High-precision incoming material alignment and positioning system and method

Abstract

A high-precision incoming material alignment and positioning system, comprising: a front alignment workpiece (1), a front driving device (4), a rear alignment workpiece (2), a rear driving device (3), two side alignment workpieces (5), a servo motor (6), a conveying device, a servo controller (7) and a main controller (9). The front driving device (4) is connected to the front alignment workpiece (1); the rear driving device (3) is connected to the rear alignment workpiece (2); the two side alignment workpieces (5) are in transmission connection to the servo motor (6); the servo controller (7) is connected to the servo motor (6); the servo controller (7) starts the servo motor (6) in a torque control mode and measures the torque of the servo motor (6). According to the technical solution, whether alignment is conducted in place is determined by measuring the torque generated by the servo motor (6) during alignment of an incoming material; by using the torque as the criterion for determining whether alignment is completed, instead of the use of the path distance as the criterion in a conventional alignment system, high-precision adaptive alignment and positioning can be performed on incoming materials of the same specification but with slight differences in size.

Description

A high-precision correction and positioning system and method for incoming materials

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on December 28, 2023, with application number 202311834031.2, and entitled “A high-precision correction and positioning system and method for incoming materials”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application belongs to the field of photovoltaic production and manufacturing technology, and in particular relates to a high-precision correction and positioning system and method for incoming materials. Background Art

[0003] In actual production, it is often necessary to align and position flat incoming materials before transferring them to the next processing step for further production. Currently, the alignment and positioning of flat incoming materials is mainly achieved by using a combination of cylinders or cylinders combined with servo positioning. This method has the following main drawbacks: 1. When the cylinder is combined with servo positioning, the existing control method uses established stroke parameters for control, that is, the stroke of the cylinder during alignment and positioning is a fixed value, but there are errors in the product size. If the product size is too small, it will affect the positioning accuracy, and if the product size is too large, it will affect the normal operation of the equipment; 2. During the production process, the size of the incoming materials fluctuates within the upper and lower limits, and the equipment needs to be constantly adjusted to meet production needs.

[0004] Summary of the Invention

[0005] The present application provides a high-precision correction and positioning system for incoming materials to solve the technical problems mentioned in the background technology.

[0006] A technical solution of the present application is as follows: A high-precision correction and positioning system for incoming materials, comprising: a front correction workpiece, a front drive device, a rear correction workpiece, a rear drive device, correction workpieces on both sides, a servo motor, a transmission device servo controller and a main controller. A correction station is set on the transmission equipment, the front correction workpiece is installed in front of the correction station in the transmission direction, the rear correction workpiece is installed in the rear of the correction station in the transmission direction, the correction workpieces on both sides are installed on both sides of the correction station, the front drive device is connected to the front correction workpiece for driving the front correction workpiece to rise and fall, the rear drive device is connected to the rear correction workpiece for driving the rear correction workpiece to rise and fall and move toward the direction of the front correction workpiece, the correction workpieces on both sides are connected to the servo motor for transmission, and the servo motor Used to drive the workpieces on both sides to move toward the correction station, the servo controller is connected to the servo motor, and the main controller is respectively connected to the front drive device, the rear drive device, the transmission device and the servo controller, and is used to control the start and stop of the front drive device, the rear drive device and the transmission device and send a start signal to the servo controller. The servo controller is used to start the servo motor and detect the torque of the servo motor in a torque control mode according to the start signal. The main controller compares the detected torque with the preset torque. When the detected torque is greater than or equal to the preset torque value, it sends a stop signal to the servo controller, and the servo controller stops the servo motor. The preset torque value is the output torque value of the servo motor when the incoming material is corrected.

[0007] Optionally, in the torque control mode, the servo controller detects the position of the servo motor, and the main controller compares the detected position with the preset limit position. When the detected position reaches the preset limit position, a stop signal is sent to the servo controller, and the servo controller stops the servo motor. The preset limit position is the position of the servo motor when the workpieces on both sides are aligned and clamped to form incoming materials.

[0008] Optionally, when it is detected that the incoming material enters the straightening station, the main controller controls the front drive device to start, and when a preset delay is reached, the main controller controls the transmission device to stop and controls the rear drive device to start.

[0009] Optionally, a transmission belt is arranged below the correction station, and the installation direction of the transmission belt is perpendicular to the conveying direction of the conveying device. Transmission wheels are arranged at both ends of the transmission belt, and one of the transmission wheels is connected to the output shaft of the servo motor. The correction workpieces on both sides are arranged on a correction workpiece mounting bracket, and the correction workpiece mounting bracket is fixed to the transmission belt.

