WO2021249580A1 - 一种滑石片全自动粘接智能控制方法及*** - Google Patents

一种滑石片全自动粘接智能控制方法及*** Download PDF

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Publication number
WO2021249580A1
WO2021249580A1 PCT/CN2021/111437 CN2021111437W WO2021249580A1 WO 2021249580 A1 WO2021249580 A1 WO 2021249580A1 CN 2021111437 W CN2021111437 W CN 2021111437W WO 2021249580 A1 WO2021249580 A1 WO 2021249580A1
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talc
bonding
silicon steel
sheet
module
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PCT/CN2021/111437
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English (en)
French (fr)
Inventor
韩志伟
燕飞东
严子红
袭建凯
杨振元
张京同
李发永
谢辉
姜世华
陈晓霖
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山东电力设备有限公司
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Application filed by 山东电力设备有限公司 filed Critical 山东电力设备有限公司
Priority to US17/601,078 priority Critical patent/US20220319771A1/en
Publication of WO2021249580A1 publication Critical patent/WO2021249580A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means

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  • the present invention belongs to the technical field of transformer production and manufacturing, and specifically relates to a method and system for automatic intelligent control of talc sheet bonding. Recognizing the position of the talc sheet involves the field of image processing and visual recognition, and the capturing and placing of the talc sheet involves the control of the position and attitude of the manipulator and the force control of the manipulator.
  • the external iron core oil passage is composed of talc sheets bonded to silicon steel sheets.
  • the talc sheet bonding process is purely manual operation, which is time-consuming and laborious, cumbersome and unsmooth, the amount of glue is not fixed, the force is uneven, and problems such as the talc sheet falling off or the glue overflow after processing and assembly may occur.
  • Patent Although the talc sheet automatic bonding device (CN106169366A) realizes the automatic bonding of talc sheet, the PLC control method is not smart enough, and the control of the robot arm is not precise enough, and it needs to be further optimized.
  • the present invention aims to use an intelligent control method and system to effectively and accurately control the mechanical arm, so as to realize the accurate, rapid and uniform bonding of the talc sheet to the silicon steel sheet.
  • the technical scheme of the present invention is as follows:
  • An intelligent control method for fully automatic bonding of talc tablets including:
  • Step 1 Preliminary manual preparation work, put the talc sheet, glue solution, and silicon steel sheet in place;
  • Step 2 After the equipment of the automatic bonding intelligent control system is started, the initialization of the system is completed;
  • Step 3 Start the high-brightness and uniform LED light source to collect the image of the silicon steel sheet, detect and identify the specifications and types of the silicon steel sheet, and call the corresponding talc sheet adhesive trajectory to plan the path according to the specifications and types of the silicon steel sheet; The image detects the edge of the silicon steel sheet to determine the placement position of the first talc sheet;
  • Step 4 Automatically start the bonding of the first talc sheet until the bonding of the first row of talc sheets is completed;
  • Step 5 Automatically start the bonding of the talc sheets in the following rows until the bonding of the talc sheets of the entire silicon steel sheet is completed.
  • step 3 it is judged whether the specifications and types of the identified silicon steel sheets are in the known specifications and types. If so, call the existing bonding workflow to automatically bond the talc sheets; if not, according to the silicon steel sheets The new specifications and types of the tablets, a new bonding workflow is set, and the newly set bonding workflow is called to automatically bond the talc tablets.
  • step 4 the single talc flakes are sequentially transported through the spiral slide and the linear slide to the fetching port through the vibration of the barrel; the vertical arm drives the vacuum adsorber to press down under the action of the motor, and the suction nozzle absorbs the talc flakes Lift; compressed air drives the glue head to spray quantitative glue up to the bottom of the talc sheet, and the excess glue is automatically sucked back; the horizontal arm extends horizontally to move the talc sheet to the top of the silicon steel sheet, and the vertical arm drives the vacuum adsorber to press down to the silicon steel sheet After the talc tablets are released after the pressure is maintained for 200 milliseconds, the bonding of the first piece is completed.
  • step 4 judge whether the current talc sheet is placed successfully according to the collected image, and set the maximum number of placement times. If the maximum number of placement times is exceeded, the alarm will stop; in step 5, when the end angle of the silicon steel sheet is detected When the bonding work is stopped, the buzzer will sound to remind the operator to take out the completed silicon steel sheet and replace it with a new silicon steel sheet to continue bonding.
  • an abnormal situation processing module is set. If the motor overvoltage, or motor overcurrent, or the mechanical device exceeds the edge of the silicon steel sheet, or the talc sheet falls off for many times, or the material in the barrel is insufficient, the alarm will be stopped; if the talc sheet is not successful Adsorb or fall off, re-take the material; if it reaches the edge of the silicon steel sheet, control the placement of the talc sheet to comply with the distance value from the edge.
