A shearing lead robot feeding and discharging collaborative control method and device

Abstract

This invention discloses a collaborative control method and device for loading and unloading a wire-cutting robot, relating to the field of industrial robot technology. The method includes: responding to machine type switching commands and establishing a reference mapping relationship between reference feature points and the robot's world coordinate system. During automatic operation, workpiece images are acquired to identify the current reference feature points, calculate coordinate offsets, correct pre-stored trajectories to generate real-time compensation trajectories, and control the robot to operate according to the trajectory. The shearing point maintains a preset force state; if the offset exceeds a safety threshold, an alarm is triggered and the entire machine's start-up permission is locked. This invention solves the technical problems of traditional fixed-trajectory operations, which cannot autonomously adapt to deviations, resulting in poor processing accuracy and changeover efficiency, and where shearing forces exacerbate workpiece displacement and cause defects. It achieves the technical effect of automatically adapting to workpiece position deviations during robot movement, improving processing accuracy, and reducing manual adjustment time and tool wear.

Description

Technical Field

[0001] This invention relates to the field of industrial robot technology, and in particular to a method and device for coordinated control of loading and unloading of a wire-cutting robot. Background Technology

[0002] PCB lead shearing is widely used in electronic assembly lines. The accuracy of robotic loading, unloading, and shearing directly affects product yield and tool life. Workpiece positioning deviation is a key issue restricting production. Existing lead shearing robots use fixed-point programming, adapting to stable, offset-free working conditions. However, incoming PCBs are prone to slight positional deviations due to transmission vibration and fixture wear. Traditional equipment lacks a dynamic compensation mechanism, relying solely on manual, repeated coordinate adjustments, resulting in low efficiency during model changeovers. Grasping deviations can easily cause burrs during lead shearing and blade chipping, and the lack of shearing force control and locking further exacerbates workpiece slippage due to shearing impact. Conventional static fixed-point vision solutions require machine downtime for image capture, reducing production cycle time. Single-point correction alone cannot simultaneously correct the entire trajectory of gripping, transferring, and shearing. There is no automatic locking protection against excessive deviations, and the mismatch between collected data and trajectory correction makes it difficult to achieve adaptive processing for incoming material deviations, failing to meet the requirements of high-precision, high-efficiency automated production management. Summary of the Invention

[0003] This application provides a collaborative control method and device for loading and unloading of a wire-cutting robot, which solves the technical problems of traditional fixed-track operations being unable to autonomously adapt to deviations, having poor processing accuracy and changeover efficiency, and having the shearing force exacerbating workpiece displacement and causing adverse wear.

[0004] The first aspect of this application provides a collaborative control method for loading and unloading a wire-cutting robot. The method includes: in response to a machine type switching command, establishing a reference mapping relationship between a reference feature point and the robot's world coordinate system; in automatic operation mode, triggering a vision acquisition module to acquire a real-time image of the current workpiece and identifying the current reference feature point in the real-time image; calculating the coordinate offset of the current reference feature point relative to the reference mapping relationship, and correcting a pre-stored set of robot running trajectory points based on the coordinate offset to generate a real-time compensated trajectory; controlling the industrial robot to perform operations according to the real-time compensated trajectory, and maintaining a preset force application state at the cutting point in response to a shearing permission signal sent by a logic controller during the operation; when the coordinate offset exceeds a preset safety threshold, triggering a vision recognition anomaly alarm and locking the entire machine's start-up permission.

[0005] A second aspect of this application provides a collaborative control device for loading and unloading a wire-cutting robot. The device includes: a reference mapping relationship construction module, used to establish a reference mapping relationship between reference feature points and the robot's world coordinate system in response to a machine type switching command; a reference feature point recognition module, used to trigger a vision acquisition module to acquire a real-time image of the current workpiece in automatic operation mode and identify the current reference feature point in the real-time image; a real-time compensation trajectory acquisition module, used to calculate the coordinate offset of the current reference feature point relative to the reference mapping relationship, and to correct a pre-stored set of robot running trajectory points based on the coordinate offset to generate a real-time compensation trajectory; a robot operation execution module, used to control the industrial robot to perform operations according to the real-time compensation trajectory, and to maintain a preset force application state at the cutting point in response to a shearing permission signal sent by a logic controller during the operation; and an abnormal alarm execution module, used to trigger a visual recognition abnormal alarm and lock the entire machine's start-up permission when the coordinate offset exceeds a preset safety threshold.

[0006] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0007] This application acquires workpiece images during robot movement, calculates workpiece position deviation by comparing with reference features, synchronously corrects the entire operation trajectory, and maintains workpiece clamping force continuously during the shearing stage. When the deviation exceeds the standard, the machine automatically stops and alarms, thereby adaptively offsetting the interference of incoming material position deviation, stably ensuring the PCB lead shearing processing accuracy, reducing manual adjustment and tool wear, and achieving the technical effect of automatically adapting to workpiece position deviation during robot movement, improving processing accuracy, and reducing manual adjustment time and tool wear. Attached Figure Description

[0008] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0009] Figure 1 This is a flowchart illustrating a collaborative control method for loading and unloading a wire-cutting robot provided in an embodiment of this application.

[0010] Figure 2 This is a schematic diagram of the structure of a wire-cutting robot loading and unloading collaborative control device provided in an embodiment of this application.

[0011] Figure labeling: 1. Reference mapping relationship construction module; 2. Reference feature point recognition module; 3. Real-time compensation trajectory acquisition module; 4. Robot operation execution module; 5. Anomaly alarm execution module. Detailed Implementation

[0012] This application provides a collaborative control method and device for loading and unloading of a wire-cutting robot, which solves the technical problems of traditional fixed-track operations being unable to autonomously adapt to deviations, having poor processing accuracy and changeover efficiency, and having the shearing force exacerbating workpiece displacement and causing adverse wear.

[0013] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0014] It should be noted that the terms "first," "second," etc., in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or modules not explicitly listed or inherent to such processes, methods, products, or devices.

[0015] Example 1, as Figure 1 As shown, a collaborative control method for loading and unloading a wire-cutting robot is provided, wherein the method includes:

[0016] In response to the machine type switching command, a reference mapping relationship is established between the reference feature points and the robot world coordinate system.

[0017] In this embodiment, the machine type switching command is a control command issued by the equipment control system to switch the production product model and synchronously load corresponding process parameters, vision templates, motion trajectories, and other exclusive configurations. The reference feature point is a fixed marker point pre-set on a standard workpiece or positioning fixture during calibration, serving as a reference for workpiece pose comparison, and is used to calculate the coordinate offset of the actual workpiece. The robot world coordinate system is a global Cartesian coordinate system established with a fixed reference point within the robot base or workspace as its origin, used to uniformly calibrate the spatial position and attitude of the robot end effector, workpiece, and trajectory points.

[0018] Specifically, in response to the machine type switching command, the vision acquisition module is controlled to acquire a standard image of the standard workpiece and identify the reference feature points in the standard image. The reference pixel coordinates of the reference feature points in the image coordinate system are extracted. The reference mapping relationship between the reference pixel coordinates and the robot world coordinate system is established through the calibration algorithm, and the reference mapping relationship is stored in the storage area of ​​the logic controller. The specific implementation process of this step will be described in detail later.