[0010] Optionally, the front straightening workpiece has a circular structure and a bearing is arranged in the center. There are multiple front straightening workpieces, and the bearings of the multiple front straightening workpieces are all connected to the connecting rod. The connecting rod is connected to the front drive device, and the front drive device is a cylinder.

[0011] Optionally, the rear drive device is a rotary telescopic cylinder.

[0012] Another technical solution of the present application is as follows: a method for high-precision alignment and positioning of incoming materials, used in any of the above-mentioned high-precision alignment and positioning systems for incoming materials, comprising:

[0013] S10: When it is detected that the incoming material enters the correction station, the front driving device is controlled to start, the front driving device drives the front correction workpiece to rise, the transmission device is controlled to stop and the rear driving device is controlled to start, the rear driving device drives the rear correction workpiece to rise and move toward the incoming material, and the rear correction workpiece clamps the incoming material;

[0014] S20: Start the servo motor in torque control mode, and the servo motor drives the workpiece on both sides to move toward the incoming material;

[0015] S30: Detecting the torque of the servo motor and comparing the detected torque with a preset torque value, where the preset torque value is the output torque value of the servo motor when the incoming material is corrected;

[0016] S40: When the detected torque value of the servo motor is less than the preset torque, it is determined that the correction is not completed and the servo motor continues to operate;

[0017] When the detected torque value of the servo motor is greater than or equal to the preset torque, it is determined that the correction is completed, the servo motor is stopped, the front drive device and the rear drive device are reset, and the transmission device is started.

[0018] Optionally, it also includes: detecting the position of the servo motor and comparing the detected position with a preset limit position, and stopping the servo motor when the detected position reaches the preset limit position. The preset limit position is the position of the servo motor when the workpieces on both sides are aligned and clamped to form incoming materials.

[0019] The beneficial effects of the present application are as follows: the present application determines whether the correction is in place by detecting the torque generated by the servo motor during the correction process of the incoming material. By using the torque size as the standard for whether the correction is completed, instead of using the path distance of the traditional correction system as the standard, high-precision adaptive correction and positioning can be achieved for incoming materials of the same specifications but with slight differences in size. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG1 is a schematic structural diagram of a high-precision correction and positioning system for incoming materials of the present application.

[0021] FIG2 is a structural block diagram of a high-precision correction and positioning system for incoming materials of the present application.

[0022] FIG3 is a schematic diagram of the installation of the workpieces on both sides of a high-precision alignment and positioning system for incoming materials of the present application.

[0023] FIG4 is a flow chart of a high-precision correction and positioning method for incoming materials of the present application. DETAILED DESCRIPTION

[0024] In order to enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. The described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0025] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0026] In a technical solution of the present application, Figures 1 and 2 are respectively a structural schematic diagram and a structural block diagram provided according to the specific structure of a high-precision correction and positioning system for incoming materials of the present application. As shown in Figures 1 and 2, the present application specifically includes: a front correction workpiece 1, a front drive device 4, a rear correction workpiece 2, a rear drive device 3, correction workpieces on both sides 5, a servo motor 6, a servo controller 7, a transmission device and a main controller 9. The transmission device is used to transmit flat-plate incoming materials, wherein a correction station is set on the transmission equipment 8.

[0027] The front return workpiece 1 is installed in front of the return station in the direction of transmission, which is the right side in the direction shown in Figure 1. The rear return workpiece 2 is installed in the rear of the return station in the direction of transmission, which is the left side in the direction shown in Figure 1. The two side return workpieces 5 are installed on both sides of the return station, which are the upper and lower sides in the direction shown in Figure 1.

[0028] The front drive device 4 is connected to the front return workpiece 1 and is used to drive the front return workpiece 1 to rise and fall. The rear drive device 3 is connected to the rear return workpiece 2 and is used to drive the rear return workpiece 2 to rise and fall and move toward the front return workpiece 1. The return workpieces 5 on both sides are connected to the servo motor 6, and the servo motor 6 is used to drive the return workpieces 5 on both sides to move toward the return station.

[0029] As shown in Figure 2, the servo controller 7 is connected to the servo motor 6, and the main controller 9 is respectively connected to the front drive device 4, the rear drive device 3, the transmission device and the servo controller 7, and is used to control the start and stop of the front drive device 4, the rear drive device 3 and the transmission device and send a start signal to the servo controller 7. The servo controller 7 is used to start the servo motor 6 and detect the torque of the servo motor 6 in a torque control mode according to the start signal. The main controller 9 compares the detected torque with the preset torque. When the detected torque is greater than or equal to the preset torque value, it sends a stop signal to the servo controller 7. The servo controller 7 stops the servo motor 6. The preset torque value is the output torque value of the servo motor 6 when the incoming material is straightened.