  • An intelligent control system for fully automatic bonding of talc tablets applying the aforementioned intelligent control method for fully automatic bonding of talc tablets, comprising: a hardware processing module, wherein the hardware processing module is electrically connected to a signal acquisition module; the signal acquisition module It is electrically connected with the main program control module, and the main program control module is electrically connected with the upper computer and the drive circuit respectively, and the drive circuit is electrically connected with the actuator.
  • the main program control module includes: a PLC controller, an image processing and recognition module, a manipulator pose control module, a manipulator force control module, and a machine vision positioning module;
  • the said PLC controller is arranged on the main pulley, and is used to implement the corresponding algorithms of the image processing and recognition module, the robot arm pose control module, the robot arm force control module, and the machine vision positioning module;
  • the image processing and recognition module obtains characteristic data through image processing, and determines the specifications and types and edge positions of silicon steel sheets;
  • the said robot arm pose control module which controls the horizontal robot arm to stably run to a designated position
  • the force control module of the mechanical arm adopts a direct torque control algorithm to control the vertical motion state of the mechanical arm, and control the vertical mechanical arm to ensure a stable output torque;
  • the machine vision positioning module is used for determining the initial working position and placing the position of the last talc in each row.
  • the signal acquisition module includes: an image acquisition device, a position sensor, a pressure sensor, and a voltage and current sensor;
  • the position sensor is located at the driving motor and installed coaxially with the driving motor of the robot arm, and is used to feedback the current position of the robot arm to realize the closed-loop control of the position of the robot arm.
  • the encoder is used to incrementally record the current moving distance and calculate the current position. ;
  • the pressure sensor is installed in a vertical mechanical arm, and is used to ensure proper pressure when the talc sheet is bonded and placed;
  • the voltage and current sensor is used to measure the voltage and current on the motor on the mechanical arm and control the operation of the mechanical arm;
  • the image acquisition device is arranged on a horizontal mechanical arm and includes a camera with visual tracking.
  • the actuator includes: a mechanical arm, a moving pulley and a feeding mechanism, the mechanical arm is composed of a vertical arm, a horizontal arm and a vacuum absorber, and the moving pulley includes a moving pulley that moves along the length of the worktable.
  • Main pulley and auxiliary pulley installed on the main pulley and moving along the width of the worktable;
  • the hardware processing module includes: a high-brightness uniform lighting LED light source, a filter, and a hardware filter module; the high-brightness uniform lighting LED light source and the filter are arranged on the upper part of the carriage;
  • the driving circuit adopts thyristor as a switch to control the speed of the motor to control the moving speed of the mechanical arm;
  • the host computer includes a display control screen and a remote remote control device.
  • the display control screen is used to select the bonding method and manually set the talc sheet bonding movement track when necessary, and the remote control device is used to stop and suspend an emergency when a fault occurs.
  • the intelligent control method and system of the present invention realize the fully automatic bonding of talc tablets, and ensure the fastness, adhesion, and accuracy of talc tablets bonding.
  • Fig. 1 is a flowchart of an intelligent control method according to an embodiment of the present invention
  • Figure 2 is a flowchart of an image recognition method according to an embodiment of the present invention.
  • FIG. 3 is a schematic diagram of the technical requirements for bonding talc sheets in a top and bottom encryption mode according to an embodiment of the present invention
  • FIG. 4 is a schematic diagram of the principle of the fully automatic bonding system according to an embodiment of the present invention.
  • Fig. 5 is a schematic diagram of the principle of a robot arm control method according to an embodiment of the present invention.
  • FIG. 1 it is a flowchart of an intelligent control method according to an embodiment of the present invention.
  • FIG. 2 it is a flowchart of an image recognition method according to an embodiment of the present invention.
  • FIG. 3 it is a schematic diagram of the technical requirements for bonding the talc sheet in a top and bottom encryption mode according to an embodiment of the present invention.
  • An intelligent control method for fully automatic bonding of talc tablets includes the following steps:
  • talc and glue into the barrel and the glue bucket respectively; place the silicon steel sheet on the workbench (such as the same size and size can be laid in multiple layers) and align the upper edge with the upper positioning block, the purpose is to ensure the silicon steel sheet Keep vertical to the moving direction of the auxiliary pulley.
  • Step 2 After the device is started, it enters the initialization stage, the vertical arm and the horizontal arm return to the mechanical zero position, and the vacuum adsorber moves to the position of the film-taking port.
