WO2019105464A1 - 一种全自动仓储货架装配生产线及其运行方法 - Google Patents

一种全自动仓储货架装配生产线及其运行方法 Download PDF

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Publication number
WO2019105464A1
WO2019105464A1 PCT/CN2018/118590 CN2018118590W WO2019105464A1 WO 2019105464 A1 WO2019105464 A1 WO 2019105464A1 CN 2018118590 W CN2018118590 W CN 2018118590W WO 2019105464 A1 WO2019105464 A1 WO 2019105464A1
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WIPO (PCT)
Prior art keywords
column
assembly
loading
shelf assembly
area
Prior art date
Application number
PCT/CN2018/118590
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English (en)
French (fr)
Inventor
田晓贺
陶凌峰
李茂盛
杨伟锋
洪鹏
张健
Original Assignee
江苏金陵智造研究院有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 江苏金陵智造研究院有限公司 filed Critical 江苏金陵智造研究院有限公司
Priority to US16/652,479 priority Critical patent/US11478884B2/en
Publication of WO2019105464A1 publication Critical patent/WO2019105464A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
    • B23P19/001—Article feeders for assembling machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P21/00—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G27/00—Jigging conveyors
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B47/00—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements
    • A47B47/02—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements made of metal only
    • A47B47/021—Racks or shelf units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P21/00—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
    • B23P21/004—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control the units passing two or more work-stations whilst being composed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/0093—Programme-controlled manipulators co-operating with conveyor means

Definitions

  • the present disclosure relates to the technical field of assembly equipment products, and in particular to a fully automatic storage shelf assembly production line and a method for operating the same.
  • the storage shelves are in the form of manual assembly on the storage site.
  • the supplier transports the parts of the shelves to the storage site.
  • the installation personnel assemble on site, from the handling of the various components of the shelf to the assembly and cutting. All work requires manual intervention. Too high.
  • the shelf product has many specifications, the product size is too large, and the handling process is complicated, which causes waste of space and is also easy to cause damage to the installer.
  • the assembly the alignment of the hole positions between multiple components and the matching relationship of each component in two positions are involved.
  • the installation personnel manually adjust and adjust frequently, the assembly efficiency is low, and the assembly site has no information means, which cannot be realized. Effective control of people, machines, materials and materials is not conducive to effective management of workshops and factories. Therefore, in view of the current situation of complicated transportation process of assembly parts, low assembly efficiency and lack of information, a comprehensive solution with high degree of automation, adaptability, good flexibility and high production efficiency is provided.
  • the purpose of the present disclosure includes providing a fully automatic storage shelf assembly production line to solve the problem of complicated transportation process and low assembly efficiency of the storage shelf components.
  • the invention provides a fully automatic storage shelf assembly production line, which comprises a logistics channel, a column loading area, a support beam loading area, an in-line logistics system, a shelf assembly area, a finished product area and a control system, and the column is loaded
  • the area, the support beam loading area, the shelf assembly area and the finished product area are connected in series as an integral production line through the in-line logistics system, wherein:
  • the logistics channel serves as a passage for the required part transportation and the transfer of the finished product in the shelf assembly production line;
  • the loading area of the column comprises a column loading truss robot and a rail type column loading vehicle, wherein the rail type column loading vehicle is configured to set up a column tray transportation, and the rail type column loading vehicle is integrated with a mechanical positioning system, mechanical positioning The system limits the rail-type column loading truck to the designated station; the column loading truss robot is configured to grab the column to the column conveyor belt, the column loading truss robot integrates a vision measuring system, and the visual measuring system is responsible for measuring the mounting hole of the column. Processing error
  • the support beam loading area comprises a support beam loading robot, a bolt loading robot and a bolt vibration loading tray, and the support beam loading robot is configured to place the support beam on the positioning pin of the shelf assembly mold of the online internal logistics system
  • the bolt loading robot is configured to place the bolt on the bolt hole of the shelf assembly mold of the online logistics system, and the bolt vibration loading tray provides the bolt with the same regularity for the bolt loading robot;
  • the in-line logistics system comprises a support beam loading area lifting conveyor belt, a finished area lifting conveyor belt, a shelf assembly area fixed conveyor belt, a column conveyor belt and a shelf assembly mold, and the shelf assembly mold is integrated with a pillar opening mechanism; the column column opening mechanism configuration Extending the slot of the column to a certain distance, and limiting the position of the column to ensure that the support beam is aligned with the assembly hole of the column; the shelf assembly mold provides a positioning reference for the placement of the support beam and the column assembly, and the shelf assembly mold can be supported on the beam
  • the shelf assembly area fixed conveyor belt comprises two independent conveyor belt systems of different heights, the support beam loading area lifting conveyor belt and the finished area lifting conveyor belt can be in two Movement between layers of independent conveyor belts;
  • the rack assembly area comprises a nut assembly truss robot, a nut vibration loading tray, a column jacking mechanism and a support beam pressing mechanism; when the shelf assembly mold reaches the shelf assembly area, the nut assembly truss robot vibrates the nut loading tray The provided nut is grabbed to the assembly hole for installation, and the column jacking mechanism pushes the column from the column conveyor to the designated assembly position, and the support beam pressing mechanism is configured to constrain the movement of the support beam;
  • the finished product area includes a finished transfer truss robot and a shelf temporary storage station, and the shelf truss robot is configured to transfer the assembled finished product to the shelf temporary storage station.
  • the control system is configured to assemble the overall control of the production line.
  • the shelf assembly mold is provided with a positioning pin
  • the shelf assembly mold is mainly composed of a shelf assembly mold support plate and a mold unit
  • the mold unit is disposed on the shelf assembly mold support plate
  • each mold unit comprises a screw system, Bevel gear system, rotary cylinder, spur gear system, bearing housing, mold unit mounting plate and two servo motors
  • positioning pins are arranged on the rotary cylinder
  • the positioning pin has 4 degrees of freedom, including the length of the mold along the shelf assembly Three degrees of freedom of movement in the width direction and the thickness direction and rotational degrees of freedom in the thickness direction
  • the servo motor is configured to drive the bevel gear system and the spur gear system to rotate
  • the bearing housings are all disposed on the mold unit mounting plate
  • the rotary cylinder is disposed on the screw system through the sliding table
  • the spur gear system cooperates with the racks on the shelf assembly mold support plate to realize the movement of the mold unit in the
  • the column loading truss robot, the support beam loading robot, the bolt loading robot, the nut assembly truss robot, and the end effector of the finished transfer truss robot each have a visual recognition system configured to identify the support beam and the bolt The type, as well as the location where the end effector is grabbed.
  • the upright loading area and the shelf assembly area are respectively provided with a column mechanical limit system configured to limit the vertical column in the longitudinal direction of the logistics channel; the shelf assembly area and the finished area are respectively provided with a shelf assembly mold A mechanical limit system configured to limit the shelf assembly mold in the length direction of the flow path.
  • the number of the shelf assembly molds is plural, and the plurality of the shelf assembly molds are configured to perform assembly work of different production beats on a plurality of specifications shelves.
  • the production line of the column loading area, the support beam loading area, the shelf assembly area and the finished product area connected in series by the in-line logistics system has a “one shape”.
