FMS transfer robot fine positioning realization system

Abstract

The utility model relates to a system for realizing fine positioning of an FMS transfer robot. The system comprises a control system PLC, an upper computer, a distance measuring sensor, a frequency converter and an encoder, the frequency converters are electrically connected with motors in corresponding directions; the encoder comprises a speed encoder A, a speed encoder B and a rotary encoder; the frequency converter comprises a horizontal-axis frequency converter, a vertical-axis frequency converter and a longitudinal-axis frequency converter; the horizontal shaft frequency converter corresponds to a walking motor in the horizontal direction; the vertical axis frequency converter corresponds to the vertical direction motor; the longitudinal shaft frequency converter corresponds to a longitudinal rotating motor; the control system PLC is electrically connected with the upper computer, the sensor, the horizontal axis frequency converter, the vertical axis frequency converter and the longitudinal axis frequency converter. The horizontal shaft frequency converter is electrically connected with the speed encoder and the horizontal laser range finder A respectively; the vertical axis frequency converter is electrically connected with the vertical laser ranging and speed encoder B respectively; the longitudinal shaft frequency converter is electrically connected with the rotary encoder; the device is reasonable in design, compact in structure and convenient to use.

Description

TECHNICAL FIELD

[0001] The utility model relates to FMS transfer robot precision positioning implementation system. BACKGROUND

[0002] In the present industrial production automation, FMS production line more and more enter various factories, the form of FMS production line of transfer robot has become an indispensable part, FMS production line can perfectly solve the processing problem of many types of small batch, its substitution mechanical labor rate is faster and faster, has great help to the improvement of production efficiency. But the positioning mode of transfer robot is generally mainly in the form of gear and rack, with the increase of production line length, the length of required rack also increases, resulting in the increase of cost. The utility model provides a low cost, high positioning precision, positioning stable mode to replace the original gear and rack structure.

[0003] The prior art has the following problems: the gear and rack mode of the transfer robot has many processing surfaces, uses more racks, and has high cost; the installation precision of the existing transfer robot is high, and it is time-consuming and laborious; the existing transfer robot has low repeatability, and is not suitable for high-precision FMS production line;

[0004] The utility model discloses the purpose of: using the new positioning mode to replace the original gear and rack mode, reducing cost, reducing the investment of manpower and material resources, realizing low cost and high precision. UTILITY MODEL CONTENTS

[0005] The utility model discloses the purpose of: using the new positioning mode to replace the original gear and rack mode, reducing cost, reducing the investment of manpower and material resources, realizing low cost and high precision.

[0006] To solve the above problems, the technical scheme adopted by the utility model is:

[0007] A kind of FMS transfer robot precision positioning implementation system, including control system PLC, host computer, range sensor, frequency converter and encoder;Frequency converter is electrically connected with motor corresponding direction;

[0008] Encoder includes speed encoder A, speed encoder B and rotary encoder;

[0009] Frequency converter includes horizontal shaft frequency converter, vertical shaft frequency converter and longitudinal shaft frequency converter;

[0010] Horizontal shaft frequency converter corresponds to horizontal direction walking motor;Vertical shaft frequency converter corresponds to vertical direction motor;Longitudinal shaft frequency converter corresponds to longitudinal rotation motor;

[0011] The control system PLC is electrically connected with the upper computer, the sensor, the horizontal shaft frequency converter, the vertical shaft frequency converter and the longitudinal shaft frequency converter respectively.

[0012] The horizontal shaft frequency converter is electrically connected with the speed encoder and the horizontal laser ranging A respectively.

[0013] The vertical shaft frequency converter is electrically connected with the vertical laser ranging and the speed encoder B respectively.

[0014] The longitudinal shaft frequency converter is electrically connected with the rotary encoder.

[0015] As a further improvement of the above technical solution:

[0016] The ranging sensor is matched with the reflector plate.

[0017] The reflector plate comprises a horizontal reflector plate and a vertical reflector plate installed on the rack, and the laser ranging sensor comprises a horizontal laser ranging sensor and a vertical laser ranging sensor.

