A semi-automated production system for fiber lasers based on human-machine collaboration
By using a semi-automated production system with human-machine collaboration, and by employing an adjustable conveyor speed double-speed chain and real-time monitoring equipment, the problems of low efficiency, insufficient precision, and ergonomics in fiber laser production have been solved. This has enabled efficient and flexible production of multiple models, reducing costs and error rates.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- MINGLEI LASER INTELLIGENT EQUIP (HEYUAN) CO LTD
- Filing Date
- 2025-05-21
- Publication Date
- 2026-06-30
AI Technical Summary
The existing fiber laser production process suffers from low efficiency, insufficient precision, ergonomic issues, lack of flexibility, and high cost. Traditional automated equipment is difficult to adapt to the production of multiple models, and information silos lead to delays in abnormal response.
A semi-automated production system based on human-machine collaboration is adopted, which utilizes adjustable conveyor speed double-speed chains, photoelectric sensors, vision inspection components, pressure detectors, etc. to achieve dynamic speed regulation and real-time monitoring. Combined with human intervention, it improves production flexibility and efficiency.
It increased production efficiency by 20%, reduced the error rate of key processes to 0.5%, supported the production of multiple laser models, reduced quality problems caused by human operation differences and fatigue, and reduced equipment complexity and cost.
Smart Images
Figure CN224429206U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of laser manufacturing technology, specifically a semi-automated production system for fiber lasers based on human-machine collaboration. Background Technology
[0002] The production of fiber lasers involves several different processes. Currently, the main methods are as follows:
[0003] 1. Low efficiency of purely manual operation mode - It takes 3-5 hours to manually assemble a single machine, which depends on the experience of skilled workers and the yield rate fluctuates greatly (60%-85%); Precision limitation - Fiber optic splicing alignment relies on visual operation under a microscope, and the repeatability is only ±5μm, which is difficult to meet the requirements of high-power lasers; It is contrary to ergonomics - The assembly of precision parts requires maintaining a fixed posture for a long time, and worker fatigue leads to a decline in quality.
[0004] 2. Pure speed-double chain conveyor solution – Fixed cycle time: Traditional speed-double chains run at a fixed speed, which can easily lead to accumulation or waiting at manual workstations, resulting in an efficiency loss of 15%-30%; Information silos: Material status and manual operation data are not integrated, and the response to abnormalities is delayed by more than 10 minutes; Lack of human-machine interaction: Workers need to repeatedly check paper work orders, and the operation error rate is as high as 8%.
[0005] 3. When building a fully automated production line, there is a lack of flexibility – its rigid automated equipment is difficult to adapt to small-batch, multi-model production, and the time spent on line changeover and adjustment exceeds 48 hours; the cost is high – the initial investment of a six-axis robotic arm + vision system exceeds 2 million yuan, which is difficult for small and medium-sized manufacturers to afford; there are also technical blind spots – complex cable routing, abnormal glue curing and other scenarios still require manual intervention, making it difficult to achieve full automation. Summary of the Invention
[0006] To address the aforementioned technical problems, this invention provides a semi-automated production system for fiber lasers based on human-machine collaboration.
[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0008] A semi-automatic fiber laser production system based on human-machine collaboration includes a frame and a control terminal. The frame is equipped with a speed-adjustable double-speed chain main conveyor line, and several workstations are arranged sequentially along the speed-adjustable double-speed chain branch conveyor lines between adjacent workstations. The speed-adjustable double-speed chain branch conveyor lines are connected to the speed-adjustable double-speed chain main conveyor line. A switch for controlling the speed-adjustable double-speed chain branch conveyor line is provided in the area where the workstation is located, and a photoelectric sensor for detecting the material accumulation state is provided in the area where the workstation is located. The speed-adjustable double-speed chain main conveyor line, the speed-adjustable double-speed chain branch conveyor line, and the photoelectric sensor are all connected to the control terminal.
[0009] As a further improvement, the double-speed chain branch conveyor line is equipped with a weighing sensor connected to the control terminal.
[0010] As a further improvement, the control terminal is connected to an alarm.
[0011] As a further improvement, the workstation area is equipped with a vision inspection component and a flat panel connected to a control terminal. The vision inspection component is used to capture and inspect the coupling angle of the optical fiber.
[0012] As a further improvement, the frame is equipped with an adjustable support for operators to sit on at the corresponding workstations, and the adjustable support is equipped with a pressure detector.
[0013] As a further improvement, a tool monitoring component is provided at the corresponding workstation inside the rack to monitor the number of times tools are picked up and put down.
[0014] As a further improvement, the tool monitoring component includes a tool holder with a pressure sensing layer inside the tool holder that is connected to a control terminal.