  • the operator can choose different bonding methods through the host computer (according to the different products, it can be divided into two types: encryption and unencrypted on the upper and lower sides, and the default is no encryption), configure the motion trajectory, and complete the initialization of the system at this time.
  • Step 3 Start the high-brightness uniform LED light source to collect the image of the silicon steel sheet, and detect and identify the type of the silicon steel sheet;
  • the device After the sharp corner of the upper right corner of the silicon steel sheet is placed in the camera shooting range of the visual recognition mechanism, the device will automatically determine the type and specification of the silicon steel sheet from the image collected by the camera after the device is started, and call the corresponding talc according to the type and specification of the silicon steel sheet Plan the path of the bonding trajectory of the chip and the chip;
  • this step it is judged whether the identified type of silicon steel sheet is among the known types. If it is, call the existing bonding workflow to automatically bond the talc sheet; if not, it will be based on the new edge type and design of the silicon steel sheet. Set a new bonding workflow, and then call the newly set bonding workflow for automatic bonding of talc tablets.
  • Step 4 Automatically start the bonding of the first talc sheet until the bonding of the first row of talc sheets is completed.
  • the vertical arm drives the vacuum adsorber to press down under the action of the motor, and the suction nozzle absorbs the talc flakes and lifts it up, while the compressed air drives the spray
  • the glue head sprays an appropriate amount of glue up to the bottom of the talc sheet, and the excess glue is automatically sucked back
  • the horizontal arm extends horizontally to move the talc sheet to the top of the silicon steel sheet, and the vertical arm drives the vacuum adsorber to press down on the silicon steel sheet and maintain the pressure for 200 After milliseconds, the talc sheet is released and lifted, and the first sheet is bonded.
  • Step 5 Automatically start the bonding of the talc sheets in the following rows until the bonding of the talc sheets of the entire silicon steel sheet is completed.
  • the main pulley moves to the second row, and the auxiliary pulley automatically completes the bonding work of this row, cyclically completing all the talc sheet bonding work.
  • the machine vision system detects the end angle, the bonding will stop, and the buzzer will sound to remind the operator to take out the completed silicon steel sheet and replace it with a new one to continue bonding.
  • an abnormal situation processing module is set in this intelligent control method.
  • the types of abnormal situations and the corresponding processing methods are shown in the following table.
  • the abnormal situation processing module may be one or more processors or chips with a communication interface that can implement a communication protocol, and may also include a memory and related interfaces, a system transmission bus, etc., if necessary;
  • the processor or chip executes the program-related code to realize the corresponding function.
  • An intelligent control system for fully automatic bonding of talc tablets includes a hardware processing module.
  • the hardware processing module is electrically connected with a signal acquisition module, and the signal acquisition is completed by the hardware of the signal acquisition module.
  • the signal acquisition module is electrically connected with the main program control module, the main program control module is electrically connected with the upper computer and the drive circuit, and the drive circuit is electrically connected with the actuator.
  • the type of silicon steel sheet, the bonding path of the talc sheet and other parameters are set through the host computer.
  • the main program control module controls the action of the mechanical device of the actuator through the drive circuit according to the real-time information collected by the signal acquisition module to complete the automatic bonding of the talc sheet. Pick up work.
  • the main program control module includes: a PLC controller, an image processing and recognition module, a manipulator pose control module, a manipulator force control module, and a machine vision positioning module.
  • the image recognition module is an image processing and recognition module;
  • the robot arm automatic control module includes a robot arm pose control module and a robot arm force control module.
  • the PLC controller is used to implement the corresponding algorithms of the image processing and recognition module, the robot arm pose control module, the robot arm force control module, and the machine vision positioning module.
  • the said PLC controller is arranged on the main pulley and is used to process various algorithms and signals, and is the core of the entire control system.
  • the image processing and recognition module processes the images collected by the camera, obtains characteristic data through image processing, determines the specifications and types of silicon steel sheets, and edge positions, thereby determining the operation flow and movement trajectory of the robot arm and the trolley.
  • the described manipulator posture control module is used to control the horizontal manipulator arm to run stably to a specified position.
  • the movement of the robot arm is divided into horizontal movement and vertical movement, and the horizontal movement mainly depends on the position and attitude control of the robot arm to ensure that the robot arm can stay accurately At the designated position; the position closed-loop control method is adopted and the feedforward compensation method is adopted to ensure the rapid movement of the robot arm.
  • the force control module of the mechanical arm is mainly used to control the vertical motion state of the mechanical arm, and to control the vertical mechanical arm to ensure stable output torque.