[0018] The horizontal reflector plate is matched with the horizontal laser ranging sensor, and the vertical reflector plate is matched with the vertical laser ranging sensor.

[0019] The upper computer dispatches the control system PLC.

[0020] The control system PLC is electrically connected with the human-machine interface HMI.

[0021] The human-machine interface HMI sets the point coordinate and modifies the parameter control system.

[0022] The control system PLC sends instructions to the horizontal shaft frequency converter, the vertical shaft frequency converter and / or the longitudinal shaft frequency converter respectively.

[0023] The laser ranging sensor collects the obstacle avoidance and limit information to the control system.

[0024] The horizontal shaft frequency converter respectively receives the speed ring of the speed encoder A and the position ring of the horizontal laser ranging.

[0025] The vertical shaft frequency converter respectively receives the speed ring of the speed encoder B and the position ring of the vertical laser ranging.

[0026] The longitudinal shaft frequency converter receives the electric connection of the rotary encoder.

[0027] In the horizontal shaft frequency converter, the incoming line ends L1-L3 are connected with the 380V branch terminal UKK through the circuit breaker QF8, and the input current; the brake resistor R2 is electrically connected between the terminals R1 and R2, which is used for energy consumption braking when the frequency converter is decelerated.

[0028] The X130 port is connected with the power supply 24V.

[0029] X134 port, as a digital input of horizontal shaft inverter, wherein +24VOUT outputs two paths, one path is connected with limit switch DI16 through horizontal negative limit switch S1, and the other path is connected with limit switch DI17 through horizontal positive limit switch;

[0030] X135 port, as a digital output of horizontal shaft inverter, wherein DO1 is used for controlling brake contactor KM2, and the brake contactor KM2 is used for supplying power to horizontal motor brake;

[0031] U, V, W, PE ports, as outputs of horizontal shaft inverter, are used for controlling horizontal traveling motor;

[0032] X136 port, connected with speed encoder of motor, is used as horizontal shaft inverter speed loop signal source;

[0033] X2100 port, connected with laser ranging encoder, is used as horizontal shaft inverter position loop signal source.

[0034] The speed encoder A or the speed encoder B is connected with the ranging encoder DL100-21AA2101 to the X2100 interface of the corresponding inverter as a position loop encoder.

[0035] The corresponding motor self-encoder is connected with the X136 interface of the corresponding inverter as a speed loop encoder.

[0036] The function block FB284 is arranged between the control system PLC and the inverter, and message communication is adopted.

[0037] The traveling motor is connected with a driving wheel;

[0038] The safety range threshold is arranged in the control system PLC, and the safety range threshold includes point position thresholds of horizontal shaft, vertical shaft and longitudinal shaft;

[0039] The actual position of the transfer robot is judged whether in the safety range based on the safety range threshold, and feedback is given to the control system PLC.

[0040] A kind of FMS transfer robot precision positioning implementation method, including the system described above;Method includes the following steps:

[0041] Step one, initialization, horizontal laser ranging sensor corresponds to horizontal shaft, vertical laser ranging sensor corresponds to vertical shaft, longitudinal shaft is fed back current position by rotary encoder;The horizontal shaft, vertical shaft, longitudinal shaft coordinates of each point position are preset in control system PLC by HMI, as preset point position coordinate value;

[0042] Step two, first, the corresponding inverter respectively feedbacks real-time position of horizontal shaft, vertical shaft, longitudinal shaft to control system PLC by message;

[0043] Step three, the control system PLC compares the real-time position with all preset point coordinate values to obtain a difference value; secondly, when the difference value is within a preset safety threshold, the corresponding axis is allowed to move in the corresponding direction, and if the difference value exceeds the safety threshold, the corresponding axis is limited to move.

