Hemming force online monitoring method and system, electronic device and storage medium

Abstract

A hemming force online monitoring method, applied to a robot hemming system. The hemming system uses a hemming tool (1) having a built-in pressure sensor (10); a pressure roller (11) is provided at the front end of a main shaft of the hemming tool; the pressure roller is used to hem a plate placed on the plane of a die (12); when a spring (13) in the hemming tool is compressed, a hemming force of the pressure roller is provided; a hemming forward angle is calculated on the basis of a spatial displacement of the pressure roller and an axial vector of the hemming tool; a hemming pressure angle is acquired; a spring pressure detected by the built-in pressure sensor is acquired; and the hemming force is calculated in real time on the basis of the hemming forward angle, the hemming pressure angle, and the spring pressure. Also disclosed are a hemming force online monitoring system, an electronic device, and a computer-readable storage medium. The method can realize accurate calculation and real-time monitoring of the hemming force, thereby saving the cost of equipment reconstruction and maintenance.

Description

Edge rolling force online monitoring method, system, electronic device and storage medium

[0001] Related applications

[0002] The present application claims priority to Chinese Patent Application No. 202410809632.6, filed on June 21, 2024, the contents of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0003] The present application relates to the technical field of robot edge rolling, and in particular to an edge rolling force online monitoring method, system, electronic device and storage medium. BACKGROUND

[0004] Edge rolling is a kind of edge covering process. Robot edge rolling process is to control the movement of edge rolling tool by robot according to predetermined program and trajectory, and to perform edge folding treatment on parts. Edge rolling process is often used to cover the edges of vehicle body parts to improve structural strength, sealing performance and appearance quality. Although there are many factors that affect the quality of edge covering, such as flanging height, edge covering radius, TCP-RTP value, edge rolling force and robot trajectory accuracy, the edge rolling force is always the key parameter that determines the forming quality of plate covering. The edge rolling force refers to the force provided by the robot to make the plate deform plastically during edge rolling forming.

[0005] In the edge rolling process, it is crucial to accurately control the edge rolling force, because it directly affects the dimensional accuracy, shape consistency of the final product and prevents material damage caused by excessive stress. The traditional edge rolling force monitoring system usually uses a one-dimensional force sensor integrated in the edge rolling tool to transmit the force value collected by the digital transmitter. The collected force value cannot reflect the true edge rolling pressure. At the same time, in the edge rolling process, human control of the edge rolling force is quite common, which is mainly based on the practical experience of the operator. However, this edge rolling force adjustment method that relies too much on individual experience and is guided by subjective judgment has significant limitations, and it is difficult to achieve precise control and real-time feedback adjustment of the edge rolling force. SUMMARY

[0006] The present application aims to provide a method and system that can accurately monitor the edge rolling force in real time.

[0007] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0008] An edge rolling force online monitoring method applied in a robot edge rolling system, the edge rolling system uses an edge rolling tool with a built-in force sensor, a pressure edge roller is arranged at the front end of the main shaft of the edge rolling tool, the pressure edge roller is used to roll the plate placed on the die plane, and the spring in the edge rolling tool provides the edge rolling force of the pressure edge roller when it is compressed. The method comprises the following steps:

[0009] According to the spatial displacement of the edge roller and the axial vector of the rolling tool, the rolling advance angle a is calculated;

[0010] An edge rolling pressure angle q is obtained, the edge rolling pressure angle q being an included angle between the generatrix of the edge roller and the axis of the main shaft of the rolling tool;

[0011] An obtained spring pressure F detected by the built-in force sensor S ;

[0012] According to the rolling advance angle a, the edge rolling pressure angle q and the spring pressure F S , the rolling force F is calculated in real time:

[0013] In an embodiment, the main shaft of the rolling tool is respectively provided with a connecting rod flange at both ends, and the axial vector of the rolling tool is a connecting vector of the center coordinates of the two connecting rod flanges;

[0014] The rolling advance angle a is an included angle between the spatial coordinate displacement of the center of the edge roller and the connecting vector of the center coordinates of the two connecting rod flanges.

[0015] In an embodiment, in the continuous rolling process, the spatial coordinates of the center of the edge roller at the initial position and the termination position are recorded at a predetermined sampling time interval, and the spatial coordinate displacement of the center of the edge roller is obtained.