[0030] When the incoming material enters the alignment station, the main controller 9 activates the front drive 4. After a preset delay, the main controller 9 stops the conveyor and activates the rear drive 3. The delay is set to prevent the incoming material flow from skewing beyond the alignment position, causing alignment errors. This delay is typically achieved by adjusting the frequency conversion deceleration delay. The duration is adjusted based on on-site commissioning and ranges from 2 to 3 seconds.

[0031] In one embodiment of the present technical solution, in the torque control mode, the servo controller 7 detects the position of the servo motor 6, and the main controller 9 compares the detected position with the preset limit position. When the detected position meets the preset limit position, a stop signal is sent to the servo controller 7, and the servo controller 7 stops the servo motor 6. The preset limit position is the position of the servo motor 6 when the two-side correction workpiece 5 clamps the incoming material. Since the incoming material may be damaged or too thin or too light, the torque of the servo motor 6 does not reach the set value when the incoming material is deformed by the clamp. At this time, if the motor position is not restricted, the two-side correction workpiece 5 will continue to move inward until the two-side correction workpiece 5 cannot move, which may cause damage to the hardware incoming material in severe cases. To this end, it is necessary to limit the limit stroke of the inward movement of the two-side correction workpiece 5 within the time period of monitoring the torque value, specifically to detect and limit the position of the servo motor 6. If the preset limit position is set too large, the correction time will be prolonged; if it is set too small, the degree of adaptability will be poor. Therefore, when the workpiece 5 on both sides is clamped to clamp the incoming material or when there is a difference of 2 to 5 mm, the position of the corresponding servo motor 6 is set to the preset limit position. The specific value can be determined based on the actual size accuracy range and technical requirements of the incoming material.

[0032] In one embodiment of the present technical solution, the front alignment workpiece 1 is circular in structure and has a bearing disposed at its center. Multiple front alignment workpieces 1 are provided, and the bearings of each of the multiple front alignment workpieces 1 are connected to a connecting rod, which is connected to the front drive device 4, which is a pneumatic cylinder. The front alignment workpiece 1 needs to be arranged horizontally. For example, as shown in FIG1 , two front alignment workpieces 1 are provided. When aligning the incoming material on both sides, the incoming material is clamped by the front alignment workpiece 1 and the rear alignment workpiece 2, i.e., it is clamped in the direction of material transmission. Therefore, a circular embedded bearing is employed to reduce the resistance to moving the incoming material during left-right alignment, thereby better completing the alignment action.

[0033] In one embodiment of this technical solution, the rear drive device 3 can be specifically implemented as a rotary telescopic cylinder. In actual use, the incoming material will pass directly above the rear return cylinder. In the reset state, the rear return cylinder and the rear return block are in the lower position, not obstructing the passage of the incoming material. When the return action begins, the rear return cylinder must first drive the rear return workpiece 2 upward, and then move it in the direction of the incoming material to achieve clamping.

[0034] In one embodiment of the present technical solution, the workpieces 5 on both sides are connected to the servo motor 6 for transmission, as shown in Figure 3. A transmission belt 74 is arranged below the correction station, and the installation direction of the transmission belt 74 is perpendicular to the transmission direction of the conveying device. Transmission wheels 72 are arranged at both ends of the transmission belt 74, and one of the transmission wheels 72 is connected to the output shaft of the servo motor 6 for transmission. Specifically, the output shaft of the servo motor 6 is connected to the coupling 71, and the coupling 71 is connected to the transmission shaft 73. Two transmission wheels 72 are arranged on the transmission shaft 73, and the two transmission wheels are respectively connected to the two transmission belts 74 on the left and right sides, and the two are controlled by one servo motor to correct the workpieces on both sides. The two alignment workpieces 5 are mounted on alignment workpiece mounting brackets 51, which are secured to the transmission belt 74. It should be noted that since two alignment workpieces 5 are provided, one on each side of the alignment station, two alignment workpiece mounting brackets 51 are also provided. The left alignment workpiece mounting bracket 51 and the right alignment workpiece mounting bracket 51 are connected to the upper and lower layers of their respective transmission belts 74, respectively, to achieve opposite movement directions. For example, if the left alignment workpiece mounting bracket 51 is connected to the upper layer of the transmission belt, the right alignment workpiece mounting bracket 51 is connected to the lower layer of the transmission belt, and vice versa. The two alignment workpieces are mounted on the alignment workpiece mounting brackets 51, which are driven by the transmission belt 74. The two alignment workpieces mounted on the alignment workpiece mounting brackets 51 form a two-point straight line correction surface, thereby aligning the incoming material. The alignment workpiece mounting brackets 51 are slidably mounted on guide rods, which are connected perpendicular to the conveying direction of the conveyor. Reference numeral 75 represents a screw, which precisely controls the movement of the alignment blocks on both sides.