[0019] Furthermore, for the wire cutting processing system, the logic controller serves as the core control hub, and is equipped with industrial robots, vision acquisition modules, and human-machine interfaces. All components are connected by electrical links and communication links to form a collaborative whole.

[0020] The logic controller is the main control unit of the system. It is used to store the reference mapping relationship, preset trajectory parameters and control logic program, and send down various instructions such as motion control, image acquisition and shearing permission. At the same time, it collects the status feedback signals of each unit and executes the control logic of abnormal alarm and whole machine permission lock. The industrial robot is the execution mechanism for loading and unloading operations. It is equipped with a workpiece end clamping mechanism. After receiving the motion instructions from the logic controller, it completes the workpiece gripping, transfer and transportation and shearing station positioning actions according to the planned trajectory. During the shearing operation, it maintains the preset clamping force and servo axis enabled state.

[0021] The vision acquisition module is the sensing unit for workpiece pose detection. It consists of a global exposure industrial area array camera and supporting optical components. After receiving the trigger signal, it acquires the real-time image of the current workpiece and transmits it to the vision processing unit, providing an image data source for calculating the workpiece coordinate offset. The human-machine interface is the human-machine interaction port of the system, allowing operators to switch operating modes, configure the vision compensation function switch, and view the equipment operating status and alarm information. The setting instructions and parameters issued by the operator are all transmitted to the logic controller for storage and execution through the human-machine interface.

[0022] During overall operation, the human-machine interface inputs operation instructions and parameter configurations to the logic controller. The logic controller coordinates the motion timing of the industrial robot and the acquisition triggering time of the vision acquisition module. The vision acquisition module outputs the acquired image data to the vision processing unit to complete the offset calculation and then sends it back to the logic controller. Finally, the logic controller drives the industrial robot to execute the compensated and corrected operation actions, forming a complete closed-loop collaborative control link.

[0023] In automatic operation mode, the vision acquisition module is triggered to acquire a real-time image of the current workpiece and identify the current reference feature points in the real-time image.

[0024] Optionally, after the equipment switches to automatic operation mode, the workpiece conveying mechanism transports the PCB workpieces to be processed to the picking station according to the production rhythm. A spring-loaded pneumatic stop pin is installed at the end of the feeding track, and a side-push positioning cylinder and a hard rubber positioning block are installed on the side of the track. A through-beam photoelectric sensor installed on the side of the feeding track detects the workpiece position in real time. When the workpiece moves to the preset stopping position, the sensor outputs a high-level workpiece arrival signal, which is transmitted to the digital input port of the logic controller through shielded hardwired wiring. After receiving the arrival signal, the logic controller controls the pneumatic stop pin to extend and stop the front end of the workpiece, and simultaneously controls the side-push positioning cylinder to push the positioning block to clamp the workpiece to the track reference side, keeping the workpiece stationary at the picking station, with the planar position deviation controlled within ±0.5mm. After confirming that the workpiece positioning is complete and there are no equipment alarms, the logic controller sends a motion start command to the industrial robot, controlling the industrial robot to move from the standby point to the material picking point along the preset motion path. The motion controller of the industrial robot reads the encoder feedback coordinates of each servo axis in real time. When the real-time coordinates are completely matched with the pre-stored fly-shot trigger coordinates, the motion controller outputs a 24V pulse trigger signal through the high-speed digital output port. The trigger signal pulse width is set to 10ms and is directly connected to the external trigger input port of the vision acquisition module.

[0025] The vision acquisition module employs an industrial area scan camera with a global exposure mode and a resolution of 2592×1944, paired with an 8mm fixed-focus industrial lens. Upon receiving a trigger signal, exposure is initiated immediately, with the exposure time set between 50μs and 200μs. During the exposure period, the robot's movement is less than the physical size corresponding to a single pixel, acquiring a real-time grayscale image of the current workpiece. After image acquisition, the vision acquisition module transmits the real-time image data completely to the vision processing unit via a gigabit Ethernet transmission line using the TCP / IP communication protocol. The vision processing unit first uses a 3×3 template median filtering algorithm to denoise the real-time image, traversing the entire image pixel by pixel, replacing the center pixel's grayscale value with the median of the pixel grayscale values ​​within the template coverage area to remove salt-and-pepper noise generated during image acquisition. Then, a linear grayscale transformation algorithm is used for contrast enhancement, linearly stretching the original grayscale distribution range of the image to the full grayscale range of 0 to 255, strengthening the edge contrast of the reference feature points, and outputting a pre-processed standard grayscale image.

[0026] The vision processing unit performs current reference feature point recognition on the preprocessed standard grayscale image. It uses the Canny edge detection algorithm, identical to that used in the calibration stage, to extract edge information from all closed contours in the image. The high threshold of the Canny algorithm is set to 80-120, and the low threshold is half of the high threshold. After edge extraction, the vision processing unit filters all contours according to a preset diameter filtering range and a roundness threshold. The diameter filtering range corresponds to a pixel range of 2.8mm to 3.2mm in actual physical size, and the roundness threshold is set to 0.85, eliminating interfering contours with incorrect diameters or substandard roundness. If three circular contours conforming to the specifications are obtained after filtering, they are determined as the reference feature points of the current workpiece. Subsequently, the vision processing unit calculates the center position of each circular contour and extracts the pixel coordinates of each current reference feature point in the image coordinate system. The image coordinate system has the upper left corner of the image as the origin, the horizontal direction to the right as the positive x-axis, and the vertical direction downwards as the positive y-axis, with the coordinate unit being pixels.

[0027] After coordinate extraction, the vision processing unit matches the current feature point with the calibration reference feature point according to a preset coordinate sorting rule. Specifically, the three feature points are first sorted by their x-axis pixel values ​​from smallest to largest. The two points with the smallest x-values ​​are then compared with their y-axis pixel values. The point with the smaller y-value corresponds to the upper left reference feature point in the calibration stage, and the point with the larger y-value corresponds to the lower left reference feature point. The remaining point with the largest x-value corresponds to the upper right reference feature point in the calibration stage. After matching, three sets of one-to-one coordinate data are formed. If the number of valid feature points that meet the specifications after contour screening is less than three, the vision processing unit immediately sends a feature recognition anomaly signal to the logic controller. The logic controller controls the industrial robot to decelerate and return to the preparatory position before the flying capture trigger coordinate, and outputs the trigger signal again to perform image re-sampling and recognition. If three valid reference feature points still cannot be recognized after re-sampling, the logic controller triggers a whole-machine audible and visual alarm, suspends the automatic operation process, and waits for the operator to check the workpiece status or adjust the vision parameters.

[0028] By triggering real-time image acquisition during the movement of the industrial robot, coupled with a workpiece positioning mechanism to ensure pose stability, and using the same preprocessing and feature recognition algorithm as the calibration stage to obtain the coordinates of the current workpiece reference feature points after matching, the system achieves the effect of accurately obtaining real-time workpiece pose data without additional production cycle time, and providing reliable input for subsequent coordinate offset calculation.

[0029] Calculate the coordinate offset of the current reference feature point relative to the reference mapping relationship, and correct the pre-stored robot running trajectory point set based on the coordinate offset to generate a real-time compensated trajectory.