[0044] As a further improvement of the above technical solution:

[0045] The threshold is limited as follows:

[0046] a. The longitudinal axis is at zero position, and the horizontal axis is allowed to move;

[0047] b. The longitudinal axis is at zero position, and the vertical axis is allowed to move;

[0048] c. The longitudinal axis is within the point position threshold, the horizontal axis is within the point position threshold, and the vertical axis is allowed to move within the threshold;

[0049] d. The horizontal axis and the vertical axis are within the point position threshold, and the longitudinal axis is allowed to extend and retract;

[0050] After step three, step four is executed, that is, the action process is as follows:

[0051] S1. The host computer issues a task, the control system PLC determines the target point coordinate according to the task, and sends it to the three frequency converters;

[0052] S2. The longitudinal axis is returned to zero, and the feedback of the rotary encoder and the zero switch is effective, and the return to zero is completed;

[0053] S3. After the longitudinal axis is returned to zero, the horizontal axis and the vertical axis are started and run to the point coordinate value respectively;

[0054] S4. When the current positions of the horizontal axis and the vertical axis are within the safety threshold range of the point position, the longitudinal axis is extended.

[0055] The longitudinal axis is extended to the position, the current position is within the safety threshold range of the point position, the vertical axis is moved, and the loading is completed;

[0056] S6. After the loading is completed, the longitudinal axis is returned to zero, and a task is completed;

[0057] The distance encoder and the speed encoder are connected to the driver;

[0058] The driver feeds back the current position to the control system PLC through the bus.

[0059] The utility model discloses reasonable in design, low in cost, solid and durable, safe and reliable, easy to operate, time and energy saving, capital saving, compact structure, convenient to install and maintain, high positioning accuracy, low laser ranging sensor cost, manpower and material resources, and the positioning accuracy of laser ranging sensor is high with double closed loop control system positioning; Laser ranging form is not basically limited by length. In addition, the installation laser ranging sensor and the reflector plate form can greatly save manpower and material resources, compared with the original gear and rack structure, the utility model does not need to buy more rack according to the length of production line, does not need to process rack installation surface, and only needs to install reflector plate and ranging sensor in the aspect of J machinery, and the double closed loop program of electrical aspect can realize accurate positioning, can greatly reduce manufacturing cost and maintenance cost in later period. BRIEF DESCRIPTION OF DRAWINGS

[0060] Figure 1 It is the reflector plate use structure schematic drawing of the utility model.

[0061] Figure 2 It is the sensor structure schematic drawing of the utility model.

[0062] Figure 3 It is the circuit frame structure schematic drawing of the utility model.

[0063] Figure 4 It is the control flow schematic drawing of the utility model.

[0064] Figure 5 It is the frequency converter circuit schematic drawing of the utility model.

[0065] Among them: 1, horizontal direction reflector plate, 2, horizontal direction laser ranging sensor, 3, vertical direction reflector plate, 4, vertical direction laser ranging sensor. DETAILED DESCRIPTION

[0066] As shown in Figures 1-5 , the utility model mainly includes system including control system PLC, host computer, man-machine interface HMI, safety range threshold, ranging sensor, frequency converter and encoder, and the frequency converter is electrically connected with the motor of corresponding direction;

[0067] The encoder includes speed encoder A, speed encoder B and rotary encoder;

[0068] The frequency converter includes horizontal shaft frequency converter, vertical shaft frequency converter and longitudinal shaft frequency converter;

[0069] The horizontal shaft frequency converter corresponds to the walking motor of horizontal direction, the vertical shaft frequency converter corresponds to the vertical motor, and the longitudinal shaft frequency converter corresponds to the rotary motor of longitudinal direction;

[0070] The ranging sensor is matched with reflector plate;

[0071] The reflective plate comprises a horizontal reflective plate (1) and a vertical reflective plate (3); the laser ranging sensor comprises a horizontal laser ranging sensor (2) and a vertical laser ranging sensor (4);

[0072] The transfer robot comprises a frame; the horizontal reflective plate (1) and the vertical reflective plate (3) are installed on the frame; the horizontal reflective plate (1) is matched with the horizontal laser ranging sensor (2), and the vertical reflective plate (3) is matched with the vertical laser ranging sensor (4), so as to perform fine positioning;

[0073] In terms of electrical control, a double closed-loop control is adopted, i.e. two feedback loops of a speed loop and a current loop / position loop are used to realize higher-level control and more accurate response;