  • the logistics channel has a “U” shape
  • the column loading area, the support beam loading area, the in-line logistics system, the shelf assembly area and the finished product area are all disposed in the U-shaped groove of the logistics channel.
  • the bolt loading robot is closer to the inline logistics system than the bolt vibrating tray.
  • the shelf temporary storage station is located at one side of the lifting belt of the finished product area.
  • the lead screw of the screw system is perpendicular to the feeding direction of the shelf assembly mold.
  • the number of the racks is two, two of the racks are parallel and spaced along a length direction of the lead screw in the screw system, and the spur gear system includes a length along the lead screw Two spur gears are disposed at intervals, and the two spur gears are engaged with the two racks in one-to-one correspondence.
  • the storage shelf comprises a support beam and a column
  • the support beam comprises a tubular cross bracing, a standard cross bracing and a diagonal bracing
  • the fully automatic storage shelf assembly production line further comprises a tubular cross bracing material plate and a standard cross bracing
  • the material tray and the slanting material tray are respectively arranged to place tubular cross braces, standard cross braces and diagonal braces.
  • tubular cross brace material tray and the standard cross brace material pan are disposed on the same side of the column conveyor belt, and the brace material tray is disposed on the other side of the pillar conveyor belt.
  • tubular cross brace material tray and the standard cross brace material disc are sequentially disposed along a feeding direction of the shelf assembly mold.
  • the purpose of the present disclosure also includes providing a method for operating a fully automated storage rack assembly line to solve the problem of complicated transportation process and low assembly efficiency of the storage shelf components.
  • the method for operating a fully automated storage rack assembly line comprises the following steps:
  • Step 1 Transfer the shelf pillars, support beams, bolts and nuts to be assembled from the warehouse to the respective loading trays by means of forklifts;
  • Step 2 the column loading truss robot, the rail type column loading cart, the shelf assembly mold, the bolt loading robot, the nut assembly truss robot and the finished transfer truss robot simultaneously acquire the shelf specification information and automatically adjust to the designated station;
  • Step 3 The shelf assembly mold enters the support beam loading area from the assembly station, and the control system controls the bolt loading robot to place the bolt provided by the bolt vibration loading tray into the bolt slot of the shelf assembly mold, when the shelf assembly mold completely enters After the support beam loading area is completed, the bolt loading work is completed, the support beam loading zone conveyor belt is raised to the support beam loading station, and the support beam loading robot waits for the loading information of the control system;
  • Step 4 After the column loading truss robot grabs the column onto the column conveyor of the in-line logistics system, the visual measurement system takes a picture to identify the first hole and the last hole of the end face, and calculates the cumulative error of the punching, and The error feedback is applied to the servo motor to adjust the spacing of the mounting holes of the shelf assembly mold support beam; the loading robot places the support beam at a specified position of the shelf assembly mold, completes the support beam loading and feeds the completion signal back to the control system;
  • Step 5 After receiving the above completion signal, the control system controls the shelf assembly mold and the column to enter the shelf assembly area, and then the support beam pressing mechanism presses and fixes the support beams, the rotary cylinder of the shelf assembly mold descends, and the column expansion mechanism drives the cylinder.
  • the piston rod extends to the opening station and waits for the column assembly;
  • Step 6 The pillar pushing mechanism pushing column is aligned with the supporting beam assembly hole, and then the column expanding mechanism cylinder piston rod is retracted, the supporting beam pressing mechanism is lifted, the rotating cylinder guides the assembly hole, and after the guiding is completed, the rotating cylinder rotates and Push the bolt to the assembly station and feed the signal back to the control system.
  • Step 7 The control system sends the bolt assembly command according to the above signal. After receiving the command, the nut assembly truss robot first obtains the nut at the predetermined position, then moves to the shelf assembly position, and corrects the position error of the pneumatic tightening gun through the end vision measurement system to meet the requirement. After the assembly work of multiple bolts on one side is completed, the nut assembly truss robot returns to the initial position after completion, and the completion signal is fed back to the control system;
  • Step 8 After receiving the above signal, the control system drives the in-line logistics system to transport the shelf assembly mold to the finished product area, and the position sensor obtains the in-position signal of the shelf assembly mold, and the control system controls the finished product transfer truss robot to grab the shelf assembly according to the signal.
  • the shelves on the mold are placed in the temporary storage area;
  • Step 9 After the above process is completed, the lifting belt of the finished product area is lowered and the shelf assembly mold is conveyed to the shelf assembly area, waiting for the instruction of the next assembly link.
  • Each robot system of the present disclosure integrates a visual recognition system, which can accurately identify material information, avoids accidental catching and leaking, and integrates positioning of each transportation system.
  • the system can realize high-precision positioning operation;
  • the automatic storage and assembly line of the present disclosure reduces the number of operators, reduces the labor intensity, reduces the number of personnel by more than 80%, improves the assembly production efficiency, and shortens the production cycle by more than 50%.
  • the production capacity is increased by 200%;
  • the degree of flexibility of the present disclosure is high, and it is suitable for assembly of a plurality of shelf products of different specifications, and each part can be set according to the production cycle and the size of the site to realize the balanced production.
  • Figure 1 is a plan layout diagram of a fully automated storage rack assembly line
  • Figure 2 is a schematic view showing the structure of a fully automatic storage shelf assembly production line
  • Figure 3 is a composition diagram of a shelf assembly mold
  • Figure 4 is a diagram of the composition of the mold unit
  • Figure 5 is a composition diagram of the storage shelf.
  • the present disclosure proposes a fully automatic storage shelf assembly production line and its operation method, and combines the characteristics of the assembly production line itself, researches and designs the layout of the key parts thereof and the specific assembly manner thereof. It effectively solves the problems of complicated transportation and low assembly efficiency of components, and also has the advantages of good assembly flexibility and strong adaptability. Therefore, it is especially suitable for the automatic storage shelves of a batch of hollow-slotted structural support members separated from each other. assembly.
  • the embodiment provides a fully automatic storage shelf assembly production line, which includes a logistics channel 22, a column loading area 23, a support beam loading area 24, an in-line logistics system 25, and a shelf assembly area.
  • 26 and the finished product area 27 are connected in series by the in-line logistics system 25 as an overall production line, wherein:
  • the logistics channel 22 is a passage for the required part transportation and the transfer of the finished product in the shelf assembly line, and the range thereof can satisfy the operation of the forklift 1.
  • the column loading area 23 includes a column loading truss robot 2 and a rail type column loading cart 3.
  • the rail-type column loading truck 3 is responsible for the transportation of the column tray
  • the mechanical positioning system is integrated on the rail-type column loading truck 3, and the mechanical positioning system limits the rail-type column loading truck 3 to the designated station
  • the column The truss robot 2 is responsible for grasping the column 38 to the column conveyor 20, and integrating a vision measuring system on the column loading truss robot 2, which is responsible for measuring the machining error of the mounting hole of the column 38.
  • the support beam loading area 24 includes a support beam loading robot 6, a bolt loading robot 17, and a bolt vibrating loading tray 18.
  • the support beam loading robot 6 is configured to place the support beam on the locating pin of the shelf assembly mold 4 of the in-line logistics system 25, the bolt loading robot 17 being configured to place the bolts in the bolt holes of the shelf assembly mold 4 of the in-line logistics system 25.
  • the bolt vibrating upper tray 18 provides bolts for the bolt loading robot 17 to be placed in the same manner.