[0030] In one embodiment of this application, the current pixel coordinates of the current reference feature point are extracted, and the coordinate offset is calculated by comparing the current pixel coordinates with the reference pixel coordinates in the reference mapping relationship. The pre-stored robot running trajectory point set is retrieved, and the coordinate offset is substituted into the preset coordinate converter to synchronously convert the coordinate data of all trajectory points in the robot running trajectory point set to generate a real-time compensation trajectory. The specific implementation process of this step will be described in detail later.

[0031] The industrial robot is controlled to perform operations according to the real-time compensation trajectory, and in response to the shearing allow signal sent by the logic controller during the operation, it maintains a preset force application state at the shearing point.

[0032] Specifically, firstly, the industrial robot is controlled to perform operations according to a real-time compensated trajectory that includes corrected gripping point coordinate data, transfer point coordinate data, and shearing point coordinate data. It performs workpiece gripping actions according to the gripping point coordinate data, performs workpiece transfer actions according to the transfer point coordinate data, and moves to the shearing area according to the shearing point coordinate data and waits for the shearing permission signal. The specific implementation process of this step will be described in detail later.

[0033] Next, in response to the industrial robot reaching the shearing point, the logic controller verifies the readiness status of the loading and unloading mechanism and sends a shearing permission signal. The industrial robot responds to the shearing permission signal, controls the end effector to maintain the preset clamping force on the workpiece and maintains the enabled state of the robot servo axis, so that the force continues to act until the logic controller feeds back the shearing action completion signal. The specific implementation process of this step will also be described in detail later.

[0034] When the coordinate offset exceeds the preset safety threshold, a visual recognition anomaly alarm is triggered and the machine startup permission is locked.

[0035] Specifically, the safety thresholds include the maximum translational deviation threshold and the maximum rotational deviation threshold. Both types of thresholds are preset and input through the parameter configuration page of the human-machine interface. Operators can set specific values ​​according to the equipment stroke, workpiece size, and machining accuracy requirements. When the operator inputs the threshold value, the logic controller automatically performs a validity check. The maximum translational deviation threshold can be set within a range of 0 to 10 mm, and the maximum rotational deviation threshold can be set within a range of 0 to 5 degrees. Values ​​exceeding the set range cannot be written to the power-off retention data register, and the interface simultaneously displays a parameter over-limit prompt, guiding the operator to adjust the value. After the parameter verification is successful, it is officially written to the corresponding data register, and automatically read and retrieved after the equipment restarts, without the need for repeated settings. The equipment has built-in default thresholds as initial reference values. The maximum translational deviation threshold is set to ±5 mm by default, and the maximum rotational deviation threshold is set to ±3 degrees by default. Operators can fine-tune and adapt based on the default values.

[0036] After the vision processing unit calculates the coordinate offset of the current workpiece, it transmits the translational and rotational deviation values ​​to the logic controller in real time. The logic controller then sequentially retrieves the maximum translational deviation threshold and the maximum rotational deviation threshold stored in the register and compares the values. The comparison process uses independent judgment logic: the translational deviation value is compared with the maximum translational deviation threshold, and the rotational deviation value is compared with the maximum rotational deviation threshold. If either parameter exceeds the corresponding threshold range, the workpiece posture is determined to be out of tolerance.

[0037] Upon determining that the workpiece's posture is out of tolerance, the logic controller immediately outputs a control signal, causing the red light of the control device's three-color indicator to remain constantly lit. Simultaneously, an alarm command is sent to the human-machine interface, displaying the workpiece posture deviation information in a fixed alarm area on the interface, clearly indicating the type of deviation and the corresponding deviation value. The logic controller also synchronously sends a prohibition command to the industrial robot's motion controller, locking the execution permission for the current workpiece's gripping action. The industrial robot stops moving towards the gripping point, maintaining its current safe position to avoid collisions or gripping failures due to excessive posture deviation.

[0038] The logic controller has a built-in continuous out-of-tolerance counting unit. When the coordinate offset of a single workpiece is within the safety threshold range, the counting unit automatically resets to zero and restarts the accumulation. If the coordinate offset of three consecutive workpieces exceeds the safety threshold, the logic controller automatically triggers a vision recognition anomaly alarm, locking the automatic operation start permission of the entire machine. At this time, the equipment cannot start a new loading / unloading cycle, and only manual jogging and reset operation permissions are retained. After the fault is locked, the operator needs to check the status of the vision acquisition module, the status of the workpiece positioning mechanism, and the installation accuracy of the fixture. After confirming that the fault has been eliminated, the operator can enter a reset command with management privileges to clear the continuous out-of-tolerance count and unlock the start permission. Only then can the equipment resume automatic operation mode.

[0039] Accurate offset verification is achieved by using configurable hierarchical safety thresholds with validity checks. Combined with a continuous out-of-tolerance counting mechanism with automatic zeroing and multi-level out-of-tolerance handling logic, the system effectively identifies abnormal workpiece postures, avoids equipment collisions and processing defects, and ensures the safety and stability of equipment operation.

[0040] Furthermore, the method provided in this application embodiment includes:

[0041] In response to the workpiece arrival signal, the industrial robot is controlled to move along a preset motion path to a predefined flying camera point, which is located between the grasping preparation point and the material picking point. During the process of the industrial robot moving to the flying camera point, the vision acquisition module is triggered to acquire the real-time image. The real-time image acquisition of the current workpiece is completed within the exposure time, and the real-time image is uploaded to the vision processing unit.

[0042] Specifically, workpiece arrival detection is achieved using a through-beam photoelectric sensor. The sensor is an NPN type DC-powered sensor, installed on the side of the feed rail at the picking station, with the detection direction facing the workpiece feed path. When the workpiece moves with the conveyor mechanism to the preset stopping position at the picking station, the workpiece blocks the sensor's emitted light path, and the sensor outputs a 24V DC high-level workpiece arrival signal. This signal is transmitted to the digital input port of the logic controller through shielded hardwiring. After recognizing this signal, the logic controller confirms that the workpiece is in a camera-ready position. The camera position is pre-programmed into the motion control program via the industrial robot's teach pendant. The camera position is set on the straight path between the gripping preparation point and the picking point, with a straight-line distance of 50mm to 100mm from the picking point. The industrial robot's running speed on this path is set to 0.2m / s to 0.5m / s to ensure smooth movement and clear imaging.

[0043] A data exchange link is established between the logic controller and the industrial robot using the PROFINET fieldbus communication protocol. After receiving the workpiece arrival signal, the logic controller sends a motion start command to the industrial robot via the bus, controlling the robot to move along a preset motion path from the standby point to the picking point. The industrial robot's motion controller reads the encoder feedback coordinate values ​​of each servo axis in real time and synchronously feeds the real-time coordinate data back to the logic controller via the bus. When the real-time coordinates perfectly match the pre-stored fly-flying trigger coordinates, the motion controller outputs a PNP type 24V pulse trigger signal through the high-speed digital output port. The pulse width of the trigger signal is set to 10ms, and the signal is directly connected to the external trigger input port of the vision acquisition module. The vision acquisition module uses an industrial area scan camera with a global exposure mode. The camera resolution is 2592×1944 pixels, paired with an 8mm fixed-focus industrial lens. The field of view is set to 120mm×90mm, which can completely cover the entire area of ​​the current workpiece and the distribution range of reference feature points. After receiving the trigger signal, the camera immediately starts exposure. The exposure time is set to 50μs to 200μs. This exposure time is matched with the moving speed of the industrial robot. During the exposure cycle, the robot's movement displacement is less than the physical size corresponding to a single pixel, so no motion blur will occur, and a clear image of the complete surface of the current workpiece can be acquired.