[0016] And, the spatial coordinates of the centers of the two connecting rod flanges at the sampling termination position are recorded respectively, and the axial vector of the rolling tool is obtained.

[0017] In an embodiment, the rolling sampling time interval is the minimum time interval of the PLC controller sampling.

[0018] In an embodiment, the rolling sampling time interval is at least 100 ms.

[0019] In an embodiment, in the rolling process, when the rolling track is determined, the edge rolling pressure angle q is set as a fixed value.

[0020] In an embodiment, the spring pressure detection value obtained by the built-in force sensor is an analog signal, and the spring pressure analog signal is converted into a digital signal by using an analog-digital conversion circuit.

[0021] Based on the same inventive concept, the embodiments of the present application also provide a rolling force online monitoring system applied in the above-mentioned rolling force online monitoring method, and the system comprises:

[0022] A first data acquisition module is configured to obtain the spatial displacement of the edge roller and the axial vector of the rolling tool, and calculate the rolling advance angle a according to the spatial displacement of the edge roller and the axial vector of the rolling tool;

[0023] a second data acquisition module, configured to acquire a rolling pressure angle θ, the rolling pressure angle θ being an included angle between a generatrix of a rolling wheel and an axis of a main shaft of a rolling tool;

[0024] a third data acquisition module, configured to acquire a spring pressure F detected by an internal force sensor; S

[0025] a calculation module, configured to calculate a rolling force F in real time according to the rolling advancing angle α, the rolling pressure angle θ and the spring pressure F S

[0026] Based on the same inventive concept, the embodiment of the present application further provides an electronic device, comprising a memory and a processor; the processor is configured to read and execute a computer program stored in the memory, so as to realize the method for monitoring rolling force on line.

[0027] Based on the same inventive concept, the embodiment of the present application further provides a computer storage medium, wherein computer executable instructions are stored in the computer storage medium, and the computer executable instructions are executed to realize the method for monitoring rolling force on line.

[0028] According to the method for monitoring rolling force on line provided by the present application, by monitoring and recording a plurality of key characteristic parameters closely related to rolling force, including a rolling pressure angle, a rolling advancing angle and a spring pressure value detected by an internal force sensor of a rolling tool, the mechanical values collected by a sensor are effectively converted into rolling force values reflecting the real rolling state. The present application establishes a rolling force mathematical model based on the selection of spatial coordinate points and the idea of micro-element calculation, and the real change value of the rolling advancing angle is reflected by capturing the spatial coordinate displacement of the edge rolling wheel and the flange of the connecting rod in the rolling process. The accurate calculation and real-time monitoring of the rolling force are realized without increasing additional force sensors, so that the cost of equipment modification and maintenance is saved.

[0029] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent to those skilled in the art from the following description, or can be learned by practice of the present application. The objects and other advantages of the present application can be realized and achieved by the structures indicated in the specification, claims and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0030] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0031] Fig. 1 is a schematic diagram of the internal structure of a rolling tool;

[0032] ​​Fig. 2 is a flow chart of the online monitoring method of the rolling force in the embodiment of the present application;

[0033] Fig. 3 is a schematic diagram of the rolling process of the rolling tool in the embodiment of the present application;

[0034] Fig. 4 is a schematic diagram of the rolling lead angle;

[0035] Fig. 5 is a schematic diagram of the rolling pressure angle;

[0036] Fig. 6 is a schematic diagram of the structure of the online monitoring system of the rolling force in the embodiment of the present application;

[0037] Rolling tool 1; pressure sensor 10; edge rolling wheel 11; tire mold 12; spring 13; sensor pressure head 14; first connecting rod flange 15; second connecting rod flange 16. DETAILED DESCRIPTION

[0038] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0039] The present application discloses an online monitoring method of rolling force, which is applied to a robot rolling system. The robot rolling system uses a rolling tool to edge cover a plate. The rolling tool generally comprises an elastic connecting assembly and a rolling head assembly. According to the characteristics of the rolling process, the rolling head assembly is composed of different shaped rolling wheels, and the appropriate rolling wheel is selected according to the shape of the plate and the process requirements.

[0040] As shown in Fig. 1, an edge rolling wheel is arranged at the front end of the main shaft of the rolling tool 1. The edge rolling wheel 11 is used to edge cover the plate placed on the plane of the tire mold 12. The pressure sensor 10 and the spring 13 are arranged in the rolling tool 1. The spring 13 in the rolling tool 1 provides the rolling force of the edge rolling wheel 11 when it is compressed. The buffering of the spring 13 to the rolling pressure is also used to protect the safety of the rolling tool 1.