  • the in-line logistics system 25 includes a support beam loading area lifting conveyor 8, a finished area lifting conveyor 13, a shelf assembly area fixed conveyor 14, a column conveyor 20 and a shelf assembly mold 4, and the shelf assembly mold 4 is integrated with a pillar opening mechanism 21.
  • the post expansion mechanism 21 is configured to extend the notch of the post 38 a certain distance while limiting the position of the post 38 to ensure alignment of the support beam with the mounting holes of the post 38.
  • the shelf assembly die 4 provides a positioning reference for the placement of the support beam and the assembly of the post 38.
  • the shelf assembly die 4 is movable on the support beam loading zone lift conveyor 8, the finished zone lift conveyor 13 and the shelf assembly zone conveyor belt 14.
  • the shelf assembly area fixed conveyor belt 14 comprises two separate conveyor belts of different heights, the support beam loading area lifting conveyor belt 8, and the finished product area lifting conveyor belt 13 being movable between two fixed conveyor belts.
  • the shelf assembly area 26 includes a nut assembly truss robot 10, a nut vibration loading tray 9, a column jacking mechanism 15, and a support beam pressing mechanism 16.
  • the support beam pressing mechanism 16 is configured to constrain the movement of the support beam, with the length direction of the flow channel 22 being the X direction, the direction perpendicular to the longitudinal direction of the flow channel 22 in the horizontal plane being the Y direction, and the up and down direction being the Z direction.
  • the support beam pressing mechanism 16 is configured to prevent the support beam from shifting in the Y direction and the Z direction.
  • the finished product area 27 includes a finished transfer truss robot 11 and a shelf temporary storage table 12 that is configured to transfer the assembled finished finished product to the shelf temporary storage station 12.
  • the control system is configured to assemble the overall control of the production line.
  • the shelf assembly mold 4 has positioning pins.
  • the shelf assembly die 4 is mainly composed of a shelf assembly die support plate 28 and a die unit 29, and the die unit 29 is disposed on the shelf mold mounting plate 28.
  • each of the mold units 29 includes a screw system 30, a bevel gear system 31, a rotary cylinder 32, a spur gear system 33, a bearing housing 34, a mold unit mounting plate 35, and two servo motors 36, which can satisfy many A variety of shelf assembly and delivery.
  • the positioning pin is provided on the rotary cylinder 32, which has four degrees of freedom, including three degrees of freedom of movement along the longitudinal direction, the width direction, and the thickness direction of the shelf assembly die 4, and rotational degrees of freedom in the thickness direction.
  • the servo motor is configured to drive the bevel gear system 31 and the spur gear system 33 to rotate.
  • the screw system 30, the bevel gear system 31, the rotary cylinder 32, the spur gear system 33, and the bearing housing 34 are all disposed on the mold unit mounting plate 35, and the rotary cylinder 32 is disposed on the screw system 30 through the slide table, the spur gear system 33.
  • the movement of the mold unit 29 in the length direction of the flow path is achieved in cooperation with the rack on the shelf assembly mold support plate 28.
  • the screw system 30 is configured to position the cross braces and the braces and fix the bolts in the assembly stage. By driving the bevel gear system 31, the lateral spacing of the pair of positioning pins is adjusted to meet the requirements of the mold width compatibility; the spur gear system 33 is configured.
  • the longitudinal spacing of the positioning pins is adjusted to meet the requirements of the length compatibility of the shelf assembly molds, and the positioning pin spacing on the adjacent screw system 30 can be finely adjusted by the spur gear system 33 during assembly to weaken the influence of the machining error of the column assembly holes.
  • the four-degree-of-freedom assembly unit freely assembles the assembly mold according to the shelf specifications.
  • the rack assembly production line is equipped with multiple rack assembly molds 4, which can meet the assembly production work of different production racks of various specifications.
  • the column loading truss robot 2, the support beam loading robot 6, the bolt loading robot 17, the nut assembly truss robot 10, and the end effector of the finished transfer truss robot 11 each have a visual recognition system configured to recognize the support The type of beam and bolt, as well as the position at which the end effector is gripped.
  • both the column loading area 23 and the shelf assembly area 26 have a column mechanical limit system
  • the shelf assembly area 26 and the finished area 27 each have a shelf assembly mold mechanical limit system, and the above mechanical limit system can ensure the column 38 and The shelf assembly mold 4 is limited in the length direction of the flow path 22.
  • the column loading area 23, the support beam loading area 24, the shelf assembly area 26 and the finished product area 27 are connected in series by the in-line logistics system 25 to form a "one" shape.
  • Such an arrangement not only ensures the smoothness of the shelf assembly mold 4, but also reduces the inconsistent assembly process caused by the jam during the turning process, and also reduces the time waste caused by the turning process.
  • the assembly efficiency of the automatic storage shelf assembly production line of the embodiment is further improved.
  • the flow channel 22 has a "U" shape, specifically, the column loading area 23, the support beam loading area 24, the in-line logistics system 25, the shelf assembly area 26, and
  • the finished product areas 27 are all disposed in the U-shaped grooves of the flow channel 22.
  • This arrangement of semi-circumfering the flow passages 22 around the respective stations allows the forklift 1 to smoothly move to various stations during the movement of the flow passage 22, reducing the loading and unloading process.
  • the interference effect in the process ensures the smooth progress of the loading and unloading process.
  • the "longitudinal direction of the stream passage 22" means the length direction of the two sides which are oppositely disposed in the U shape.
  • the bolt loading robot 17 is closer to the inline logistics system 25 than the bolt vibrating tray 18.
  • Such an arrangement effectively shortens the gripping path of the bolt loading robot 17, and saves the time required for the bolt grabbing process, thereby further improving the assembly efficiency of the automatic storage rack assembly line of the embodiment.
  • the lead screw of the screw system 30 is perpendicular to the feeding direction of the shelf assembly die 4.
  • the number of racks is two, the two racks are arranged parallel and spaced along the length direction of the lead screw in the screw system 30, and the spur gear system 33 includes two spur gears spaced along the length direction of the screw rod, two The spur gears mesh with the two racks in one-to-one correspondence.
  • Such an arrangement ensures the balance of the force on both sides of the shelf assembly mold 4 during the adjustment of the spur gear system 33, and also reduces the damage of the mold unit 29 due to local stress concentration, and prolongs the use of the mold unit 29. life.
  • the storage rack includes a support beam and a column 38, and the support beam includes a tubular cross bracing 37, a standard cross bracing 39, and a bracing 40.
  • the fully automated storage rack assembly line further includes a tubular cross brace material plate 5, a standard cross brace material pan 7 and a brace material pan 19, respectively configured to place tubular cross braces 37, standard cross braces 39 and braces 40.
  • a method for operating a fully automated storage rack assembly line includes the following steps:
  • the shelf pillars, support beams, bolts and nuts to be assembled are transported from the warehouse to the respective loading trays by the forklift 1.
  • the parts in each loading tray are placed neatly by the automatic palletizing machine according to the assembly requirements before being discharged from the warehouse. Both can meet the single-shift production requirements of the production line.