[0015] This utility model has the following beneficial technical effects:
[0016] 1. Efficiency Improvement: By dynamically adjusting speed to reduce production line idle time, overall production capacity is increased by 20%;
[0017] 2. Controllable quality: Real-time verification of manual operation data reduces the error rate of key processes to below 0.5%; 3. Flexible expansion: Supports mixed production of 5 laser models on the same production line with a changeover time of less than 30 minutes. Attached Figure Description
[0018] Figure 1 This is a three-dimensional structural diagram of the present invention. Detailed Implementation
[0019] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0020] In the description of this invention, it should be understood that if terms such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.
[0022] like Figure 1 As shown, a semi-automatic fiber laser production system based on human-machine collaboration includes a frame 1 and a control terminal. The frame 1 is equipped with a speed-adjustable double-speed chain main conveyor 2. Several workstations 6 are arranged sequentially along the speed-adjustable double-speed chain main conveyor 2. A speed-adjustable double-speed chain branch conveyor 3 is connected to each adjacent workstation. A switch for controlling the speed-adjustable double-speed chain branch conveyor is located in the area of each workstation. A photoelectric sensor 4 for detecting the material accumulation state is also located in the area of each workstation. The speed-adjustable double-speed chain main conveyor 2, the speed-adjustable double-speed chain branch conveyor 3, and the photoelectric sensor 4 are all connected to the control terminal. The speed-adjustable double-speed chain main conveyor and the speed-adjustable double-speed chain branch conveyor can each be composed of a corresponding variable frequency motor and a connected belt conveyor. The variable speed of the variable frequency motor allows for speed adjustment. The number of workstations depends on the needs and production line.
[0023] The double-speed chain main conveyor line is the core channel for transporting materials between workstations. Its conveying speed can be adjusted by a variable frequency motor to adapt to the cycle time requirements of different processes. The double-speed chain branch conveyor line refers to auxiliary conveying units set up between adjacent workstations. It can adopt a chain plate structure with independent drive wheels to achieve local flow rate adjustment and alleviate the problem of mismatched production capacity between processes. Photoelectric sensors determine the accumulation state by monitoring the material's obstruction time, providing real-time feedback data to the control end. Switches are usually set as foot switches for convenient operation by the operator, improving ease of operation and allowing the operator to intervene in control according to the actual work progress.
[0024] Specifically, the main conveyor line continuously transports materials at a baseline speed. When material accumulates at the inlet of a workstation due to operational delays, a photoelectric sensor triggers a signal to the control unit, automatically reducing the speed of the upstream conveyor line or suspending conveying to prevent further congestion. If the operator finds that the automatic adjustment of the equipment is insufficient, they can manually adjust the operating status of the double-speed chain branch conveyor line via a switch. After integrating the data from various sensors, the control unit dynamically optimizes the speed ratio between the double-speed chain main conveyor line and the double-speed chain branch conveyor line, ensuring that the material flow rate between processes matches the rhythm of manual operation.
[0025] By employing an independent speed control mechanism for branch conveyor lines, each workstation can autonomously adjust its material supply speed according to actual operating conditions. Compared to fully automated production lines that rely on complex robotic arms for flexibility, this solution combines adjustable conveyor lines with manual intervention, significantly reducing equipment complexity while ensuring efficiency.
[0026] This application effectively reduces downtime caused by material accumulation between processes, avoiding manual idleness or overload issues due to fixed cycle times. The combination of real-time material status monitoring and manual intervention makes the production rhythm more aligned with actual working conditions. The coordinated control of adjustable-speed branch conveyors and the main conveyor maintains necessary flexibility for manual operation while preserving the efficiency of automated conveying.
[0027] In addition, the double-speed chain branch conveyor line is equipped with a weighing sensor connected to the control end, which is a device capable of detecting the weight of the material. Specifically, it can be implemented using a resistance strain gauge sensor or a piezoelectric sensor. By detecting the weight changes of the material on the branch conveyor line in real time, it is possible to determine whether the material is accumulating or if there is an abnormality in the conveying process.
[0028] The control unit refers to the computing device used to receive and process sensor signals, which can be implemented using a programmable logic controller (PLC) or an industrial computer. By receiving data signals from the weighing sensors, it can dynamically adjust the operating speed of the branch conveyor lines, thereby achieving coordinated control with the main conveyor line.
[0029] Specifically, during the operation of the double-speed chain branch conveyor line 3, load cells continuously collect the weight data of the conveyed materials and transmit the data to the control terminal in real time. The control terminal determines whether the current material conveying status is normal based on a preset weight threshold range. When the weight exceeds the threshold, it indicates that material accumulation or conveying stagnation may occur at that station. At this time, the control terminal sends a speed adjustment command to the double-speed chain branch conveyor line to match the rhythm of the main conveyor line by reducing or increasing the conveying speed. If the weight remains abnormal, an alarm mechanism is triggered to notify the operator to intervene. In this way, abnormal states during material conveying can be identified in real time, avoiding production line efficiency losses due to untimely manual inspections.