  • the direct torque control algorithm is adopted to ensure the constant torque output of the robot arm, so as to ensure that the talc sheet is firmly bonded, and effectively prevent the problem of the talc sheet falling off due to excessive pressure or the glue overflow caused by excessive pressure.
  • the machine vision positioning module is mainly used to determine the initial working position and place the last talc sheet in each row, and control the talc sheet to be placed at a distance of 7 mm from the edge of the silicon steel sheet. Using the characteristics of the corners of the silicon steel sheet, determine the placement position of the first talc sheet, and perform edge detection at the last position, placing the talc sheet 7mm away from the edge. Since there is no need to measure the distance in the depth direction, it can be realized by only a single eye.
  • the driving circuit adopts thyristor as a switch to control the speed of the motor to control the moving speed of the mechanical arm.
  • the driving circuit amplifies the PLC controller signal and the motion signal of the robot arm, converts the control signal of the PLC controller into the driving signal of the driving motor on the robot arm, and then controls the running state of the motor.
  • the signal acquisition module includes: an image acquisition device, a position sensor, a pressure sensor, and a voltage and current sensor.
  • the position sensor is located at the drive motor and installed coaxially with the drive motor of the robotic arm. It is used to feed back the current position of the robotic arm to realize the closed-loop control of the robotic arm position control.
  • the encoder is used to incrementally record the current movement distance and calculate the current Location.
  • the pressure sensor is used to monitor the pressure of the mechanical arm on the silicon steel sheet to ensure the constant torque output of the motor.
  • the pressure sensor is installed in the vertical mechanical arm, and is mainly used to ensure proper pressure when the talc sheet is bonded and placed.
  • the PLC controller controls the operating status of the mechanical arm according to the feedback information of the position sensor and the pressure sensor to ensure the accuracy of the bonding position of the talc sheet and ensure that the talc sheet is evenly stressed.
  • the voltage and current sensor is used to measure the voltage and current on the motor on the mechanical arm, control the operation of the mechanical arm, and ensure the speed and followability of the mechanical arm.
  • the current sensor in the voltage and current sensor is used to realize closed-loop control and overcurrent monitoring of the manipulator drive motor, and the voltage sensor in the voltage and current sensor realizes the reconstruction of the motor phase voltage and the overvoltage monitoring.
  • the image acquisition device is set on a horizontal mechanical arm and includes a camera with visual tracking, which is mainly used to collect the types of silicon steel sheets. Use high-brightness uniform lighting LED light source and filter to optically process the silicon steel sheet, and use a camera with a visual tracking system for image collection. All the above signal acquisition modules are connected to the PLC controller.
  • the implementing mechanism includes: a mechanical arm, a moving pulley, and a feeding mechanism.
  • the mechanical arm is composed of a vertical arm, a horizontal arm and a vacuum adsorber.
  • the mobile trolley includes a main trolley that moves along the length of the worktable and an auxiliary trolley that is installed on the main trolley and moves along the width of the worktable.
  • the hardware processing module includes: a high-brightness uniform lighting LED light source, a filter, and a hardware filter module.
  • the high-brightness uniform lighting LED light source and the filter are arranged on the upper part of the carriage, provide optical processing on the hardware, improve the recognition of the object, and cooperate with the image acquisition device to collect clear images.
  • the hardware processing module is a hardware device that includes a high-brightness uniform lighting LED light source, a filter, and a hardware filter module.
  • the hardware filter module may be a communication interface capable of implementing a communication protocol. Or multiple processors or chips, and the processors or chips execute program-related codes to realize corresponding functions.
  • the signal acquisition module is a hardware device including an image acquisition device, a position sensor, a pressure sensor, and a voltage and current sensor.
  • the main program control module is a hardware device including a PLC controller, an image processing and recognition module, a manipulator pose control module, a manipulator force control module, and a machine vision positioning module. Specifically, it may be a hardware device with a communication interface that can implement a communication protocol. Controller.
  • the image processing and recognition module, the manipulator pose control module, the manipulator force control module, and the machine vision positioning module are integrated in a PLC controller, and the PLC controller executes program-related codes to realize corresponding functions.
  • the image recognition module is the image processing and recognition module;
  • the automatic control module of the robot arm includes the position and attitude control module of the robot arm and the force control module of the robot arm, the image recognition module and the automatic control module of the robot arm can be Integrate into a controller with communication interface capable of realizing communication protocol.
  • the controller executes program-related codes to realize corresponding functions.
  • the host computer includes a display control screen, a remote control device, and the display control screen is mainly used for selecting the bonding method and manually setting the movement track when necessary.
  • the remote control device is used for emergency shutdown and pause in case of failure.