  • the shelf assembly mold 4 enters the support beam loading area 24 from the assembly station, and the control system controls the bolt loading robot 17 to place the bolts provided by the bolt vibration loading tray 18 into the bolt slots of the shelf assembly mold 4, when After the shelf assembly mold 4 completely enters the support beam loading area 24, the bolt loading work is completed, the support beam loading area lifting conveyor belt 8 is raised to the support beam loading station, and the support beam loading robot 6 waits for the control system. Information.
  • the visual measurement system takes a picture to identify the first hole and the last hole of the end face, and calculates the cumulative error of the punching hole. And the error is fed back to the servo motor 36 to adjust the mounting hole spacing of the shelf assembly mold 4 support beam.
  • the loading robot 6 places the support beam at a designated position of the shelf assembly mold 4, completes the support beam loading, and feeds the completion signal back to the control system.
  • the control system controls the shelf assembly die 4 and the column 38 to enter the shelf assembly area 26.
  • the shelf assembly die 4 and the column 38 ensure uniform assembly standards through the limit adjustment system, and then the support beam pressing mechanism 16 is pressed down to fix each of the support beams, the rotary cylinder 32 of the shelf assembly die 4 is lowered, and the column expansion mechanism 21 drives the cylinder piston rod to extend to the expansion station, waiting for the column 38 to be assembled.
  • the control system sends the bolt assembly command according to the above signal, and after receiving the command, the nut assembly truss robot 10 first obtains the nut at the predetermined position, then moves to the shelf assembly position, and corrects the position error of the pneumatic tightening gun through the end vision measurement system, which satisfies After the request, the assembly work of the plurality of bolts on one side is realized, and after completion, the nut assembly truss robot 10 returns to the initial position, and the completion signal is fed back to the control system.
  • the control system transports the shelf assembly mold 4 of the in-line logistics system 25 to the finished product area 27, and the position sensor acquires the in-position signal of the shelf assembly mold 4, and the control system controls the finished transfer truss according to the signal.
  • the robot 11 grabs the shelves on the shelf assembly mold 4 and places them in the temporary storage area.
  • the invention provides a fully automatic storage shelf assembly production line and a running method thereof, which reduces the labor intensity in the assembly process of the storage shelf, improves the assembly production efficiency, and has high degree of flexibility, and can be adapted to the assembly of a plurality of different specifications of the shelf products. And, each part can set the number and distribution of stations according to the production cycle and the size of the site to achieve balanced production.

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Abstract

本申请公开了一种全自动仓储货架装配生产线及其运行方法，该生产线包括物流通道、立柱上料区、支撑梁上料区、线内物流***、货架装配区、成品区和控制***，立柱上料区、支撑梁上料区、货架装配区和成品区通过线内物流***串联为一个整体生产线。本申请公开的全自动仓储货架装配生产线降低了仓储货架装配过程中的劳动强度，提高了装配生产效率，且柔性化程度高，能够适应多种不同规格货架产品的装配，并且，各部分可根据生产节拍和场地大小设置工位数量和分布方式，实现均衡生产。