[0035] In one technical solution of the present application, FIG4 is a flowchart provided according to a specific process of a high-precision alignment method for incoming materials of the present application, which is used in any of the above-mentioned high-precision alignment systems for incoming materials, including:

[0036] S10: When it is detected that the incoming material enters the correction station, the front drive device 4 is controlled to start, the front drive device 4 drives the front correction workpiece 1 to rise, the transmission device is controlled to stop and the rear drive device 3 is controlled to start, the rear drive device 3 drives the rear correction workpiece 2 to rise and move toward the incoming material, and the rear correction workpiece 2 clamps the incoming material to complete the correction of the front and rear sides of the incoming material.

[0037] When the incoming material is detected entering the alignment station, the front alignment workpiece is raised, and the conveyor continues to transmit. After a preset delay, the conveyor stops. The delay is set to prevent the incoming material flow from skewing beyond the alignment position and causing alignment errors. Generally, the delay is adjusted by adjusting the frequency conversion deceleration delay. The duration is adjusted according to on-site commissioning and ranges from 2 to 3 seconds. After the front and rear sides of the incoming material are aligned, the incoming material is perpendicular to the transmission direction of the conveyor 8.

[0038] S20: The servo motor 6 is activated in torque control mode. The servo motor 6 drives the two side alignment workpieces 5 to move toward the incoming material. The two alignment blocks are parked parallel to each other on either side of the alignment station. After the incoming material completes the first alignment, the servo motor 6 is activated by the servo controller 7. The servo motor 6 stops when it reaches the set parameter value through torque control, achieving normal alignment of the incoming material.

[0039] S30: Detecting the torque of the servo motor 6 and comparing the detected torque with a preset torque value, where the preset torque value is the output torque value of the servo motor 6 when the incoming material is corrected.

[0040] When the servo motor 6 is running, the control module switches to torque control, detects the current torque value, and compares it with the preset set torque value. Among them, the detection of the torque value is a function of the servo controller 7 itself and will not be repeated here.

[0041] When the incoming material has no contact with the return workpieces 5 on both sides, if the return workpieces on both sides move in the direction of incoming material transmission, there will be no torque before contact with the incoming material. When the incoming material is contacted and clamped, the resistance will become greater and greater; considering that the incoming material is not centered, there will be friction between the incoming material and the conveyor belt during the process of pushing the incoming material, so there will be a certain resistance during the return process, and the torque output by the motor will increase.

[0042] S40: When the detected torque value of the servo motor 6 is less than the preset torque, it is determined that the correction is not completed, and the servo motor 6 continues to operate.

[0043] The incoming material is considered not yet properly aligned. The workpiece 5, aligned on both sides, continues to move inward, clamping, and re-aligning, during which the current torque value is monitored in real time. To prevent the incoming material from being aligned but the detection device detects abnormal operation, a torque control action limit has been added. During the alignment process, alignment is considered complete if any of the following conditions are met: 1. The current torque value is greater than or equal to the set torque value; 2. The torque control action value reaches the set limit.

[0044] Among them, 2 specifically means: detecting the position of the servo motor 6, and comparing the detected position with the preset limit position, and stopping the servo motor 6 when the detected position reaches the preset limit position. The preset limit position is the position of the servo motor 6 when the workpiece 5 on both sides is clamped to clamp the incoming material.

[0045] When the detected torque value of the servo motor 6 is greater than or equal to the preset torque, it is determined that the reset is completed, the servo motor 6 is stopped, the front drive device 4 and the rear drive device 3 are reset, and the transmission device is started.

[0046] It is considered that the correction has been completed and the entire correction action is completed. A command is issued to reset all the correction workpieces and cylinders. The incoming materials that have been corrected and positioned continue to be transported to the next production position.

[0047] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present application and are not limiting. Although the present application has been described in detail with reference to examples, ordinary technicians in this field should understand that the technical solutions of the present application can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present application, which should be included in the scope of protection of the claims of the present application.