[0030] This application, by installing a weighing sensor in the double-speed chain branch conveyor line 3, enables real-time interaction between material weight data and the control system, thereby dynamically adjusting the conveying speed and eliminating production line imbalance caused by differences in manual operation or fluctuations in process time. It solves the problem of material accumulation or idle waiting caused by information silos in traditional production lines, achieving dynamic coordination between the branch conveyor line and the main conveyor line. Real-time monitoring of material weight data allows for rapid identification of abnormal conditions, avoiding production interruptions caused by delays in manual inspections, and reducing efficiency losses due to fixed cycle times.
[0031] For better alerts, an alarm is connected to the control unit. An alarm is a device that uses audible and visual signals to indicate abnormal conditions. Specifically, it can be implemented using an integrated device with a buzzer module and LED warning lights, which can be triggered when materials accumulate or tools malfunction.
[0032] Specifically, when the photoelectric sensor detects that the material accumulation on the branch conveyor line exceeds a set threshold, the control unit receives the signal and immediately triggers the alarm to issue a warning. Similarly, when the tool monitoring component detects that the number of times a tool has not returned to its position exceeds a preset value, the control unit will also trigger the alarm to remind the operator to handle the abnormality. Alarm signals can be set with different prompting modes according to the fault level; for example, continuous beeping accompanied by a red flash indicates an emergency shutdown event, while intermittent beeping accompanied by a yellow light indicates a normal abnormality requiring manual intervention.
[0033] By linking the control unit with the alarm, an alert is immediately triggered when the sensor detects an anomaly, enabling operators to respond to faults promptly. In a purely manual operation mode, workers rely on experience to judge problems, while this solution reduces the probability of human error through standardized alarm signals.
[0034] The workstation area is equipped with a vision inspection component 7 and a flat plate connected to the control terminal. The vision inspection component 7 is used to capture and inspect the coupling angle of the optical fiber.
[0035] The visual inspection component refers to a device that obtains the coupling state of the fiber end face through optical imaging. Specifically, it can be implemented by using an industrial camera in conjunction with a microscope lens to capture image data of the fiber docking area in real time.
[0036] Among them, the tablet refers to a display terminal with human-computer interaction function, which can be implemented by a touch LCD screen, and is used to provide operators with feedback on visual inspection results and process parameters.
[0037] Coupling angle detection refers to the process of analyzing the axial offset of the fiber end face using image processing algorithms. Specifically, it can be implemented using edge recognition combined with geometric fitting algorithms to quantitatively evaluate the alignment accuracy of fiber optic splices. These algorithms can be built into the corresponding chips.
[0038] Specifically, the vision inspection component 7 is fixedly installed above the workstation, with its lens axis perpendicular to the fiber optic delivery direction. When the material arrives at the workstation, a trigger mechanism activates the vision inspection component to capture an image of the fiber optic end face. The image data is transmitted to the control terminal via the industrial bus. The control terminal runs an image processing program to automatically calculate the included angle between the axes of the two fibers to be coupled and synchronously displays the deviation value on the workstation's flat panel. The operator adjusts the fiber optic clamps based on the real-time data displayed on the flat panel, while the control terminal records the angle data after each adjustment for process optimization.
[0039] Compared to existing technologies, current production processes rely on visual inspection using microscopes to determine alignment, which leads to the accumulation of subjective errors. This solution uses machine vision to digitally measure the coupling angle, eliminating the accuracy fluctuations caused by manual visual inspection. Traditional paper-based work order operations require workers to repeatedly check process parameters, while this solution uses a tablet to display the deviation between measured and standard values in real time, reducing information retrieval time during operation.
[0040] The application achieved online automatic detection of fiber coupling angle, transforming manual experience-based judgment into quantitative data guidance, effectively improving the positioning accuracy and consistency of the fiber optic splicing process. The human-machine interface design of the flat panel enhances the timeliness of operation guidance, avoids assembly errors caused by misremembering process parameters, and provides a structured record basis for the traceability and analysis of production data.
[0041] The machine frame 1 is equipped with an adjustable support frame 8 for the operator to sit on at the corresponding work station, and the adjustable support frame 8 is equipped with a pressure detector.
[0042] Among them, the adjustable support frame 8 refers to a support structure that can adjust the height or tilt angle according to the operator's body shape and operating needs. Specifically, it can be achieved by using a pneumatic lifting rod in conjunction with a multi-stage buckle mechanism, and the adjustment can be controlled by rotating a handle or an electric button. The pressure detector refers to a sensor unit embedded inside the support frame seat surface. Specifically, it can be achieved by using a piezoresistive thin-film sensor or a distributed fiber optic pressure sensor, which can monitor the pressure distribution of the operator's sitting posture in real time.