[0044] After image acquisition, the vision acquisition module transmits the acquired real-time image data to the vision processing unit via a gigabit Ethernet transmission line using the TCP / IP communication protocol. The vision processing unit first performs image noise reduction using a median filtering algorithm. Specifically, a 3×3 filtering template is used to traverse the entire image pixel by pixel, replacing the gray value of the center pixel with the median gray value of all pixels within the template coverage area, thus removing salt-and-pepper noise generated during image acquisition. Next, a linear grayscale transformation algorithm is used for contrast enhancement, linearly stretching the original grayscale distribution range of the image to the full grayscale range of 0 to 255, enhancing the edge contrast of the reference feature points on the workpiece surface. After preprocessing, a standard grayscale image is output for subsequent reference feature point recognition and coordinate calculation.

[0045] During the calibration phase of machine type switching, the above process is executed to acquire images of a standard workpiece. The output image data is used to subsequently establish the reference mapping relationship between the reference feature points and the robot's world coordinate system. During the automated production phase, the above process is executed to acquire real-time images of the workpiece to be processed. The output image data is used to subsequently calculate the coordinate offset of the current workpiece. The flight trigger logic, image acquisition parameters, and preprocessing procedures are completely consistent in both phases, ensuring the consistency of the reference between calibration data and production inspection data, and avoiding offset calculation errors caused by differences in acquisition conditions.

[0046] By setting fixed camera points along the industrial robot's movement path and triggering image acquisition during uniform movement, and by matching the movement speed, exposure parameters, and camera hardware selection, the goal is to obtain clear workpiece images without stopping the machine and without taking up extra production time.

[0047] Furthermore, the method provided in this application embodiment includes:

[0048] The control vision acquisition module acquires a standard image of a standard workpiece and identifies reference feature points in the standard image; it extracts the reference pixel coordinates of the reference feature points in the image coordinate system, establishes a reference mapping relationship between the reference pixel coordinates and the robot world coordinate system through a calibration algorithm, and stores the reference mapping relationship in the storage area of ​​the logic controller.

[0049] Optionally, the operator selects the target processing machine type through the human-machine interface and issues a machine type switching command. After the command is transmitted to the logic controller, the logic controller switches to the calibration working mode and simultaneously calls the motion path parameters and visual inspection parameters of the corresponding machine type. The standard workpiece is pre-placed on the positioning fixture at the material handling station. The standard workpiece is a standard PCB board whose dimensions and positional accuracy have been calibrated. Three non-collinearly distributed circular markers are set on the surface of the workpiece as reference feature points. The three reference feature points are respectively located in the upper left, upper right, and lower left corners of the standard PCB board, with a spacing of not less than 50mm between each pair. The line connecting the three points forms a non-isosceles triangle. The diameter of each reference feature point is uniformly set to 3mm. The markers are printed with black matte ink to form a stable grayscale contrast with the green substrate of the PCB board, serving as a unified reference for calculating the pose deviation.

[0050] The logic controller sends calibration motion commands to the industrial robot, controlling the robot to move from the standby position to the picking point along a preset motion path. When the industrial robot moves to the predefined flying camera point, the motion controller outputs a trigger signal to the vision acquisition module. The vision acquisition module uses a global exposure industrial area array camera to complete the standard image acquisition of the standard workpiece. The acquired standard image is transmitted to the vision processing unit via gigabit Ethernet. The vision processing unit first completes the image preprocessing according to the preset median filtering and linear grayscale transformation process, and outputs a clear standard grayscale image.

[0051] The vision processing unit performs baseline feature point recognition on the standard grayscale image. It uses the Canny edge detection algorithm to extract edge information from all closed contours in the image. The high threshold of the Canny algorithm is set to 80-120, and the low threshold is set to half of the high threshold. After edge extraction, all contours are filtered according to preset baseline feature point diameter ranges and roundness thresholds. The diameter filtering range is set to the pixel interval corresponding to 2.8mm to 3.2mm, and the roundness threshold is set to 0.85. Interference contours with incorrect diameters or substandard roundness are removed, and the three remaining circular contours are the identified baseline feature points. After feature point recognition, the vision processing unit calculates the center position of each baseline feature point contour and extracts the baseline pixel coordinates of each baseline feature point in the image coordinate system. The image coordinate system has the top-left corner of the image as the origin, the positive x-axis pointing horizontally to the right, and the positive y-axis pointing vertically downwards, with the coordinate unit being pixels.

[0052] The vision processing unit uses a two-dimensional affine transformation calibration algorithm to establish a reference mapping relationship between the reference pixel coordinates and the robot's world coordinate system. The world coordinates are obtained in advance through industrial robot teaching operations. Specifically, a calibration needle with a tip diameter of 0.5mm is fixed to a special clamping seat on the end flange of the industrial robot through a threaded locking structure, ensuring that the axis of the calibration needle is perpendicular to the end face of the robot's end flange. The robot is manually operated to gradually adjust the end pose in a jog mode, so that the tip of the calibration needle is aligned with the center position of three reference feature points in sequence. The alignment process is judged by visual inspection combined with micro-adjustment. When the offset between the projection of the calibration needle tip and the center of the feature point does not exceed 0.1mm, the physical coordinates of the robot's world coordinate system corresponding to the current position are recorded. The general calculation expressions for two-dimensional affine transformation are x'=ax+by+c and y'=dx+ey+f, where (x,y) are the image pixel coordinates of the reference feature point, (x',y') are the robot world coordinates of the corresponding feature point, and a, b, c, d, e, and f are the six transformation parameters to be solved. Substituting the three sets of known pixel coordinates and corresponding world coordinates into the above expressions respectively, a system of linear equations containing six independent equations is formed. All transformation parameters are obtained by solving the matrix inversion method, and finally a complete two-dimensional affine transformation matrix is ​​formed. This matrix is ​​the reference mapping relationship, which can realize the point-to-point conversion calculation from image pixel coordinates to robot world coordinates.

[0053] The vision processing unit transmits the calculated reference mapping parameters to the logic controller via industrial Ethernet. The logic controller binds the reference mapping parameters to the number of the current model and stores them in the non-volatile memory area inside the logic controller. After storage, the calibration process ends. In subsequent automatic operation mode, the reference mapping parameters of the corresponding model can be directly retrieved. The stored parameter data will not be lost after the equipment is powered off.

[0054] By acquiring standard workpiece images, identifying three sets of non-collinear reference feature points, and combining them with a two-dimensional affine transformation calibration algorithm to establish coordinate mapping relationships, the goal of providing a unified and accurate coordinate reference for workpiece pose offset calculation and ensuring the accuracy of subsequent trajectory correction is achieved.

[0055] Furthermore, the method provided in this application embodiment includes:

[0056] Extract the current pixel coordinates of the current reference feature point, compare the current pixel coordinates with the reference pixel coordinates in the reference mapping relationship, and calculate the coordinate offset; retrieve the pre-stored robot running trajectory point set, substitute the coordinate offset into the preset coordinate converter, and synchronously convert the coordinate data of all trajectory points in the robot running trajectory point set to generate the real-time compensation trajectory.