Description

一种全自动仓储货架装配生产线及其运行方法
相关申请的交叉引用
本申请要求于2017年11月30日提交中国专利局的申请号为201711244705.8、名称为“一种全自动仓储货架装配生产线及其运行方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本公开涉及装配设备产品技术领域，具体涉及一种全自动仓储货架装配生产线及其运行方法。
背景技术
随着智能制造技术的发展，智能仓储装备作为智能制造的核心组成部分以及构建未来“智能工厂”的重要基石，正受到业界的高度关注，仓储货架的装配也成为亟待解决的问题。
当前关于仓储货架采用仓储现场人工装配的形式，供应商将货架各零件运输至仓储现场，安装人员现场装配，从货架各零部件的搬运到装配和下料，所有工作均需人工介入，人力成本过高。并且，货架产品规格众多、产品尺寸过大、搬运过程复杂，造成了空间的浪费，还易对安装人员造成伤害。在装配中涉及多个零部件之间孔位的对齐以及每个零部件在两个位置的配合关系，安装人员人工操作调整频繁，装配效率低，再者装配现场无信息化手段，无法实现对人、机、物、料等有效管控，不利于车间和工厂的有效管理。因此，针对当前仓储货架装配零部件运输过程复杂、装配效率低且缺乏信息化的现状，提供一种自动化程度高、适应性强、柔性程度好、生产效率高的综合解决方案。
发明内容
本公开的目的包括，提供一种全自动仓储货架装配生产线，以解决仓储货架零部件运输过程繁杂、装配效率低的问题。
本公开提供的一种全自动仓储货架装配生产线，该生产线包括物流通道、立柱上料区、支撑梁上料区、线内物流***、货架装配区、成品区和控制***，所述立柱上料区、支撑梁上料区、货架装配区和成品区通过线内物流***串联为一个整体生产线，其中：
所述物流通道作为货架装配生产线中所需零件输送和货架成品转移的通道；
所述立柱上料区包括立柱上料桁架机器人和轨道式立柱上料车，所述轨道式立柱上料车配置成立柱料盘的运输，轨道式立柱上料车集成有机械定位***，机械定位***将轨道式立柱上料车限定至指定工位；立柱上料桁架机器人配置成将立柱抓取至立柱传送带，立柱上料桁架机器人集成有视觉测量***，视觉测量***负责测量立柱的安装孔的加工误差；
所述支撑梁上料区包括支撑梁上料机器人、螺栓上料机器人和螺栓振动上料盘，所述 支撑梁上料机器人配置成将支撑梁放置在线内物流***的货架装配模具的定位销钉上，螺栓上料机器人配置成将螺栓放置在线内物流***的货架装配模具的螺栓孔上，螺栓振动上料盘为螺栓上料机器人提供摆放规则一致的螺栓；
所述线内物流***包括支撑梁上料区升降传送带、成品区升降传送带、货架装配区固定传送带、立柱传送带和货架装配模具，货架装配模具集成有立柱撑开机构；所述立柱撑开机构配置成将立柱槽口撑开一定距离，同时限制立柱的位置，保证支撑梁与立柱装配孔对齐；所述货架装配模具为支撑梁的摆放和立柱装配提供定位基准，货架装配模具能够在支撑梁上料区升降传送带、成品区升降传送带和货架装配区固定传送带上移动；货架装配区固定传送带包含高度不同的两层独立的传送带***，支撑梁上料区升降传送带和成品区升降传送带能够在两层独立传送带之间运动；
所述货架装配区包括螺母装配桁架机器人、螺母振动上料盘、立柱顶进机构和支撑梁压紧机构；当所述货架装配模具到达货架装配区后，螺母装配桁架机器人将螺母振动上料盘提供的螺母抓取至装配孔位置安装，立柱顶进机构将立柱由立柱传送带推顶至指定装配位置，支撑梁压紧机构配置成约束支撑梁的运动；
所述成品区包括成品转移桁架机器人和货架暂存台，货架桁架机器人配置成将装配完成的货架成品转移至货架暂存台。
所述控制***配置成装配生产线总体控制。
可选地，所述货架装配模具上设置有定位销钉，货架装配模具主要由货架装配模具支撑板和模具单元组成，模具单元设置在货架装配模具支撑板上，每个模具单元包括丝杆***、锥齿轮***、旋转气缸、直齿轮***、轴承座、模具单元安装板和两个伺服电机，定位销钉设置在旋转气缸上，所述定位销钉具有4个自由度，包括沿货架装配模具的长度方向、宽度方向、厚度方向的三个移动自由度及沿厚度方向的旋转自由度；伺服电机配置成驱动锥齿轮***和直齿轮***转动；丝杆***、锥齿轮***、旋转气缸、直齿轮***和轴承座均设置在模具单元安装板上，旋转气缸通过滑台设置在丝杆***上，直齿轮***与货架装配模具支撑板上的齿条配合，实现模具单元在物流通道长度方向上的移动；丝杆***配置成横撑和斜撑的定位及装配阶段螺栓的固定，通过驱动锥齿轮***，调整一对定位销钉的横向间距，直齿轮***配置成调整相邻两个所述丝杆***的定位销钉的纵向间距。
可选地，所述立柱上料桁架机器人、支撑梁上料机器人、螺栓上料机器人、螺母装配桁架机器人和成品转移桁架机器人的末端执行器均带有视觉识别***，配置成识别支撑梁和螺栓的种类，以及定位末端执行器抓取的位置。
可选地，所述立柱上料区和货架装配区均设置有立柱机械限位***，配置成在物 流通道的长度方向对立柱限位；所述货架装配区和成品区均设置有货架装配模具机械限位***，配置成在物流通道的长度方向对货架装配模具进行限位。
可选地，所述货架装配模具的数量为多个，多个所述货架装配模具配置成对多种规格货架进行不同生产节拍的装配工作。
可选地，所述立柱上料区、支撑梁上料区、货架装配区和成品区通过线内物流***串联形成的生产线呈“一”字形。
可选地，所述物流通道呈“U”形，所述立柱上料区、支撑梁上料区、线内物流***、货架装配区和成品区均设置在所述物流通道的U形槽中。
可选地，所述螺栓上料机器人比所述螺栓振动料盘更靠近所述线内物流***。
可选地，所述货架暂存台位于所述成品区升降传送带的一侧。
可选地，所述丝杆***的丝杆与所述货架装配模具的进给方向垂直。
可选地，所述齿条的数量为两个，两个所述齿条沿所述丝杆***中丝杆的长度方向平行且间隔设置，所述直齿轮***包括沿所述丝杆的长度方向间隔设置的两个直齿轮，两个所述直齿轮与两个所述齿条一一对应地啮合。
可选地，所述仓储货架包括支撑梁和立柱，支撑梁包括管型横撑、标准型横撑和斜撑；所述全自动仓储货架装配生产线还包括管型横撑物料盘、标准横撑物料盘和斜撑物料盘，分别配置成放置管型横撑、标准型横撑和斜撑。
可选地，所述管型横撑物料盘与所述标准横撑物料盘设置在所述立柱传送带的同一侧，所述斜撑物料盘设置在所述立柱传送带的另一侧。
可选地，沿所述货架装配模具的进给方向，所述管型横撑物料盘与所述标准横撑物料盘依次设置。
本公开的目的还包括，提供一种全自动仓储货架装配生产线的运行方法，以解决仓储货架零部件运输过程繁杂、装配效率低的问题。
本公开提供的全自动仓储货架装配生产线的运行方法，包括以下步骤：
步骤1，将待装配货架立柱、支撑梁、螺栓和螺母从仓库依靠叉车输送至各个上料盘；
步骤2，立柱上料桁架机器人、轨道式立柱上料车、货架装配模具、螺栓上料机器人、螺母装配桁架机器人和成品转移桁架机器人同步获取货架规格信息并进行自动调整至指定工位；
步骤3，货架装配模具从装配工位进入支撑梁上料区，控制***控制螺栓上料机器人将螺栓振动上料盘提供的螺栓摆放至货架装配模具的螺栓槽内，当货架装配模具完全进入支撑梁上料区后，螺栓上料工作全部完成，支撑梁上料区传送带升高至支撑梁上料工位，支撑梁上料机器人等待控制***的上料信息；
步骤4，立柱上料桁架机器人将立柱抓取至线内物流***的立柱传送带上后，视觉测量***拍照识别距离端面的第一个孔和最后一个孔，计算出冲孔累计误差，并将该误差反馈给伺服电机调整货架装配模具支撑梁装配孔间距；上料机器人将支撑梁摆放至货架装配模具的指定位置，完成支撑梁上料并将完工信号反馈至控制***；