[0043] Specifically, during the fiber laser assembly process, operators adjust the height of the support frame according to their own height, allowing their arms to hang naturally on the workstation's operating surface. Pressure detectors continuously collect seated pressure data and transmit it to the control unit. When an abnormal pressure distribution is detected, such as pressure on one side consistently exceeding a threshold, the control unit triggers an alert prompting the operator to adjust their posture. Simultaneously, it automatically reduces the operating speed of the corresponding branch conveyor line to prevent assembly errors caused by fatigue.
[0044] Compared with existing technologies, traditional workstations do not have ergonomic support devices, requiring operators to stand or bend over for long periods of time, leading to muscle fatigue. This solution, however, uses an adjustable support frame to adapt to different body types and combines pressure detection to monitor the human body's condition in real time. This not only avoids the movement restrictions caused by fixed seats but also actively intervenes in poor working postures.
[0045] This application effectively alleviates operational errors caused by improper posture in precision assembly scenarios, reduces coupling angle deviation or uneven glue application caused by fatigue, and reduces the risk of occupational injury to operators due to prolonged fixed posture.
[0046] In addition, a tool monitoring component is installed at the corresponding workstation within rack 1 to monitor the number of times tools are picked up and put down. The tool monitoring component includes a tool rack 5, within which a pressure-sensing layer is arranged. When the operator picks up a tool from the tool rack, the pressure-sensing layer detects a decrease in weight, generates a pick-up signal, and records the number of times. After the tool is returned to its position, the pressure recovers, generates a put-back signal, and updates the number of times. The control terminal receives data in real time, establishes a tool usage log, and triggers an alert mechanism when the number of pick-up and put-down operations is abnormal.
[0047] Among them, the tool usage frequency monitoring refers to the function of recording the frequency of tool use. Specifically, it can be achieved through data interaction between the pressure sensing layer and the control terminal. When the tool is taken out or put back, a signal transmission is triggered, and the count is automatically accumulated.
[0048] This solution utilizes automated monitoring technology to transform tool usage behavior into a quantifiable data stream, enabling dynamic tracking and anomaly warnings. It solves the problem of inefficient tool management in manual operations, avoids process interruptions due to tool omissions, and improves production process reliability. Simultaneously, data accumulation provides a basis for process optimization, such as identifying the need to adjust the location of frequently used tools, thereby improving operational convenience.
[0049] In the specific production process of this invention, materials are first transported to the first workstation by the double-speed chain main conveyor. After processing at the first workstation, the operator controls a switch to increase the transmission speed of the double-speed chain branch conveyor, enabling the assembled materials to be quickly transported to the next workstation. When a deviation in the coupling angle of the materials is detected, an alarm is triggered, and the operator then corrects the deviation. Real-time monitoring is performed using a weighing sensor. If the weight of the materials on the double-speed chain branch conveyor exceeds a set value within a set time, it indicates material accumulation, triggering an alarm, and the operator promptly addresses the issue.
[0050] It should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A semi-automatic production system for fiber lasers based on human-machine collaboration, comprising a frame and a control terminal, characterized in that, The frame is equipped with a speed-adjustable double-speed chain main conveyor line, and several workstations are arranged sequentially along the speed-adjustable double-speed chain branch conveyor line between two adjacent workstations. The speed-adjustable double-speed chain branch conveyor line is connected to the speed-adjustable double-speed chain main conveyor line. A switch for controlling the speed-adjustable double-speed chain branch conveyor line is provided in the area where the workstation is located, and a photoelectric sensor for detecting the material accumulation state is provided in the area where the workstation is located. The speed-adjustable double-speed chain main conveyor line, the speed-adjustable double-speed chain branch conveyor line and the photoelectric sensor are all connected to the control terminal.
2. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 1, characterized in that, The double-speed chain branch conveyor line is equipped with a weighing sensor connected to the control terminal.
3. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 1, characterized in that, The control terminal is connected to an alarm.
4. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 1, characterized in that, The workstation area is equipped with a vision inspection component and a flat panel connected to the control terminal. The vision inspection component is used to capture and inspect the coupling angle of the optical fiber.
5. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 1, characterized in that, The machine frame is equipped with an adjustable support frame for operators to sit on at the corresponding workstations, and the adjustable support frame is equipped with a pressure detector.
6. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 1, characterized in that, The corresponding workstation within the rack is equipped with a tool monitoring component to monitor the number of times tools are picked up and placed.
7. The semi-automatic fiber laser production system based on human-machine collaboration according to claim 6, characterized in that, The tool monitoring component includes a tool rack, and a pressure sensing layer connected to the control terminal is provided inside the tool rack.