[0057] Specifically, after the vision processing unit completes the identification of the current reference feature point, pixel coordinate extraction and point matching, it sends a coordinate calculation request to the logic controller via industrial Ethernet. It retrieves the reference mapping relationship parameters corresponding to the current processing machine from the non-volatile storage area of ​​the logic controller, and at the same time extracts the reference pixel coordinates corresponding to the three sets of reference feature points bound in the reference mapping relationship, as well as the reference world coordinates corresponding to the three sets of reference feature points obtained in the calibration stage.

[0058] The vision processing unit sequentially substitutes the current pixel coordinates of the three sets of current reference feature points into the two-dimensional affine transformation matrix corresponding to the reference mapping relationship, and calculates the current physical coordinates of the three sets of current reference feature points in the robot world coordinate system through matrix operations. Subsequently, the vision processing unit calculates the reference centroid coordinates and the current centroid coordinates. The reference centroid is the arithmetic mean of the reference world coordinates of the three reference feature points; that is, the X-coordinate of the reference centroid is obtained by averaging the X-axis coordinates of the three reference points, and the Y-coordinate is obtained by averaging the Y-axis coordinates of the three reference points. The current centroid is calculated using the same arithmetic averaging method from the current physical coordinates of the three current reference feature points.

[0059] When calculating the coordinate offset, the X-axis and Y-axis translation of the workpiece as a whole are first obtained directly from the difference between the current centroid coordinates and the reference centroid coordinates. Then, the relative coordinates of three sets of corresponding points with respect to their respective centroids are calculated. The plane rotation angle of a single set of corresponding points is calculated by comparing the vector angle between the two sets of relative coordinates. The arithmetic mean of the three calculated rotation angles is taken as the final plane rotation angle of the workpiece. Then, the distance ratio of the three sets of corresponding points with respect to their own centroids is calculated. The arithmetic mean of the three distance ratios is taken as the final overall scaling factor. Finally, the complete coordinate offset containing translation, rotation, and scaling parameters is output.

[0060] After receiving the coordinate offset from the vision processing unit, the logic controller first compares the coordinate offset with pre-stored allowable deviation thresholds. The allowable deviation thresholds for X-axis and Y-axis translation are set to ±5mm, for planar rotation angles to ±3°, and for scaling factors to a range of 0.98 to 1.02. If any parameter of the coordinate offset exceeds the corresponding allowable deviation threshold, the logic controller immediately triggers an audible and visual alarm and pauses the automatic operation process to prevent the robot from exceeding its safe travel range. If the coordinate offset is within the allowable deviation range, the logic controller retrieves a pre-stored set of robot trajectory points from the storage area. This set of points includes the robot's world coordinate data for all work points, such as workpiece gripping points, transition transfer points, and lead wire placement points, arranged in the work sequence. A preset coordinate converter is built into the logic controller's motion control module. Based on a two-dimensional rigid body transformation model, the coordinate converter supports simultaneous translation, rotation, and scaling transformations of planar coordinate points in batches. The transformation process uses the reference centroid as a unified reference point to ensure the overall consistency of trajectory correction.

[0061] The logic controller substitutes the calculated coordinate offset into a preset coordinate converter. The coordinate converter sequentially traverses each trajectory point in the robot's trajectory point set according to the original point position order, and performs scaling, rotation, and translation transformations on the world coordinate data of each trajectory point in sequence. The scaling transformation, centered on the reference centroid, first subtracts the reference centroid coordinates from the original trajectory point coordinates to obtain the relative coordinates, and then multiplies the X and Y components of the relative coordinates by a scaling factor to obtain the scaled relative coordinates. The rotation transformation, centered on the reference centroid, performs a planar rotation transformation on the scaled relative coordinates. The transformation formula is: , ,in, , The scaled relative coordinate components are θ, where θ is the workpiece plane rotation angle. The translation transformation first adds the rotated relative coordinates to the reference centroid coordinates, then superimposes the X-axis and Y-axis translation amounts, ultimately obtaining the corrected real-time coordinate data for each trajectory point. After all trajectory points have undergone coordinate transformation, the coordinate converter maintains the original trajectory point order and motion planning parameters between points, recombines all corrected coordinates into a complete real-time compensated trajectory, and writes the real-time compensated trajectory into the motion buffer of the logic controller, awaiting execution by the industrial robot.

[0062] The real-time world coordinates of the workpiece are obtained by transforming the reference mapping relationship. The overall coordinate offset is solved by centroid calculation and multi-point mean value calculation. Then, the coordinate converter with explicit transformation formula is used to batch synchronously transform all trajectory points to generate real-time compensation trajectory. This achieves the effect of automatically correcting the robot's operation path according to the actual position of the workpiece and ensuring the position accuracy of loading, unloading and shearing.

[0063] Furthermore, the method provided in this application embodiment includes:

[0064] The real-time compensation trajectory includes corrected gripping point coordinate data, transfer point coordinate data, and shearing point coordinate data; the industrial robot is controlled to perform workpiece gripping actions according to the gripping point coordinate data, perform workpiece transfer actions according to the transfer point coordinate data, and move to the shearing area according to the shearing point coordinate data, waiting for the shearing permission signal.

[0065] Specifically, after the logic controller generates the real-time compensation trajectory and writes it into the motion buffer, it sends a work start command and complete trajectory point set data to the motion controller of the industrial robot via the PROFINET fieldbus. Each trajectory point contains the spatial position coordinates of the X, Y, and Z axes and the rotation attitude angle around the Z axis. The planar rotation angle in the coordinate offset will be synchronously compensated to the attitude angle parameters of all trajectory points. After the robot controller completes the integrity and validity verification of the trajectory data, it automatically loads the running parameters.

[0066] The industrial robot's end effector is a parallel pneumatic gripper. The gripper's airflow is controlled by a 2-position 5-way solenoid valve. A built-in magnetic switch detects the gripping position, and a pressure sensor monitors the air pressure in real-time. The robot first moves smoothly from its standby position to the gripping point using linear interpolation, based on the coordinates and corresponding attitude angles of the gripping point in its real-time compensated trajectory. Upon reaching the target position, the motion controller outputs a digital control signal to the solenoid valve, which then reverses to close the gripper and clamp the workpiece. If the magnetic switch triggers within 0.5 seconds of the solenoid valve being energized, a gripping completion signal is sent back to the robot controller, confirming successful workpiece gripping. If the magnetic switch fails to trigger on time, the robot controller controls the solenoid valve to release the gripper. After a 0.3-second interval, it attempts to close the gripper again. If the gripping signal is still not triggered after one retrieval, the robot immediately stops and sends a gripping failure signal to the logic controller. The logic controller then triggers an audible and visual alarm for the entire robot, awaiting operator intervention.

[0067] After successful grasping, the industrial robot executes the workpiece transfer action according to the coordinate data of the transfer point in the real-time compensation trajectory. Three transfer points are set: a lifting point above the picking station, a safe transition point in the middle of the equipment, and a descending point above the shearing station. Each point is located in the safe area above the picking and shearing stations, with a height at least 50mm higher than the top surface of surrounding conveyor tracks, protective covers, and other structures to completely avoid interference from surrounding equipment. During the transfer process, the robot uses linear interpolation to sequentially pass through each transfer point. The transfer speed is set to 400mm / s, and the acceleration is set to 500mm / s². The solenoid valve remains continuously energized throughout the movement, maintaining stable gripping force of the gripper through air pressure maintenance. Pressure sensors monitor the air supply pressure in real time; if the pressure falls below the preset lower limit, an insufficient air pressure alarm is immediately triggered. Each time the robot reaches a transfer point, it sends a signal to the logic controller to indicate that the point has been reached. The logic controller simultaneously records the operation progress, ensuring the timing of the transfer process is controllable.