步骤5，控制***接收到上述完工信号后，控制货架装配模具和立柱进入货架装配区，之后支撑梁压紧机构下压固定各支撑梁，货架装配模具的旋转气缸下降，立柱撑开机构驱动气缸活塞杆伸出至撑开工位，等待立柱装配；
步骤6，立柱顶进机构推顶立柱与支撑梁装配孔对齐，之后立柱撑开机构气缸活塞杆缩回、支撑梁压紧机构提升，旋转气缸对装配孔进行导向，导向完成后旋转气缸旋转并将螺栓推顶至装配工位，并将该信号反馈至控制***。
步骤7，控制***根据上述信号发送螺栓装配指令，螺母装配桁架机器人接收到指令后，先到预定位置取得螺母，然后运动至货架装配位置，通过末端视觉测量***矫正气动拧紧枪位置误差，满足要求后实现单侧多个螺栓的装配工作，完成后螺母装配桁架机器人回归至初始位置，并将完工信号反馈至控制***；
步骤8，控制***接收到上述信号后，驱动线内物流***将货架装配模具输送至成品区，位置传感器将获取货架装配模具的到位信号，控制***根据此信号控制成品转移桁架机器人抓取货架装配模具上的货架，摆放至暂存区；
步骤9，上述工序完成后，成品区升降传送带下降并将货架装配模具输送至货架装配区，等待下一装配环节的指令。
与现有技术相比，本公开的有益效果为：(1)本公开的各机器人***集成有视觉识别***，可以准确识别物料信息，避免误抓、漏抓的情况，各运输***集成有定位***，可以实现高精度定位操作；(2)本公开的全自动仓储货装配生产线减少了操作人员，降低了劳动强度，人员缩减80％以上；提高了装配生产效率，生产周期缩短50％以上，产能提高200％；(3)本公开柔性化程度高，适应多种不同规格货架产品的装配，各部分可根据生产节拍和场地大小设置工位数量和分布方式，实现均衡生产。
附图说明
图1为全自动仓储货架装配生产线平面布局图；
图2为全自动仓储货架装配生产线结构示意图；
图3为货架装配模具组成图；
图4为模具单元组成图；
图5为仓储货架组成图。
附图标记：
1-叉车；2-立柱上料桁架机器人；3-轨道式立柱上料车；4-货架装配模具；5-管型横撑物料盘；6-上料机器人；7-标准横撑物料盘；8-支撑梁上料区升降传送带；9-螺母振动上料盘；10-螺母装配桁架机器人；11-成品转移桁架机器人；12-货架暂存台；13-成品区升降传送带；14-货架装配区固定传送带；15-立柱顶进机构；16-支撑梁压紧机构；17—螺栓上料机器人；18-螺栓振动上料盘；19-斜撑物料盘；20-立柱传送带；21-立柱撑开机构；22-物流通道；23-立柱上料区；24-支撑梁上料区；25-线内物流***；26-货架装配区；27-成品区；28-货架装配模具支撑板；29-模具单元；30-丝杆***；31-锥齿轮***；32-旋转气缸；33-直齿轮***；34-轴承座；35-模具单元安装板；36-伺服电机；37-管型横撑；38-立柱；39-标准型横撑；40-斜撑。
具体实施方式
针对现有技术的缺陷或改进需求，本公开提出一种全自动仓储货架装配生产线及其运行方法，结合装配生产线自身的特点，对其关键部分的布局及其具体装配方式进行研究和设计，可以有效解决零部件运输过程繁杂、装配效率低的问题，同时还具备装配柔性好、适应性强的优点，因而尤其适用于相互分离的一批空心带槽缝的结构支承件的全自动仓储货架的装配。
结合图1、图2，本实施例提供了一种全自动仓储货架装配生产线，该生产线包括物流通道22、立柱上料区23、支撑梁上料区24、线内物流***25、货架装配区26和成品区27，立柱上料区23、支撑梁上料区24、货架装配区26和成品区27通过线内物流***25串联为一个整体生产线，其中：
物流通道22是货架装配生产线中所需零件输送和货架成品转移的通道，其范围可以满足叉车1的运行。
立柱上料区23包括立柱上料桁架机器人2和轨道式立柱上料车3。其中，轨道式立柱上料车3负责立柱料盘的运输，在轨道式立柱上料车3上集成有机械定位***，机械定位***将轨道式立柱上料车3限定至指定工位，立柱上料桁架机器人2负责将立柱38抓取至立柱传送带20，在立柱上料桁架机器人2上集成有视觉测量***，视觉测量***负责测量立柱38的安装孔的加工误差。
支撑梁上料区24包括支撑梁上料机器人6、螺栓上料机器人17和螺栓振动上料盘18。支撑梁上料机器人6配置成将支撑梁放置在线内物流***25的货架装配模具4的定位销上，螺栓上料机器人17配置成将螺栓放置在线内物流***25的货架装配模具4的螺栓孔上，螺栓振动上料盘18为螺栓上料机器人17提供摆放规则一致的螺栓。
线内物流***25包括支撑梁上料区升降传送带8、成品区升降传送带13、货架装配区 固定传送带14、立柱传送带20和货架装配模具4，货架装配模具4集成有立柱撑开机构21。立柱撑开机构21配置成将立柱38的槽口撑开一定距离，同时限制立柱38的位置，保证支撑梁与立柱38装配孔对齐。货架装配模具4为支撑梁的摆放和立柱38装配提供定位基准，货架装配模具4能够在支撑梁上料区升降传送带8、成品区升降传送带13和货架装配区固定传送带14上移动。货架装配区固定传送带14包含高度不同的两层独立传送带，支撑梁上料区升降传送带8、成品区升降传送带13可以在两层固定传送带之间运动。
货架装配区26包括螺母装配桁架机器人10、螺母振动上料盘9、立柱顶进机构15和支撑梁压紧机构16。当货架装配模具4到达货架装配区26后，螺母装配桁架机器人10将螺母振动上料盘9提供的螺母抓取至装配孔位置安装，立柱顶进机构15将立柱38由立柱传送带20推顶至指定装配位置，支撑梁压紧机构16配置成约束支撑梁的运动，以物流通道22的长度方向为X方向，水平面内垂直于物流通道22长度方向的方向为Y方向，上下方向为Z方向，支撑梁压紧机构16配置成防止支撑梁在Y方向和Z方向偏移。
成品区27包括成品转移桁架机器人11和货架暂存台12，货架桁架机器人11配置成将装配完成的货架成品转移至货架暂存台12。
控制***配置成装配生产线总体控制。
可选地，货架装配模具4上具有定位销钉，如图3所示，货架装配模具4主要由货架装配模具支撑板28和模具单元29组成，模具单元29设置在货架模具安装板28上。如图4所示，每个模具单元29包括丝杆***30、锥齿轮***31、旋转气缸32、直齿轮***33、轴承座34、模具单元安装板35和两个伺服电机36，可以满足多种规格的货架装配及输送。定位销钉设置在旋转气缸32上，该定位销钉具有4个自由度，包括沿货架装配模具4的长度方向、宽度方向、厚度方向的三个移动自由度及沿厚度方向的旋转自由度。伺服电机配置成驱动锥齿轮***31和直齿轮***33转动。丝杆***30、锥齿轮***31、旋转气缸32、直齿轮***33和轴承座34均设置在模具单元安装板35上，旋转气缸32通过滑台设置在丝杆***30上，直齿轮***33与货架装配模具支撑板28上的齿条配合，实现模具单元29在物流通道长度方向上的移动。丝杆***30配置成横撑和斜撑的定位及装配阶段螺栓的固定，通过驱动锥齿轮***31，调整一对定位销钉的横向间距，以满足模具宽度兼容性的要求；直齿轮***33配置成调整定位销钉纵向间距，以满足货架装配模具长度兼容性的要求，装配时可以通过直齿轮***33微调整相邻丝杆***30上的定位销钉间距，以削弱立柱装配孔加工误差的影响，四自由度装配单元根据货架规格自由组合装配模具。
货架装配生产线配置多台货架装配模具4，可以满足多种规格货架不同生产节拍的装配生产工作。
可选地，立柱上料桁架机器人2、支撑梁上料机器人6、螺栓上料机器人17、螺母装配桁架机器人10和成品转移桁架机器人11的末端执行器均带有视觉识别***，配置成识别支撑梁和螺栓的种类，以及定位末端执行器抓取的位置。
可选地，立柱上料区23和货架装配区26均具有立柱机械限位***，货架装配区26和成品区27均具有货架装配模具机械限位***，上述机械限位***能够保证立柱38和货架装配模具4在物流通道22长度方向的限位。