[0074] The control system PLC is electrically connected with the upper computer, the human-machine interface HMI, the safety range threshold, the sensor, the horizontal shaft frequency converter, the vertical shaft frequency converter and the longitudinal shaft frequency converter respectively;

[0075] The horizontal shaft frequency converter is electrically connected with the speed encoder and the horizontal laser ranging A respectively;

[0076] The vertical shaft frequency converter is electrically connected with the vertical laser ranging and the speed encoder B respectively;

[0077] The longitudinal shaft frequency converter is electrically connected with the rotary encoder;

[0078] Embodiment 2, as a further improvement of embodiment 1, wherein,

[0079] The upper computer dispatches the control system PLC;

[0080] The human-machine interface HMI sets the point coordinate and modifies the parameter control system;

[0081] The safety range threshold judges whether the position of the transfer robot is in the safety range, and feeds back to the control system;

[0082] The control system PLC sends instructions to the horizontal shaft frequency converter, the vertical shaft frequency converter and / or the longitudinal shaft frequency converter respectively;

[0083] The laser ranging sensor collects the obstacle avoidance and limit information to the control system;

[0084] The horizontal shaft frequency converter respectively receives the speed loop of the speed encoder A and the position loop of the horizontal laser ranging;

[0085] The vertical shaft frequency converter respectively receives the speed loop of the speed encoder B and the position loop of the vertical laser ranging;

[0086] The longitudinal shaft frequency converter receives the electric connection of the rotary encoder;

[0087] Three frequency converter wiring principle is the same, wherein, in the horizontal shaft frequency converter, incoming line L1~L3 through the circuit breaker QF8 380v branch terminal UKK, input current; between the terminal R1 and R2 electrically connected with the brake resistor R2, for frequency converter deceleration when the energy consumption brake;

[0088] X130 port, access to power 24V;

[0089] X134 port, as the digital input of horizontal shaft frequency converter, wherein, +24VOUT output two way, one way through the horizontal negative limit switch S1 limit switch DI16 and the other way through the horizontal positive limit switch limit switch DI17;

[0090] X135 port, as the digital output of horizontal shaft frequency converter, wherein, DO1 is used for controlling the clutch contactor KM2, through the clutch contactor KM2, for the horizontal motor clutch power supply;

[0091] U, V, W, PE port, as the output of horizontal shaft frequency converter, for controlling the walking motor in horizontal direction;

[0092] X136 port, access to the speed encoder of motor, as the speed loop signal source of horizontal shaft frequency converter;

[0093] X2100 port, access to laser ranging encoder, as the position loop signal source of horizontal shaft frequency converter;

[0094] Example 3, speed encoder A or speed encoder B preferably specific to ranging encoder DL100-21AA2101 (SSI interface, absolute value) access G120 frequency converter X2100 interface as position loop encoder, laser ranging is independent of transmission structure, feedback current ranging position, motor with encoder OG73 UN 1024 (incremental encoder) access frequency converter X136 interface as speed loop encoder.

[0095] The control system PLC and frequency converter use message, send control instruction to frequency converter through standard function block FB284, frequency converter receives instruction, complete instruction under the guidance of two encoders, wherein the form of laser ranging is basically not limited by length.

[0096] This drive form is direct drive wheel through reduction motor in mechanical aspect, through friction to make the stacker walking, abandon the original gear and rack transmission form. Through the speed loop control the speed of drive wheel, current loop control the current of motor, ensure that the motor can quickly and accurately respond according to the speed instruction of speed loop, so that this control system can realize more efficient and more accurate control at different levels. Through this kind of control mode, with laser ranging sensor can make the repeat positioning accuracy of transfer robot reach within ±1mm.