[0068] After completing the operation at all transfer points, the industrial robot switches to low-speed linear interpolation mode, smoothly approaching the shearing area according to the coordinate data and corresponding attitude angle of the shearing point. The speed during the low-speed approach phase is set to 50mm / s to ensure that the positioning accuracy is controlled within ±0.05mm. Upon reaching the shearing point, the robot controller immediately sends a positioning feedback signal to the logic controller, while simultaneously controlling all servo axes to remain enabled and initiating the position closed-loop holding mode to lock the current spatial position and attitude. After receiving the positioning feedback signal, the logic controller reads the actual position data and attitude angle data fed back by the robot servo encoder and performs deviation verification with the coordinate parameters of the target shearing point. The allowable threshold for position deviation is set to ±0.05mm, and the allowable threshold for attitude angle deviation is set to ±0.1°. If the deviation is within the allowable range, the workpiece is confirmed to be positioned normally, and the robot is controlled to maintain the current attitude and wait for the shearing permission signal. If the deviation exceeds the allowable range, the logic controller controls the robot to retreat to the previous transfer point and re-execute the shearing point approach action. If the deviation still exceeds the tolerance after the retry, a position abnormality alarm is immediately triggered, and the subsequent shearing process is suspended.

[0069] By supplementing the positional parameters of the points, clarifying the rules for the layout of the transfer points, adding a multi-scenario anomaly handling mechanism and a quantitative deviation verification threshold, the entire process of grasping, transferring, and shearing positioning is precisely controlled at each point. This achieves the effect of completing the workpiece transfer and precise positioning stably and reliably according to the compensated trajectory, and ensuring the smooth execution of subsequent shearing operations.

[0070] Furthermore, the method provided in this application embodiment includes:

[0071] In response to the industrial robot reaching the shearing point, the logic controller verifies the readiness status of the loading and unloading mechanism and sends a shearing permission signal. In response to the shearing permission signal, the industrial robot controls the end effector to maintain a preset clamping force on the workpiece and maintains the enabled state of the robot servo axis, so that the force application state continues until the logic controller feeds back a shearing action completion signal.

[0072] Specifically, after the industrial robot reaches the shearing point and sends a positioning feedback signal to the logic controller, the logic controller immediately initiates a full-station readiness verification process. The logic controller polls all associated input signals of the shearing station at a preset 10ms cycle, including the reset magnetic switch signal of the shearing actuator cylinder, the extension signal of the station positioning block, the operation feedback signal of the dust removal device, and the closing and locking signal of the safety gate. Simultaneously, it confirms that there are no equipment fault alarms or emergency stop trigger signals. When all verification items meet the readiness conditions, the logic controller generates a shearing allow signal and synchronously sends it to the industrial robot's motion controller via the PROFINET fieldbus. If any verification item fails to meet the requirements, the logic controller does not send a shearing allow signal and simultaneously triggers a readiness anomaly alarm for the corresponding station, prompting the operator to troubleshoot the fault.

[0073] Upon receiving the shearing permission signal, the industrial robot's motion controller immediately switches to steady-state holding mode, maintaining the preset force application state. The parallel pneumatic gripper of the end effector has its clamping air pressure stably controlled by an electronically controlled proportional precision pressure regulating valve in the air supply circuit. The pressure regulating valve is adjusted in real time by a 0-10V analog signal output from the logic controller. The preset clamping force corresponds to a working air pressure of 0.3MPa, which translates to a single-sided clamping force of approximately 15N. A digital display pressure switch is installed downstream of the pressure regulating valve to monitor the air circuit pressure in real time. If the pressure fluctuation exceeds ±0.02MPa, an abnormal clamping force alarm is triggered immediately. All servo axes of the industrial robot remain enabled, activating a high-rigidity position closed-loop control mode. Actual testing has verified that the maximum lateral reaction force generated by the shearing action at this station is approximately 20N. Adjusting the position loop gain to 1.15 times the normal operating value allows for real-time position correction at the microsecond level to offset the shearing reaction force without causing servo oscillation. This keeps the workpiece's position deviation within ±0.08mm during the holding phase, ensuring that the workpiece does not deviate beyond the allowable range during the entire shearing process and stably maintains the preset force-bearing posture.

[0074] Throughout the shearing operation, the industrial robot maintains a continuous state of force application and does not respond to any displacement commands. Simultaneously, the logic controller sends a shearing allow signal and outputs an action trigger signal to the solenoid valve of the shearing cylinder, driving the shearing cutter downwards to complete the wire shearing action. After the shearing action is completed, the magnetic switch at the end of the cylinder is triggered, sending an action completion signal back to the logic controller. Once the logic controller confirms that the positioning signal is stable and continuous for 100ms without jitter, it determines that the shearing action is complete and immediately sends a shearing action completion signal to the industrial robot's motion controller. If the industrial robot does not receive a shearing action completion signal within 3 seconds of receiving the shearing allow signal, or if the real-time position deviation exceeds the ±0.08mm threshold, it automatically triggers a shearing anomaly alarm, exits the holding mode, and returns to the upper safe transfer point to avoid hard interference that could cause structural damage.

[0075] By triggering the shearing allow signal through a multi-dimensional readiness verification mechanism across all workstations, combined with electronically controlled proportional voltage regulation and clamping, and a high-rigidity servo closed-loop control adapted to the shearing reaction force, the stable force state of the shearing process is maintained. With the addition of position deviation monitoring, abnormal alarm and timeout protection logic, the system achieves the effect of ensuring the safe and orderly execution of shearing operations, stabilizing the workpiece shearing position accuracy, and avoiding workpiece displacement or equipment damage caused by the shearing reaction force.

[0076] Furthermore, the method provided in this application embodiment includes:

[0077] A visual compensation mode switch is configured in the human-computer interaction interface. The state of the visual compensation mode switch is related to the calculation step of the coordinate offset. When the visual compensation mode switch is in the on state, the manually input coordinate offset parameter is blocked, and the calculation of the coordinate offset and the generation of the real-time compensation trajectory are forced. When the visual compensation mode switch is in the off state, the visual acquisition module is disabled, and the pre-stored historical trajectory point coordinate data or the manually set coordinate offset parameter is used.

[0078] In one embodiment, the parameter setting page of the human-machine interface is configured with a primary vision compensation mode switch control. The switch is a Boolean touch button, and its corresponding state value is stored in the power-off retention data register of the logic controller. The switch state is automatically retained after the device restarts. The vision compensation mode switch is a primary master switch. The secondary trajectory mode selection bar is only displayed on the interface when the switch is in the off state, containing two mutually exclusive single-selection options: baseline trajectory and manual offset. When the switch is in the on state, the secondary selection bar is automatically hidden and the data source is locked to vision calculation to prevent operator error. The output state of the vision compensation mode switch is associated with the coordinate offset calculation program block and the power supply control circuit of the vision acquisition module through the interlocking logic block inside the logic controller. The two modes are mutually exclusive, and only one trajectory compensation logic is active at a time. Switch state switching and secondary sub-mode switching are only allowed when the device is in standby or stopped state and there is no workpiece in the material handling station. Switching operations triggered during automatic operation will be directly blocked by the system, and a prompt message prohibiting switching during operation will pop up on the interface to prevent abnormal equipment operation caused by sudden changes in working conditions.