Claims

1. A high-precision incoming material rectifying and positioning system, characterized in that, Including: a front rectifying workpiece (1), a front driving device (4), a rear rectifying workpiece (2), a rear driving device (3), two side rectifying workpieces (5), a servo motor (6), a servo controller (7), a transmission device (8) and a main controller (9). A rectifying station is arranged on the transmission device (8). The front rectifying workpiece (1) is installed in front of the transmission direction of the rectifying station. The rear rectifying workpiece (2) is installed behind the transmission direction of the rectifying station. The two side rectifying workpieces (5) are installed on both sides of the rectifying station. The front driving device (4) is connected to the front rectifying workpiece (1) and is used to drive the front rectifying workpiece (1) to move up and down. The rear driving device (3) is connected to the rear rectifying workpiece (2) and is used to drive the rear rectifying workpiece (2) to move up and down and move towards the front rectifying workpiece (1). The two side rectifying workpieces (5) are in transmission connection with the servo motor (6). The servo motor (6) is used to drive the two side rectifying workpieces (5) to move towards the rectifying station. The servo controller (7) is connected to the servo motor (6). The main controller (9) is respectively connected to the front driving device (4), the rear driving device (3), the transmission device and the servo controller (7), and is used to control the start and stop of the front driving device (4), the rear driving device (3) and the transmission device and send a start signal to the servo controller (7). The servo controller (7) is used to start the servo motor (6) in a torque control mode according to the start signal and detect the torque of the servo motor (6). The main controller (9) compares the detected torque with a preset torque. When it is satisfied that the detected torque is greater than or equal to the preset torque value, a stop signal is sent to the servo controller (7). The servo controller (7) stops the servo motor (6). The preset torque value is the output torque value of the servo motor (6) when rectifying the incoming material.

2. The high-precision incoming material alignment and positioning system according to claim 1, wherein In the torque control mode, the servo controller (7) detects the position of the servo motor (6). The main controller (9) compares the detected position with a preset limit position. When it is satisfied that the detected position reaches the preset limit position, a stop signal is sent to the servo controller (7). The servo controller (7) stops the servo motor (6). The preset limit position is the position of the servo motor (6) when the two side rectifying workpieces (5) clamp the incoming material.

3. The high-precision incoming material alignment and positioning system according to claim 1, characterized in that When it is detected that the incoming material enters the rectifying station, the main controller (9) controls the front driving device (4) to start. When the preset delay is reached, the main controller (9) controls the transmission device to stop and controls the rear driving device (3) to start.

4. The high-precision incoming material alignment and positioning system according to claim 1, characterized in that A conveyor belt (74) is provided below the alignment station. The installation direction of the conveyor belt (74) is perpendicular to the conveying direction of the conveying device. Driving wheels (72) are provided at both ends of the conveyor belt (74). One of the driving wheels (72) is in transmission connection with the output shaft of the servo motor (6). The two-sided alignment workpieces (5) are arranged on an alignment workpiece mounting bracket (51), and the alignment workpiece mounting bracket (51) is fixed to the conveyor belt (74).

5. The high-precision incoming material alignment and positioning system according to claim 1, wherein, The front alignment workpiece (1) has a circular structure and a bearing is provided at the center. A plurality of the front alignment workpieces (1) are provided. The bearings of the plurality of front alignment workpieces (1) are all connected to a connecting rod, and the connecting rod is connected to the front driving device (4). The front driving device (4) is a cylinder.

6. The high-precision incoming material alignment and positioning system according to claim 1, characterized in that, The rear driving device (3) is a rotary telescopic cylinder.

7. A high-precision incoming material rectification and positioning method, characterized in that, The high-precision incoming material alignment and positioning system according to any one of claims 1 to 7, comprising: S10: When it is detected that the incoming material enters the alignment station, control the front driving device (4) to start. The front driving device (4) drives the front alignment workpiece (1) to rise. Control the conveying device to stop and control the rear driving device (3) to start. The rear driving device (3) drives the rear alignment workpiece (2) to rise and move towards the incoming material, and the rear alignment workpiece (2) clamps the incoming material. S20: Start the servo motor (6) in a torque control mode. The servo motor (6) drives the two-sided alignment workpieces (5) to move towards the incoming material. S30: Detect the torque of the servo motor (6), and compare the detected torque with a preset torque value. The preset torque value is the output torque value of the servo motor (6) when aligning the incoming material. S40: When the detected torque value of the servo motor (6) is less than the preset torque, it is determined that the alignment is not completed, and the servo motor (6) continues to run. When the detected torque value of the servo motor (6) is greater than or equal to the preset torque, it is determined that the alignment is completed, stop the servo motor (6), reset the front driving device (4) and the rear driving device (3), and start the conveying device.

8. The high-precision incoming material alignment and positioning method according to claim 7, wherein It further comprises: Detect the position of the servo motor (6), and compare the detected position with a preset limit position. When the detected position reaches the preset limit position, stop the servo motor (6). The preset limit position is the position of the servo motor (6) when the two-sided alignment workpieces (5) clamp the incoming material.

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