[0097] The utility model discloses a method for controlling the movement of a stacker, which can be applied to a stacker device, the stacker device comprising two laser ranging sensors, a horizontal motor shaft and a vertical lifting shaft, a longitudinal telescopic shaft, the method comprising:

[0098] Step one, initialization, the horizontal laser ranging sensor (2) corresponds to the horizontal shaft, the vertical laser ranging sensor (4) corresponds to the vertical shaft, and the longitudinal shaft is fed back with the current position by a rotary encoder; the horizontal shaft, the vertical shaft and the longitudinal shaft coordinates of each point are preset in the control system PLC through HMI, as the preset point coordinate value;

[0099] Step two, first, the real-time position of the horizontal shaft, the vertical shaft and the longitudinal shaft is fed back to the control system PLC through the corresponding frequency converter respectively by message;

[0100] Step three, the control system PLC compares the feedback real-time position with all the preset point coordinate values to obtain the difference value; secondly, when the difference value is within the preset safety threshold, the shaft in the corresponding direction is allowed to move, and if the difference value exceeds the safety threshold, the corresponding shaft movement is limited; wherein the threshold limit is as follows:

[0101] a, the longitudinal shaft is at zero position, and the horizontal shaft is allowed to move;

[0102] b, the longitudinal shaft is at zero position, and the vertical shaft is allowed to move;

[0103] c, the longitudinal shaft is within the point position threshold, the horizontal shaft is within the point position threshold, and the vertical shaft is allowed to move within the threshold;

[0104] d, the horizontal shaft and the vertical shaft are within the point position threshold, and the longitudinal shaft is allowed to extend and retract;

[0105] Step four, execute the action flow;

[0106] S1, the host computer issues a task, and the control system PLC determines the target point coordinate according to the task and sends it to the three frequency converters;

[0107] S2, the longitudinal shaft is returned to zero, the rotary encoder feedback and the zero position switch are effective, and the returning to zero is completed;

[0108] S3, after the longitudinal shaft is returned to zero, the horizontal shaft and the vertical shaft are started and run to the point coordinate value respectively;

[0109] S4, when the current position of the horizontal shaft and the vertical shaft is within the safety threshold range of the point, the longitudinal shaft is extended.

[0110] S5, the longitudinal shaft is extended to the position, the current position is within the safety threshold range of the point, the vertical shaft is moved, and the loading is completed;

[0111] S6, after the loading is completed, the longitudinal shaft is returned to zero, and a task is completed.

[0112] During operation, the laser rangefinder is independent of the transmission mechanism and is not affected by the mechanical structure. The rangefinder feedback value is only related to the installation position of the laser rangefinder and the reflector, and will not be affected by skipped teeth, slippage, or loosening.

[0113] Laser ranging only identifies the laser reflected back from the reflector to determine the position. When there is obstruction or abnormal wiring, the feedback distance will immediately return to zero, triggering the driver to alarm and stop. This can effectively prevent foreign objects from intruding and affecting the positioning operation.

[0114] The control system performs safety threshold judgments in real time, not only for the target location, but also for the drive in manual and debugging conditions, which must also meet the safety threshold judgments before it can operate.

[0115] Both the distance encoder and the speed encoder are connected to the driver, which controls the speed loop and the position loop, improving response speed and control accuracy, making the shaft movement smoother and reducing jamming.

[0116] The driver feeds back its current position to the control system PLC via a bus. The control system PLC can complete the threshold judgment of the current position within 50ms, ensuring the safe and stable execution of the action.

[0117] Mechanically, this drive system uses a geared motor to directly drive the wheels, employing friction to propel the stacker crane, thus eliminating the need for the traditional rack and pinion transmission. Furthermore, the installation of a laser rangefinder and reflector significantly reduces manpower and material costs. Compared to the original rack and pinion structure, this design eliminates the need to purchase additional racks based on production line length or to machine rack mounting surfaces. Mechanically, it only requires simple installation of a reflector and rangefinder, coupled with a dual closed-loop electrical system to achieve precise positioning. This greatly reduces manufacturing costs, as well as subsequent installation, commissioning, and maintenance costs.

[0118] This utility model is described in detail for the purpose of making the disclosure clearer, and the prior art will not be listed one by one.

[0119] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. It is obvious to those skilled in the art that multiple technical solutions of this utility model can be combined. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model. All technical contents not described in detail in this utility model are publicly known technologies.