[0041] The pressure sensor 10 is coaxially arranged at the main shaft of the rolling tool 1, and the spring 13 is compressed by the sensor pressure head 14. The edge rolling roller 11 rolls the plate on the plane of the tire mold 12 to form the edge between the inner plate and the outer plate. In actual application, the edge rolling roller needs to be close to the outer plate during pre-rolling, and the outer plate needs to be close to the tire membrane after edge rolling. That is, the bending point of the pre-rolling part coincides with the edge rolling roller, and the fillet of the outer plate part coincides with the tire membrane after edge rolling. During the rolling process, the edge rolling roller 11 is subjected to pressure and transmits the pressure to the spring 13 in the rolling tool 1. The spring 13 is compressed, and the spring pressure provides the rolling force of the edge rolling roller 11. The spring pressure is transmitted to the pressure sensor 10 by the sensor pressure head 14, and the pressure sensor 10 is used to detect the spring pressure.

[0042] In the prior art, the spring in the rolling tool and the pressure sensor are used to realize the force feedback of the rolling force. In order to more accurately monitor the size and change of the rolling force, as shown in FIG. 2, the online monitoring method of the rolling force provided by the embodiment of the present application is as follows:

[0043] Step S1, calculating the rolling advance angle a according to the spatial displacement of the edge rolling roller and the axial vector of the rolling tool;

[0044] Step S2, obtaining the rolling pressure angle θ;

[0045] In actual application, the rolling pressure angle θ is the included angle between the generatrix of the roller and the axis of the main shaft of the rolling tool;

[0046] Step S3, obtaining the spring pressure F detected by the built-in force sensor S ;

[0047] The built-in force sensor is the pressure sensor 10 in FIG. 1;

[0048] Step S4, calculating the rolling force F in real time according to the rolling advance angle a, the rolling pressure angle θ, and the spring pressure F S ;

[0049] In the embodiment of the present application, the main shaft of the rolling tool is respectively provided with a connecting rod flange at both ends. The axial vector of the rolling tool is the connecting vector of the center coordinates of the two connecting rod flanges. The rolling advance angle a is the included angle between the spatial coordinate displacement of the center of the edge rolling roller and the connecting vector of the center coordinates of the two connecting rod flanges.

[0050] According to the embodiment of the present application, in the continuous rolling process, the spatial coordinates of the center of the edge rolling roller at the initial position and the termination position are recorded at a predetermined sampling time interval to obtain the spatial coordinate displacement of the center of the edge rolling roller. In addition, the spatial coordinates of the centers of the two connecting rod flanges at the sampling termination position are recorded respectively to obtain the connecting vector of the center coordinates of the two connecting rod flanges, which is recorded as the axial vector of the rolling tool.

[0051] According to one specific embodiment, as shown in Fig. 3, the first connecting rod flange 15 and the second connecting rod flange 16 are respectively arranged at the two ends of the main shaft of the rolling tool, and the calculation method of the rolling advance angle a is as follows:

[0052] Step S10, obtaining the first spatial coordinates A1(x1, y1, z1) of the center of the blanking roller 11 at the initial sampling position;

[0053] Step S11, obtaining the second spatial coordinates A2(x2, y2, z2) of the center of the blanking roller 11 at the termination sampling position after a predetermined sampling interval;

[0054] Step S12, obtaining the spatial coordinates B1(x3, y3, z3) of the center of the first connecting rod flange 15 and the spatial coordinates B2(x4, y4, z4) of the center of the second connecting rod flange 16 at the termination sampling position;

[0055] Step S13, calculating the rolling advance angle a according to the spatial coordinate displacement (x2-x1, y2-y1, z2-z1) of the center of the blanking roller and the axial vector (x4-x3, y4-y3, z4-z3) of the rolling tool;

[0056] The calculation formula is:

[0057] Wherein,

[0058] As shown in Fig. 4, the rolling advance angle a can be regarded as the included angle between the axis of the main shaft of the rolling tool and the tire membrane.

[0059] According to the embodiment of the present application, the rolling sampling time interval is the minimum time interval of the PLC controller sampling.

[0060] According to the embodiment of the present application, the rolling sampling time interval is at least 100 ms.