请继续参照图1和图2，本实施例中，立柱上料区23、支撑梁上料区24、货架装配区26和成品区27通过线内物流***25串联形成“一”字形。这样的设置，不仅保证了货架装配模具4向前进给的顺畅性，降低了转弯过程中因卡死而导致的装配过程不连贯的情形，而且，还减少了因转弯过程而导致的时间浪费，进一步提高了本实施例全自动仓储货架装配生产线的装配效率。
请继续参照图1和图2，本实施例中，物流通道22呈“U”形，具体地，立柱上料区23、支撑梁上料区24、线内物流***25、货架装配区26和成品区27均设置在物流通道22的U形槽中。这种将物流通道22半包围设置在上述各个工位的周围的设置形式，使得叉车1在物流通道22运动的过程中，能够顺利地运动至各个工位处，减少了上料与下料过程中的干涉影响，保证了上料与下料过程的顺利进行。
需要说明的是，本实施例中，“物流通道22的长度方向”指的是：U形中相对设置的两个边的长度方向。
请继续参照图图2，本实施例中，螺栓上料机器人17比螺栓振动料盘18更靠近线内物流***25。这样的设置，有效地缩短了螺栓上料机器人17的抓取路径，节约了螺栓抓取过程中所需的时间，从而进一步提高了本实施例全自动仓储货架装配生产线的装配效率。
请继续参照图3，本实施例中，丝杆***30的丝杆与货架装配模具4的进给方向垂直。并且，齿条的数量为两个，两个齿条沿丝杆***30中丝杆的长度方向平行且间隔设置，直齿轮***33包括沿丝杆的长度方向间隔设置的两个直齿轮，两个直齿轮与两个齿条一一对应地啮合。
这样的设置，保证了直齿轮***33调节过程中，货架装配模具4两侧受力的平衡性，同时也降低了因局部应力集中导致的模具单元29损坏的情形，延长了模具单元29的使用寿命。
可选地，如图5所示，仓储货架包括支撑梁和立柱38，支撑梁包括管型横撑37、标准型横撑39和斜撑40。该全自动仓储货架装配生产线还包括管型横撑物料盘5、标准横撑物料盘7和斜撑物料盘19，分别配置成放置管型横撑37、标准型横撑39和斜撑40。
一种全自动仓储货架装配生产线的运行方法，包括以下步骤：
(1)将待装配货架立柱、支撑梁、螺栓和螺母从仓库依靠叉车1输送至各个上料盘，各个上料盘内的零件出库前按照装配要求由自动码垛机摆放整齐，数量均能满足该生产线单班制生产要求。
(2)立柱上料桁架机器人2、轨道式立柱上料车3、货架装配模具4、螺栓上料机器人17、螺母装配桁架机器人10和成品转移桁架机器人11同步获取货架规格信息并进行自动调整至指定工位。
(3)货架装配模具4从装配工位进入支撑梁上料区24，控制***控制螺栓上料机器人17将螺栓振动上料盘18提供的螺栓摆放至货架装配模具4的螺栓槽内，当货架装配模具4完全进入支撑梁上料区24后，螺栓上料工作全部完成，支撑梁上料区升降传送带8升高至支撑梁上料工位，支撑梁上料机器人6等待控制***的上料信息。
(4)立柱上料桁架机器人2将立柱38抓取至线内物流***25的立柱传送带20上后，视觉测量***拍照识别距离端面的第一个孔和最后一个孔，计算出冲孔累计误差，并将该误差反馈给伺服电机36以调整货架装配模具4支撑梁装配孔间距。上料机器人6将支撑梁摆放至货架装配模具4的指定位置，完成支撑梁上料并将完工信号反馈至控制***。
(5)控制***接收到上述完工信号后，控制货架装配模具4和立柱38进入货架装配区26，货架装配模具4和立柱38通过限位调整***保证装配基准的统一，之后支撑梁压紧机构16下压固定各支撑梁，货架装配模具4的旋转气缸32下降，立柱撑开机构21驱动气缸活塞杆伸出至撑开工位，等待立柱38装配。
(6)立柱顶进机构15推顶立柱38与支撑梁装配孔对齐，立柱撑开机构21的机械限位保证立柱38到达指定装配工位，以避免立柱38推顶过量；之后立柱撑开机构21气缸活塞杆缩回、支撑梁压紧机构16提升，旋转气缸32对装配孔进行导向，导向完成后气缸旋转并将螺栓推顶至装配工位，并将该信号反馈至控制***。
(7)控制***根据上述信号发送螺栓装配指令，螺母装配桁架机器人10接收到指令后，先到预定位置取得螺母，然后运动至货架装配位置，通过末端视觉测量***矫正气动拧紧枪位置误差，满足要求后实现单侧多个螺栓的装配工作，完成后螺母装配桁架机器人10回归至初始位置，并将完工信号反馈至控制***。
(8)控制***接收到上述信号后，将驱动线内物流***25的货架装配模具4输送至成品区27，位置传感器将获取货架装配模具4的到位信号，控制***根据此信号控制成品转移桁架机器人11抓取货架装配模具4上的货架，摆放至暂存区。
(9)上述工序完成后，成品区升降传送带13下降并将货架装配模具4输送至货架装 配区26，等待下一装配环节的指令。
本领域的技术人员容易理解，以上所述仅为本公开的较佳实施例而已，并不用以限制本公开，凡在本公开的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本公开的保护范围之内。
工业实用性
本公开提供的一种全自动仓储货架装配生产线及其运行方法，降低了仓储货架装配过程中的劳动强度，提高了装配生产效率，且柔性化程度高，能够适应多种不同规格货架产品的装配，并且，各部分可根据生产节拍和场地大小设置工位数量和分布方式，实现均衡生产。

Claims (15)

  1. 一种全自动仓储货架装配生产线，其特征在于，该生产线包括物流通道(22)、立柱上料区(23)、支撑梁上料区(24)、线内物流***(25)、货架装配区(26)、成品区(27)和控制***，所述立柱上料区(23)、支撑梁上料区(24)、货架装配区(26)和成品区(27)通过线内物流***(25)串联为一个整体生产线，其中：
    所述物流通道(22)作为货架装配生产线中所需零件输送和货架成品转移的通道；
    所述立柱上料区(23)包括立柱上料桁架机器人(2)和轨道式立柱上料车(3)，所述轨道式立柱上料车(3)配置成立柱料盘的运输，轨道式立柱上料车(3)集成有机械定位***，机械定位***将轨道式立柱上料车(3)限定至指定工位；立柱上料桁架机器人(2)配置成将立柱抓取至立柱传送带(20)，立柱上料桁架机器人(2)集成有视觉测量***，视觉测量***负责测量立柱安装孔的加工误差；
    所述支撑梁上料区(24)包括支撑梁上料机器人(6)、螺栓上料机器人(17)和螺栓振动上料盘(18)，所述支撑梁上料机器人(6)配置成将支撑梁放置在线内物流***(25)的货架装配模具(4)的定位销钉上，螺栓上料机器人(17)配置成将螺栓放置在线内物流***(25)的货架装配模具(4)的螺栓孔上，螺栓振动上料盘(18)为螺栓上料机器人(17)提供摆放规则一致的螺栓；
    所述线内物流***(25)包括支撑梁上料区升降传送带(8)、成品区升降传送带(13)、货架装配区固定传送带(14)、立柱传送带(20)和货架装配模具(4)，货架装配模具(4)集成有立柱撑开机构(21)；所述立柱撑开机构(21)配置成将立柱槽口撑开一定距离，同时限制立柱的位置，保证支撑梁与立柱装配孔对齐；所述货架装配模具(4)为支撑梁的摆放和立柱装配提供定位基准，货架装配模具(4)能够在支撑梁上料区升降传送带(8)、成品区升降传送带(13)和货架装配区固定传送带(14)上移动；货架装配区固定传送带(14)包含高度不同的两层独立的传送带***，支撑梁上料区升降传送带(8)和成品区升降传送带(13)能够在两层独立传送带之间运动；
    所述货架装配区(26)包括螺母装配桁架机器人(10)、螺母振动上料盘(9)、立柱顶进机构(15)和支撑梁压紧机构(16)；当所述货架装配模具(4)到达货架装配区(26)后，螺母装配桁架机器人(10)将螺母振动上料盘(9)提供的螺母抓取至装配孔位置安装，立柱顶进机构(15)将立柱由立柱传送带(20)推顶至指定装配位置，支撑梁压紧机构(16)配置成限制支撑梁的运动；
    所述成品区(27)包括成品转移桁架机器人(11)和货架暂存台(12)，货架桁架机器人(11)配置成将装配完成的货架成品转移至货架暂存台(12)；
    所述控制***配置成装配生产线总体控制。