[0079] When the vision compensation mode switch is on, the logic controller automatically blocks the input channel for manual coordinate offset. Manual offset parameters entered by the operator on the interface will not be loaded into the trajectory conversion module, forcibly enabling the complete vision compensation process. Each time the equipment performs a loading / unloading cycle, the vision acquisition module is triggered according to a preset sequence to acquire the image of the current workpiece. Image preprocessing, reference feature point recognition, pixel coordinate transformation, and coordinate offset calculation are then performed sequentially. Finally, a real-time compensated trajectory is generated based on the real-time calculated offset, driving the industrial robot to perform the operation. If vision recognition of a single workpiece fails for the first time, the system automatically controls the robot to retreat to the photo-taking trigger position and retry once. If recognition fails twice consecutively, the current workpiece's visual characteristics are deemed abnormal, triggering an audible and visual alarm and pausing automatic operation, awaiting operator intervention to check the workpiece status or visual parameters. If recognition fails for three consecutive workpieces, the system automatically locks the automatic operation permission. Management personnel must confirm the on-site conditions and reset the fault count before restarting operation. When enabled, the human-machine interface displays the X-axis translation, Y-axis translation, and rotation angle offset values ​​of the current workpiece in real time. It will not automatically switch to manual parameter mode under any abnormal working conditions, ensuring the consistency of the compensation logic.

[0080] When the vision compensation mode switch is off, the logic controller disconnects the power supply circuit of the vision acquisition module by controlling the relay, disables the industrial area scan camera and supplementary light source, stops image acquisition and vision processing programs, reduces hardware idle loss, and extends the service life of components. In this state, the operator can switch between two operating modes via the secondary trajectory mode selection bar. The two modes are mutually exclusive and must be clicked after switching to write the parameters to the power-off holding register for the changes to take effect. The first is the baseline trajectory mode. When selected, the manual offset parameter input box is automatically grayed out and locked. The system directly calls the pre-stored standard robot trajectory point set without adding any coordinate offset correction, suitable for production scenarios with sufficient fixture positioning accuracy and high workpiece consistency. The second is the manual offset mode. When selected, the parameter input box is activated, allowing the operator to input manual offset parameters for X-axis translation, Y-axis translation, and planar rotation angle. After parameter input, the system first verifies whether the values ​​are within the allowable range. The allowable range for translation is ±5 mm, and the allowable range for rotation angle is ±3 degrees. After verification, the manual parameters are substituted into the coordinate converter to complete the synchronous conversion of all trajectory points, generating the corrected operating trajectory.

[0081] The mode interlock logic employs a dual verification mechanism. Before the device starts automatic operation, the logic controller performs a mode consistency verification according to a fixed procedure. The first step reads the status register value of the vision compensation mode switch; the second step reads the feedback contact status of the power supply relay of the vision acquisition module; and the third step reads the flag of the currently active offset data source. A matching judgment is then performed: if the switch is on, the power supply relay feedback must be in the engaged state, and the data source flag must be in vision calculation mode; otherwise, the mode configuration is considered abnormal. If the switch is off, the power supply relay feedback must be in the disengaged state, and the data source flag must be in the baseline trajectory or manual offset mode; otherwise, the mode configuration is considered abnormal. If an abnormality is detected, the system triggers a mode configuration alarm, disables automatic operation, and displays the specific abnormal item on the interface to guide troubleshooting. During operation, the logic controller checks the correspondence between the switch status and the operating logic every 100 milliseconds to prevent mode jumps caused by external signal interference. If a logic conflict is detected, the current operation is immediately paused, and the robot is controlled to retreat to a safe position to ensure safe operation of the equipment.

[0082] By implementing a hierarchical mode switch architecture, hardware-level interlocking control between visual compensation mode and manual reference mode is achieved. The hierarchical handling rules for single workpiece retry and continuous anomaly locking are clarified, and the consistency verification and judgment steps of the whole process mode are refined. This achieves the effect of avoiding trajectory errors caused by the simultaneous effect of multiple source offset parameters, while taking into account the different working conditions such as high-precision production and rapid debugging, and improving the safety of equipment operation and the adaptability of scenarios.

[0083] In summary, the collaborative control method for loading and unloading a wire-cutting robot provided in this application has the following technical effects:

[0084] This application calculates the coordinate offset by acquiring images of the workpiece's reference feature points, generates a real-time compensation trajectory through trajectory conversion processing, and adapts and adjusts it by combining the shearing station force holding control and mode interlocking mechanism. This achieves precise coordination of loading and unloading on the shearing guide, making the workpiece positioning and shearing operation accuracy more stable and reliable. It achieves the technical effect of automatically adapting to workpiece position deviations during robot movement, improving processing accuracy, and reducing manual debugging time and tool wear.

[0085] Example 2, as Figure 2 As shown, based on the same inventive concept as in Embodiment 1 above, this application provides a collaborative control device for loading and unloading a wire-cutting robot, the device comprising:

[0086] The reference mapping relationship construction module 1 is used to establish a reference mapping relationship between reference feature points and the robot world coordinate system in response to the machine type switching command.

[0087] The reference feature point recognition module 2 is used to trigger the vision acquisition module to acquire a real-time image of the current workpiece in automatic operation mode and identify the current reference feature points in the real-time image.

[0088] The real-time compensation trajectory acquisition module 3 is used to calculate the coordinate offset of the current reference feature point relative to the reference mapping relationship, and to correct the pre-stored robot running trajectory point set based on the coordinate offset to generate a real-time compensation trajectory.

[0089] Robot operation execution module 4 is used to control the industrial robot to perform operations according to the real-time compensation trajectory, and to maintain a preset force application state at the shearing point in response to the shearing allow signal sent by the logic controller during the operation.

[0090] An abnormal alarm execution module 5 is used to trigger a visual recognition abnormal alarm and lock the whole machine startup permission when the coordinate offset exceeds a preset safety threshold.

[0091] Furthermore, the reference mapping relationship construction module 1 is used to perform the following steps:

[0092] The control vision acquisition module acquires a standard image of a standard workpiece and identifies reference feature points in the standard image; it extracts the reference pixel coordinates of the reference feature points in the image coordinate system, establishes a reference mapping relationship between the reference pixel coordinates and the robot world coordinate system through a calibration algorithm, and stores the reference mapping relationship in the storage area of ​​the logic controller.

[0093] Furthermore, the real-time compensation trajectory acquisition module 3 is used to perform the following steps:

[0094] Extract the current pixel coordinates of the current reference feature point, compare the current pixel coordinates with the reference pixel coordinates in the reference mapping relationship, and calculate the coordinate offset; retrieve the pre-stored robot running trajectory point set, substitute the coordinate offset into the preset coordinate converter, and synchronously convert the coordinate data of all trajectory points in the robot running trajectory point set to generate the real-time compensation trajectory.