[0061] According to the embodiment of the present application, as shown in Fig. 5, the rolling pressure angle θ is the included angle between the generatrix of the roller and the axis of the main shaft of the rolling tool. Generally, the rolling pressure angle θ is taken as an acute angle. In the rolling process, when the rolling track is determined, the rolling pressure angle θ is set as a fixed value.

[0062] According to the embodiment of the present application, the spring pressure detection value obtained by the built-in force sensor of the rolling tool in real time is an analog signal, the spring pressure analog signal is converted into a digital signal by using an analog-digital conversion circuit, and the digital signal is sent to a signal processor for calculating the rolling force.

[0063] According to the online monitoring method of the rolling force provided in the application, by monitoring and recording a plurality of key characteristic parameters closely related to the rolling force, including the rolling pressure angle, the rolling forward angle and the spring pressure value detected by the built-in force sensor of the rolling tool, the mechanical values collected by the sensor are effectively converted into the rolling force value reflecting the real rolling state. The application establishes a rolling force mathematical model based on the selection of spatial coordinate points and the idea of micro-element calculation, and reflects the real change value of the rolling forward angle by capturing the spatial coordinate displacement of the edge roller and the flange of the connecting rod in the rolling process, so as to realize the accurate calculation and real-time monitoring of the rolling force without increasing additional force sensors, thereby saving the cost of equipment modification and maintenance.

[0064] The embodiment of the application also provides an online monitoring system of the rolling force, as shown in Figure 6, which comprises:

[0065] The first data acquisition module is used for acquiring the spatial coordinate displacement of the edge roller and the axial vector of the rolling tool, and calculating the rolling forward angle a according to the spatial displacement of the edge roller and the axial vector of the rolling tool;

[0066] The second data acquisition module is used for acquiring the rolling pressure angle θ, which is the included angle between the roller generatrix and the spindle axis of the rolling tool;

[0067] The third data acquisition module is used for acquiring the spring pressure F detected by the built-in force sensor S ;

[0068] The calculation module is used for calculating the rolling force F in real time according to the rolling forward angle a, the rolling pressure angle θ and the spring pressure F S .

[0069] The online monitoring system of the rolling force provided in the application is a data acquisition and analysis intelligent platform based on an integrated terminal, which effectively monitors the entire rolling process by acquiring comprehensive, accurate and reliable process data. The hardware configuration thereof includes sensors, transmitters, X20 buses, bus controllers, integrated circuits and the like. The real change value of the rolling forward angle is reflected by capturing the spatial displacement of the edge roller and the axial vector of the rolling tool in the rolling process, so as to realize the accurate calculation and real-time monitoring of the rolling force without increasing additional force sensors, thereby saving the cost of equipment modification and maintenance.

[0070] As to the system in the above embodiment, the specific manner in which each unit module performs the operation has been described in detail in the embodiment related to the method, and will not be described in detail here.

[0071] Based on the same inventive concept, the embodiment of the application also provides an electronic device, comprising a memory and a processor, wherein the processor is configured to read and execute a computer program stored in the memory to realize the online monitoring method of the rolling force described above.

[0072] Based on the same inventive concept, the application further provides a computer storage medium, which stores computer executable instructions, and the computer executable instructions implement the edge rolling force online monitoring method when executed.

[0073] In several embodiments provided in the application, it should be understood that the disclosed apparatus and method can be implemented in other manners. For example, the described apparatus embodiments are merely schematic. For example, the division of the modules is merely a logical function division. There can be another division manner for actual implementation. For example, a plurality of modules or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the displayed or discussed mutual couplings or direct couplings or communication connections can be indirect couplings or communication connections through some interfaces, devices or modules, and can be electrical, mechanical or in other forms.

[0074] The modules illustrated as separated components can or can not be physically separated, and the components illustrated as modules can or can not be physical modules, i.e., can be located in one place, or can be distributed to a plurality of network modules. Part or all of the modules can be selected according to actual needs to achieve the purpose of the embodiment scheme. In addition, each functional module in each embodiment of the application can be integrated in one processing module, or each module can be physically present alone, or two or more modules can be integrated in one module. The integrated module can be realized in the form of hardware or in the form of a software functional module.