Claims

1. A precision positioning system for an FMS (Flexible Management System) transport robot, characterized in that: It includes a control system PLC, a host computer, a distance sensor, a frequency converter, and an encoder; the frequency converter is electrically connected to a motor in the corresponding direction; The encoders include speed encoder A, speed encoder B, and rotary encoder; Frequency converters include horizontal axis frequency converters, vertical axis frequency converters, and longitudinal axis frequency converters; Horizontal axis frequency converters correspond to horizontal walking motors; vertical axis frequency converters correspond to vertical motors; and longitudinal axis frequency converters correspond to longitudinal rotating motors. The control system PLC is electrically connected to the host computer, sensors, horizontal axis frequency converter, vertical axis frequency converter, and longitudinal axis frequency converter, respectively. The horizontal axis frequency converter is electrically connected to the speed encoder and the horizontal laser rangefinder A respectively; The vertical axis frequency converter is electrically connected to the vertical laser rangefinder and speed encoder B respectively; The longitudinal axis frequency converter is electrically connected to the rotary encoder.

2. The FMS transfer robot precision positioning system according to claim 1, characterized in that: Range sensor with reflector; The reflector includes a horizontal reflector (1) and a vertical reflector (3) mounted on the frame; the laser rangefinder includes a horizontal laser rangefinder (2) and a vertical laser rangefinder (4). A horizontal reflector (1) is equipped with a horizontal laser rangefinder (2), and a vertical reflector (3) is equipped with a vertical laser rangefinder (4).

3. The FMS transfer robot precision positioning system according to claim 1, characterized in that: PLC (Power Control System) for upper computer scheduling and control; The control system PLC is electrically connected to the human-machine interface (HMI). Human-Machine Interface (HMI) system for setting point coordinates and modifying parameters; The control system PLC sends commands to the horizontal axis frequency converter, the vertical axis frequency converter, and / or the longitudinal axis frequency converter, respectively. The laser rangefinder collects obstacle avoidance and limit information and sends it to the control system. The horizontal axis frequency converter receives the speed loop of the speed encoder A and the position loop of the horizontal laser rangefinder, respectively. The vertical axis frequency converter receives the speed loop of the speed encoder B and the position loop of the vertical laser rangefinder, respectively. The longitudinal axis frequency converter receives the electrical connection of the rotary encoder.

4. The FMS transfer robot precision positioning system according to claim 1, characterized in that: In the horizontal axis frequency converter, the input terminals L1~L3 are connected to the 380V branch terminal UKK through the circuit breaker QF8 to input current; a braking resistor R2 is electrically connected between terminals R1 and R2 for energy-saving braking when the frequency converter decelerates. X130 port, connected to 24V power supply; The X134 port serves as the digital input of the horizontal axis inverter. It has two +24VOUT outputs: one is connected to limit switch DI16 via horizontal negative limit switch S1, and the other is connected to limit switch DI17 via horizontal positive limit switch S1. The X135 port serves as the digital output of the horizontal axis inverter. DO1 is used to control the brake contactor KM2, which in turn supplies power to the horizontal motor brake. The U, V, W, and PE ports serve as the outputs of the horizontal axis frequency converter, used to control the horizontal walking motor. The X136 port is connected to the motor's speed encoder, serving as the speed loop signal source for the horizontal axis inverter. The X2100 port is connected to a laser rangefinder encoder, serving as the position loop signal source for the horizontal axis inverter.

5. The FMS transfer robot precision positioning system according to claim 1, characterized in that: Speed ​​encoder A or speed encoder B uses a distance measuring encoder DL100-21AA2101 connected to the X2100 interface of the corresponding strain frequency converter as a position loop encoder.

6. The FMS transfer robot precision positioning system according to claim 1, characterized in that: The motor's built-in encoder is connected to the corresponding strain gauge X136 interface as a speed loop encoder.

7. The FMS transfer robot precision positioning system according to claim 1, characterized in that: The control system PLC and the frequency converter are connected by a function block FB284 and use message communication.

8. The FMS transfer robot precision positioning system according to claim 1, characterized in that: The walking motor is connected to the drive wheels; The control system PLC has safety range thresholds set, which include point thresholds for the horizontal axis, vertical axis and longitudinal axis. Based on the safety range threshold, it is determined whether the actual position of the transfer robot is within the safety range, and the result is fed back to the control system PLC.

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