[0095] Furthermore, the robot task execution module 4 is used to perform the following steps:

[0096] The real-time compensation trajectory includes corrected gripping point coordinate data, transfer point coordinate data, and shearing point coordinate data; the industrial robot is controlled to perform workpiece gripping actions according to the gripping point coordinate data, perform workpiece transfer actions according to the transfer point coordinate data, and move to the shearing area according to the shearing point coordinate data, waiting for the shearing permission signal.

[0097] Furthermore, the robot task execution module 4 is used to perform the following steps:

[0098] In response to the industrial robot reaching the shearing point, the logic controller verifies the readiness status of the loading and unloading mechanism and sends a shearing permission signal. In response to the shearing permission signal, the industrial robot controls the end effector to maintain a preset clamping force on the workpiece and maintains the enabled state of the robot servo axis, so that the force application state continues until the logic controller feeds back a shearing action completion signal.

[0099] Furthermore, the abnormal alarm execution module 5 is used to perform the following steps:

[0100] A visual compensation mode switch is configured in the human-computer interaction interface. The state of the visual compensation mode switch is related to the calculation step of the coordinate offset. When the visual compensation mode switch is in the on state, the manually input coordinate offset parameter is blocked, and the calculation of the coordinate offset and the generation of the real-time compensation trajectory are forced. When the visual compensation mode switch is in the off state, the visual acquisition module is disabled, and the pre-stored historical trajectory point coordinate data or the manually set coordinate offset parameter is used.

[0101] Furthermore, the reference mapping relationship construction module 1 is used to perform the following steps:

[0102] In response to the workpiece arrival signal, the industrial robot is controlled to move along a preset motion path to a predefined flying camera point, which is located between the grasping preparation point and the material picking point. During the process of the industrial robot moving to the flying camera point, the vision acquisition module is triggered to acquire the real-time image. The real-time image acquisition of the current workpiece is completed within the exposure time, and the real-time image is uploaded to the vision processing unit.

[0103] The wire-cutting robot loading and unloading collaborative control device provided in this embodiment of the invention can execute the wire-cutting robot loading and unloading collaborative control method provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0104] Although this application makes various references to certain modules in the apparatus according to the embodiments of this application, any number of different modules can be used and run on user terminals and / or servers. The various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of each functional unit are only for easy distinction between each other and are not intended to limit the scope of protection of this invention.

[0105] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application. In some cases, the actions or steps described in this application can be performed in a different order than that shown in the embodiments and still achieve the desired results. Furthermore, the processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A method for coordinated control of loading and unloading of a wire-cutting robot, characterized in that, Applicable to wire trimming systems, including industrial robots, vision acquisition modules, logic controllers, and human-machine interfaces, the method includes: In response to machine type switching commands, a reference mapping relationship is established between the reference feature points and the robot's world coordinate system; In automatic operation mode, the vision acquisition module is triggered to acquire a real-time image of the current workpiece and identify the current reference feature points in the real-time image; Calculate the coordinate offset of the current reference feature point relative to the reference mapping relationship, and correct the pre-stored robot running trajectory point set based on the coordinate offset to generate a real-time compensation trajectory. The industrial robot is controlled to perform operations according to the real-time compensation trajectory, and in response to the shearing allow signal sent by the logic controller during the operation, it maintains a preset force application state at the shearing point. When the coordinate offset exceeds the preset safety threshold, a visual recognition anomaly alarm is triggered and the machine startup permission is locked.

2. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, In response to machine type switching commands, a reference mapping relationship is established between reference feature points and the robot's world coordinate system, including: The vision acquisition module is controlled to acquire standard images of standard workpieces and identify reference feature points in the standard images. Extract the reference pixel coordinates of the reference feature points in the image coordinate system, establish the reference mapping relationship between the reference pixel coordinates and the robot world coordinate system through a calibration algorithm, and store the reference mapping relationship in the storage area of ​​the logic controller.

3. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, The pre-stored set of robot trajectory points is corrected based on the coordinate offset, including: Extract the current pixel coordinates of the current reference feature point, compare the current pixel coordinates with the reference pixel coordinates in the reference mapping relationship, and calculate the coordinate offset. The pre-stored set of robot trajectory points is retrieved, and the coordinate offset is substituted into a preset coordinate converter to synchronously convert the coordinate data of all trajectory points in the set of robot trajectory points, thereby generating the real-time compensated trajectory.

4. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, Controlling the industrial robot to perform tasks according to the real-time compensated trajectory includes: The real-time compensation trajectory includes corrected capture point coordinate data, transfer point coordinate data, and shearing point coordinate data; The industrial robot is controlled to perform workpiece gripping actions according to the gripping point coordinate data, perform workpiece transfer actions according to the transfer point coordinate data, move to the shearing area according to the shearing point coordinate data, and wait for the shearing permission signal.

5. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, In response to a shear enable signal sent by the logic controller, a preset force application state is maintained at the shear point, including: In response to the industrial robot reaching the shearing point, the logic controller verifies the readiness status of the loading and unloading mechanism and then sends a shearing permission signal. In response to the shearing permission signal, the industrial robot controls the end effector to maintain a preset clamping force on the workpiece and keep the robot servo axis enabled, so that the force application state continues until the logic controller feeds back a shearing action completion signal.

6. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, The method also includes mode interlocking: A visual compensation mode switch is configured in the human-computer interaction interface, and the state of the visual compensation mode switch is related to the calculation steps of the coordinate offset. When the visual compensation mode switch is turned on, manually input coordinate offset parameters are blocked, and the calculation of the coordinate offset and the generation of real-time compensation trajectory are forced. When the visual compensation mode switch is in the off state, the visual acquisition module is disabled, and the pre-stored historical trajectory point coordinate data or manually set coordinate offset parameters are used.

7. The method for coordinated loading and unloading control of a wire-cutting robot as described in claim 1, characterized in that, Before establishing the datum mapping relationship between the datum feature points and the robot's world coordinate system, the following steps are also included: In response to the workpiece arrival signal, the industrial robot is controlled to move along a preset motion path to a predefined flying point, which is located between the grasping preparation point and the material picking point. During the process of the industrial robot moving to the aerial photography location, the vision acquisition module is triggered to acquire the real-time image. The real-time image acquisition of the current workpiece is completed within the exposure time, and the real-time image is uploaded to the vision processing unit.

8. A collaborative control device for loading and unloading a wire-cutting robot, characterized in that, The apparatus for implementing the collaborative control method for loading and unloading a wire-cutting robot according to any one of claims 1-7, the apparatus comprising: The reference mapping relationship construction module is used to establish the reference mapping relationship between reference feature points and the robot world coordinate system in response to machine type switching commands; The reference feature point recognition module is used to trigger the vision acquisition module to acquire a real-time image of the current workpiece in automatic operation mode, and to identify the current reference feature points in the real-time image. The real-time compensation trajectory acquisition module is used to calculate the coordinate offset of the current reference feature point relative to the reference mapping relationship, and to correct the pre-stored robot running trajectory point set based on the coordinate offset to generate a real-time compensation trajectory. The robot operation execution module is used to control the industrial robot to perform operations according to the real-time compensation trajectory, and to maintain a preset force application state at the shearing point in response to the shearing allow signal sent by the logic controller during the operation. The abnormal alarm execution module is used to trigger a visual recognition abnormal alarm and lock the whole machine startup permission when the coordinate offset exceeds the preset safety threshold.

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