[0075] The integrated module, if realized in the form of a software functional module and sold or used as an independent product, can be stored in a computer readable storage medium. Based on this understanding, the technical solutions of the application essentially or the part of the prior art that contributes to the technical solutions or the whole or part of the technical solutions can be embodied in the form of a software product. The computer software product is stored in a storage medium, and includes a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the method described in each embodiment of the application. The foregoing storage medium includes a U disk, a mobile hard disk, a read-only memory (ROM, Read-Only Memory), a random access memory (RAM, Random Access Memory), a magnetic disk or an optical disk, and various media that can store program codes.

[0076] It should be noted that, for the foregoing method embodiments, the purposes of brief description, they are all expressed as a series of action combinations, but those skilled in the art should know that the present application is not limited to the order of the actions described, because according to the present application, certain steps can be performed in other orders or simultaneously. Secondly, those skilled in the art should know that the embodiments described in the specification are all preferred embodiments, and the actions and modules involved are not necessarily essential to the present application.

[0077] In the above embodiments, the description of each embodiment has its own focus, and the parts not described in detail in a certain embodiment can be referred to the related description of other embodiments.

[0078] Finally, it should be noted that: the above only describes the preferred embodiments of the present application and is not intended to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent replacements to some technical features within the spirit and principles of the present application. Any modification, equivalent replacement, improvement, etc. made within the scope of the present application should be included in the protection scope of the present application.

Claims

1. A method for online monitoring of hemming force, applied in a robotic hemming system, wherein the hemming system employs a hemming tool with a built-in force sensor, a pressure roller is provided at the front end of the spindle of the hemming tool, and the pressure roller is used to hemm a sheet metal placed on a mold plane; a spring in the hemming tool provides the hemming force to the pressure roller when compressed, wherein... The method includes: The edge-rolling advance angle α is calculated based on the spatial displacement of the pressure roller and the axial vector of the edge-rolling tool. Obtain the hemming angle θ, which is the angle between the generatrix of the roller and the axis of the hemming tool spindle; Obtain the spring pressure F detected by the built-in force sensor S ; Based on the hemming advance angle α, the hemming pressure angle θ, and the spring pressure F S Real-time calculation of the hemming force F:

2. The method according to claim 1, wherein, The main shaft of the hemming tool is provided with connecting rod flanges at both ends, and the axial vector of the hemming tool is the connecting vector of the center coordinates of the two connecting rod flanges. The rolling advance angle α is the angle between the spatial coordinate displacement of the center of the pressing roller and the connecting vector of the coordinates of the centers of the two connecting rod flanges.

3. The method according to claim 2, wherein, During continuous hemming, the spatial coordinates of the center of the hemming roller at the initial and final positions are recorded at predetermined sampling time intervals to obtain the spatial coordinate displacement of the center of the hemming roller. Additionally, at the sampling termination position, the spatial coordinates of the two connecting rod flange centers are recorded respectively to obtain the axial vector of the hemming tool.

4. The method according to claim 3, wherein, The edge sampling time interval is the minimum sampling time interval of the PLC controller.

5. The method according to claim 3, wherein, The sampling interval for the edge rolling is at least 100ms.

6. The method according to claim 1, wherein, In the hemming process, when the hemming trajectory is determined, the hemming pressure angle θ is set to a fixed value.

7. The method according to claim 1, wherein, The spring pressure detected in real time by the built-in force sensor is an analog signal, and the analog spring pressure signal is converted into a digital signal using an analog-to-digital converter circuit.

8. An online monitoring system for hemming force, applied to the method of any one of claims 1 to 7, wherein, The system includes: The first data acquisition module is used to acquire the spatial displacement of the pressing roller and the axial vector of the rolling tool, and to calculate the rolling advance angle α based on the spatial displacement of the pressing roller and the axial vector of the rolling tool. The second data acquisition module is used to acquire the hemming angle θ, where the hemming angle θ is the roller generatrix. The angle between the roller and the spindle axis of the hemming tool; The third data acquisition module is used to acquire the spring pressure F detected by the built-in force sensor. S ; The calculation module is used to calculate based on the hemming advance angle α, the hemming pressure angle θ, and the spring. Pressure F S The rolling force F is calculated in real time.

9. An electronic device, wherein, The electronic device includes: a memory and a processor; the processor is configured to read and execute a computer program stored in the memory to implement the method of any one of claims 1 to 7.

10. A computer-readable storage medium, wherein, The computer-readable storage medium stores computer-executable instructions that, when executed, implement the method of any one of claims 1 to 7.

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