  2. 根据权利要求1所述的一种全自动仓储货架装配生产线，其特征在于，所述货架装配模具(4)上设置有定位销钉，货架装配模具(4)主要由货架装配模具支撑板(28)和模具单元(29)组成，模具单元(29)设置在货架装配模具支撑板(28)上，每个模具单元(29)包括丝杆***(30)、锥齿轮***(31)、旋转气缸(32)、直齿轮***(33)、轴承座(34)、模具单元安装板(35)和两个伺服电机(36)，定位销钉设置在旋转气缸(32)上，所述定位销钉具有4个自由度，包括沿货架装配模具(4)的长度方向、宽度方向、厚度方向的三个移动自由度及沿厚度方向的旋转自由度；伺服电机配置成驱动锥齿轮***(31)和直齿轮***(33)转动；丝杆***(30)、锥齿轮***(31)、旋转气缸(32)、直齿轮***(33)和轴承座(34)均设置在模具单元安装板(35)上，旋转气缸(32)通过滑台设置在丝杆***(30)上，直齿轮***(33)与货架装配模具支撑板(28)上的齿条配合，实现模具单元(29)在物流通道(22)长度方向上的移动；丝杆***(30)配置成横撑和斜撑的定位及装配阶段螺栓的固定，通过驱动锥齿轮***(31)，调整一对定位销钉的横向间距，直齿轮***(33)配置成调整相邻两个所述丝杆***(30)的定位销钉的纵向间距。
  3. 根据权利要求2所述的一种全自动仓储货架装配生产线，其特征在于，所述立柱上料桁架机器人(2)、支撑梁上料机器人(6)、螺栓上料机器人(17)、螺母装配桁架机器人(10)和成品转移桁架机器人(11)的末端执行器均带有视觉识别***，配置成识别支撑梁和螺栓的种类，以及定位末端执行器抓取的位置。
  4. 根据权利要求3所述的一种全自动仓储货架装配生产线，其特征在于，所述立柱上料区(23)和货架装配区(26)均设置有立柱机械限位***，配置成在物流通道(22)的长度方向对立柱(38)限位；所述货架装配区(26)和成品区(27)均设置有货架装配模具机械限位***，配置成在物流通道(22)的长度方向对货架装配模具(4)进行限位。
  5. 根据权利要求1-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述货架装配模具(4)的数量为多个，多个所述货架装配模具(4)配置成对多种规格货架进行不同生产节拍的装配工作。
  6. 根据权利要求1-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述立柱上料区(23)、支撑梁上料区(24)、货架装配区(26)和成品区(27)通过线内物流***(25)串联形成的生产线呈“一”字形。
  7. 根据权利要求1-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述物流通道(22)呈“U”形，所述立柱上料区(23)、支撑梁上料区(24)、线内物流***(25)、货架装配区(26)和成品区(27)均设置在所述物流通道(22)的U 形槽中。
  8. 根据权利要求1-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述螺栓上料机器人(17)比所述螺栓振动料盘(18)更靠近所述线内物流***(25)。
  9. 根据权利要求1-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述货架暂存台(12)位于所述成品区升降传送带(13)的一侧。
  10. 根据权利要求2-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述丝杆***(30)的丝杆与所述货架装配模具(4)的进给方向垂直。
  11. 根据权利要求2-4任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述齿条的数量为两个，两个所述齿条沿所述丝杆***(30)中丝杆的长度方向平行且间隔设置，所述直齿轮***(33)包括沿所述丝杆的长度方向间隔设置的两个直齿轮，两个所述直齿轮与两个所述齿条一一对应地啮合。
  12. 根据权利要求1-11任一项所述的一种全自动仓储货架装配生产线，其特征在于，所述仓储货架包括支撑梁和立柱(38)，支撑梁包括管型横撑(37)、标准型横撑(39)和斜撑(40)；所述全自动仓储货架装配生产线还包括管型横撑物料盘(5)、标准横撑物料盘(7)和斜撑物料盘(19)，分别配置成放置管型横撑(37)、标准型横撑(39)和斜撑(40)。
  13. 根据权利要求12所述的一种全自动仓储货架装配生产线，其特征在于，所述管型横撑物料盘(5)与所述标准横撑物料盘(7)设置在所述立柱传送带(20)的同一侧，所述斜撑物料盘(19)设置在所述立柱传送带(20)的另一侧。
  14. 根据权利要求13所述的一种全自动仓储货架装配生产线，其特征在于，沿所述货架装配模具(4)的进给方向，所述管型横撑物料盘(5)与所述标准横撑物料盘(7)依次设置。
  15. 一种基于权利要求1-14所述的全自动仓储货架装配生产线的运行方法，其特征在于，包括以下步骤：
    步骤1，将待装配货架立柱、支撑梁、螺栓和螺母从仓库依靠叉车(1)输送至各个上料盘；
    步骤2，立柱上料桁架机器人(2)、轨道式立柱上料车(3)、货架装配模具(4)、螺栓上料机器人(17)、螺母装配桁架机器人(10)和成品转移桁架机器人(11)同步获取货架规格信息并进行自动调整至指定工位；
    步骤3，货架装配模具(4)从装配工位进入支撑梁上料区(24)，控制***控制螺栓上料机器人(17)将螺栓振动上料盘(18)提供的螺栓摆放至货架装配模具(4)的螺栓槽内，当货架装配模具(4)完全进入支撑梁上料区(24)后，螺栓上料工作全 部完成，支撑梁上料区传送带(8)升高至支撑梁上料工位，支撑梁上料机器人等待控制***的上料信息；
    步骤4，立柱上料桁架机器人将立柱(38)抓取至线内物流***(25)的立柱传送带(20)上后，视觉测量***拍照识别距离端面的第一个孔和最后一个孔，计算出冲孔累计误差，并将该误差反馈给伺服电机(36)以调整货架装配模具(4)支撑梁装配孔间距；上料机器人(6)将支撑梁摆放至货架装配模具(4)的指定位置，完成支撑梁上料并将完工信号反馈至控制***；
    步骤5，控制***接收到上述完工信号后，控制货架装配模具(4)和立柱(38)进入货架装配区(26)，之后支撑梁压紧机构(16)下压固定各支撑梁，货架装配模具(4)的旋转气缸(32)下降，立柱撑开机构驱动气缸活塞杆伸出至撑开工位，等待立柱(38)装配；
    步骤6，立柱顶进机构(15)推顶立柱(38)与支撑梁装配孔对齐，之后立柱撑开机构(21)气缸活塞杆缩回、支撑梁压紧机构(16)提升，旋转气缸(32)对装配孔进行导向，导向完成后旋转气缸(32)旋转并将螺栓推顶至装配工位，并将该信号反馈至控制***；
    步骤7，控制***根据上述信号发送螺栓装配指令，螺母装配桁架机器人(10)接收到指令后，先到预定位置取得螺母，然后运动至货架装配位置，通过末端视觉测量***矫正气动拧紧枪位置误差，满足要求后实现单侧多个螺栓的装配工作，完成后螺母装配桁架机器人(10)回归至初始位置，并将完工信号反馈至控制***；
    步骤8，控制***接收到上述信号后，驱动线内物流***(25)将货架装配模具(4)输送至成品区(27)，位置传感器将获取货架装配模具(4)的到位信号，控制***根据此信号控制成品转移桁架机器人(11)抓取货架装配模具(4)上的货架，摆放至暂存区；
    步骤9，上述工序完成后，成品区升降传送带(13)下降并将货架装配模具(4)输送至货架装配区(26)，等待下一装配环节的指令。
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