user coordinate system and the origin of the tool coordinate system, generate an initial simulation trajectory under the preset outer panel contour line, and obtain the production simulation trajectory after configuring preset hemming process parameters. The offline hemming program is then obtained through virtual operation. This offline hemming program, under the offset reference, compensates for the positional deviation between the simulation environment and the actual on-site environment. The resulting production on-site program reduces the deviation between the simulation environment and the actual on-site hemming, thereby improving the accuracy of the body hemming. Furthermore, the above process of first exporting the offline program and then offsetting the coordinates allows the simulation trajectory generation and deviation correction processes to be independent of each other. Deviation correction can be achieved solely by the calibration needle on the robot and the calibration block on the tooling, eliminating the need for external precision measuring equipment to correct the positional deviation between the simulation environment and the actual site. This reduces dependence on measuring equipment and improves the accuracy of the vehicle body hemming.

[0065] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A hemming method based on a calibration block and a calibration needle, characterized in that, Includes the following steps: Obtain the simulated position point corresponding to the calibration block on the cap rolling edge tool, and control the calibration point of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point; An offset reference is generated based on the simulated location point and the actual location point; Obtain the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory on the preset outer plate contour line based on the origin of the user coordinate system and the origin of the tool coordinate system. Based on the initial simulation trajectory, the production process simulation trajectory is obtained by configuring the preset hemming process parameters, and the offline hemming program is obtained by virtual operation based on the production process simulation trajectory. The offline hemming program is offset under the offset reference to obtain the production site program; The target car body is rolled according to the aforementioned production site procedures.

2. The hemming method based on a calibration block and a calibration needle as described in claim 1, characterized in that, The step of obtaining the simulated position point corresponding to the calibration block on the cap rolling edge fixture, and controlling the calibration point of the robot rolling head tool to align with the calibration block based on the simulated position point to obtain the actual position point, includes: Obtain the simulation position point corresponding to the center of the calibration block on the cap rolling edge fixture; Based on the simulation location points, calibration simulation location points are selected under the conditions of preset calibration quantity and preset distance; Based on the center of the calibration block corresponding to the calibration simulation position point, the calibration pin of the robot rolling tool is aligned to obtain the actual position point.

3. The hemming method based on a calibration block and a calibration needle as described in claim 2, characterized in that, The step of obtaining the origin of the user coordinate system and the origin of the tool coordinate system, and generating an initial simulation trajectory on the preset outer plate contour line based on the origin of the user coordinate system and the origin of the tool coordinate system, includes: Obtain the center point of the robot base and use the center point of the robot base as the origin of the user coordinate system; Obtain the contact point between the robot's rolling head tool and the outer plate, and use the contact point as the origin of the tool's coordinate system; The original simulation trajectory is generated based on the origin of the user coordinate system and the origin of the tool coordinate system at a preset pitch. Based on the preset outer panel outline, shape features are obtained, and the original simulation trajectory is processed by adding or subtracting trajectory points according to the shape features to obtain a controllable simulation trajectory. Based on the controllable simulation trajectory, collision interference inspection is performed to obtain the interference trajectory points of the interference rolling tool; Based on the interference trajectory points, motion transition points are added to obtain transition trajectory points, and based on the transition trajectory points and the controllable simulation trajectory, an interference-free simulation trajectory is obtained; Within the preset robot working range, the reachability check of the non-interference simulation trajectory is performed to obtain out-of-range trajectory points. Based on the out-of-range trajectory points, the non-interference simulation trajectory is adjusted to generate an initial simulation trajectory.

4. The hemming method based on a calibration block and a calibration needle as described in claim 3, characterized in that, The process of obtaining shape features based on a preset outer panel outline, and then adding or subtracting trajectory points from the original simulation trajectory based on these shape features to obtain a controllable simulation trajectory, includes: The shape features are obtained based on the preset outer panel outline, and the corner positions and arc positions of the original simulation trajectory are obtained based on the shape features. Based on the corner position and the arc position, trajectory points are added to the trajectory segment corresponding to the original simulation trajectory to obtain an initial controllable simulation trajectory. The direction of all trajectory points in the initial controllable simulation trajectory is adjusted to the preset direction to obtain the controllable simulation trajectory.

5. The hemming method based on a calibration block and a calibration needle as described in claim 2, characterized in that, The process of configuring the initial simulation trajectory under preset hemming process parameters to obtain the production process simulation trajectory, and then performing virtual operation based on the production process simulation trajectory to obtain the offline hemming program, includes: Based on the initial simulation trajectory, the initial production process simulation trajectory is obtained by configuring the preset hemming process parameters. The production process simulation trajectory is obtained by adding path transition process points to the initial production process simulation trajectory. The offline rolling edge program is obtained by virtually running the simulation trajectory of the production process.

6. The hemming method based on a calibration block and a calibration needle as described in claim 5, characterized in that, The virtual operation to obtain the offline rolling edge program based on the simulation trajectory of the production process includes: The production process simulation trajectory is run in a preset rolling edge virtual environment to obtain the simulation running status, and an alarm cancellation offline program is obtained based on the simulation running status. Based on the aforementioned alarm-eliminating offline program, configuration information is improved to obtain the edge-rolling offline program.

7. A hemming system based on a calibration block and a calibration needle, characterized in that, A method for implementing a hemming method based on a calibration block and a calibration needle as described in any one of claims 1 to 6 includes: The position point acquisition module is used to acquire the simulated position point corresponding to the calibration block on the cover rolling edge tool, and control the calibration point of the robot rolling head tool to align with the calibration block according to the simulated position point to obtain the actual position point; The offset reference generation module is used to generate an offset reference based on the simulated position point and the actual position point; The simulation trajectory generation module is used to obtain the origin of the user coordinate system and the origin of the tool coordinate system, and generate an initial simulation trajectory on the preset outer plate contour line based on the origin of the user coordinate system and the origin of the tool coordinate system. The offline rolling program acquisition module is used to configure the initial simulation trajectory under preset rolling process parameters to obtain the production process simulation trajectory, and to perform virtual operation based on the production process simulation trajectory to obtain the offline rolling program. The offset correction module is used to perform coordinate offset on the offline hemming program under the offset reference to obtain the production site program. The hemming module is used to hem the target car body according to the production site program.

8. The hemming system based on a calibration block and a calibration needle as described in claim 7, characterized in that, The location point acquisition module is specifically used for: Obtain the simulated position point corresponding to the calibration block on the cap rolling edge fixture, and control the calibration point of the robot rolling head tool to align with the calibration block based on the simulated position point to obtain the actual position point, including: Obtain the simulation position point corresponding to the center of the calibration block on the cap rolling edge fixture; Based on the simulation location points, calibration simulation location points are selected under the conditions of preset calibration quantity and preset distance; Based on the center of the calibration block corresponding to the calibration simulation position point, the calibration pin of the robot rolling tool is aligned to obtain the actual position point.

9. A terminal device, characterized in that, The device includes a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, it implements a hemming method based on a calibration block and a calibration needle as described in any one of claims 1 to 6.

10. A computer-readable storage medium, characterized in that, include: A stored computer program, wherein, when the computer program is executed, it controls the device containing the computer-readable storage medium to perform a hemming method based on a calibration block and a calibration needle as described in any one of claims 1 to 6.

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