  • the upper computer is separated from the PLC controller, which is convenient for the operator to issue commands to the control system and plan the movement trajectory of the bonding.

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Abstract

本发明涉及一种滑石片全自动粘接智能控制方法，利用图像识别模块，自动识别待加工的硅钢片的规格和种类；根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径，通过机械臂自动控制模块按照粘接轨迹规划路径自动将滑石片粘接到硅钢片的相应位置。本发明还涉及一种滑石片全自动粘接智能控制***。本发明的智能控制方法和***，实现了滑石片全自动粘接，保证了滑石片粘接的快速性、粘接性、准确性；生产结果表明滑石片粘接符合工艺标准和规范，滑石片排列整齐，粘接质量好；应用本发明生产效率极大提升，完全可以代替人工操作。

Description

一种滑石片全自动粘接智能控制方法及*** 技术领域
本发明属于变压器生产制造技术领域，具体涉及一种滑石片全自动粘接智能控制方法及***，具备自动识别滑石片位置功能，捕获滑石片并放置在指定位置进行粘接，其中，所述自动识别滑石片位置涉及图像处理和视觉识别领域，所述捕获和放置滑石片涉及机械臂位姿控制、机械臂力控制。
背景技术
在大型电力变压器、换流变压器中，外部铁芯油道是由滑石片粘接到硅钢片上构成的。目前，滑石片粘接工艺流程为纯手工操作，费时费力、繁琐不畅，点胶量不固定，受力不均匀，加工装配后可能会出现滑石片脱落或者胶液溢出等问题。
专利：滑石片全自动粘接装置(CN106169366A)虽然实现了滑石片的自动粘接，但是，其中的PLC控制方法还不够智能、机械臂的控制还不够精准，有待进一步优化。
发明内容
针对上述技术问题，本发明旨在利用智能化控制方法和***，有效且准确地控制机械臂，实现滑石片准确快速均匀的粘接到硅钢片上。为解决上述问题，本发明的技术方案为：
一种滑石片全自动粘接智能控制方法，包括：
利用图像识别模块，自动识别待加工的硅钢片的规格和种类；根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径，通过机械臂自动控制模块按照粘接轨迹规划路径自动将滑石片粘接到硅钢片的相应位置。
优选的，包括以下步骤：
步骤1、前期人工准备工作，将滑石片和胶液、硅钢片摆放到位；
步骤2、全自动粘接智能控制***的设备启动后完成***的初始化工作；
步骤3、启动高亮度均匀LED光源对硅钢片进行图像采集，检测辨识硅钢片的规格和种类，根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径；根据采集的图像对硅钢片进行边沿检测，确定第一个滑石片的放置位置；
步骤4、自动开始第一片滑石片的粘接，直至完成第一列滑石片的粘接；
步骤5、自动开始后面各列滑石片的粘接，直至完成整个硅钢片的滑石片的粘接。
优选的，步骤3中，判断所辨识的硅钢片的规格和种类是否在已知规格和种类中，如果是、调用已有的粘接工作流程进行滑石片的自动粘接；如果否，根据硅钢片的新的规格和种类、设定新的粘接工作流程，调用新设定的粘接工作流程进行滑石片的自动粘接。
优选的，步骤4中，通过料筒的振动使单片滑石片经螺旋滑道、直线滑道顺次输送至取片口；垂直臂在电机作用下带动真空吸附器下压，吸嘴吸附滑石片上提；压缩空气带动喷胶头将定量胶液向上喷至滑石片底部，多余胶液自动吸回；水平臂水平伸出将滑石片移动到硅钢片上方，垂直臂带动真空吸附器下压到硅钢片上，并保压200毫秒后释放滑石片后，第一片粘接完成。
优选的，步骤4中，根据采集的图像判断当前滑石片是否放置成功，设置最多的放置次数，如果超过设置的最多的放置次数、则报警停机；步骤5中，当检测到硅钢片的结束角时停止粘接工作，蜂鸣器发出响声提醒操作者取出已完成的硅钢片，更换新硅钢片继续粘接。
优选的，设置异常情况处理模块，如果电机过电压、或电机过电流、或机械装置超过硅钢片边沿、或滑石片多次脱落、或料桶内材料不足，则报警停机；如果滑石片未成功吸附或脱落，则重新取料；如果到达硅钢片边沿，则控制滑石片的放置符合距离边沿的距离值。
一种滑石片全自动粘接智能控制***，应用前述的滑石片全自动粘接智能控制方法，包括：硬件处理模块，所述的硬件处理模块与信号采集模块电连接；所述的信号采集模块与主程序控制模块电连接，所述的主程序控制模块分别与上位机、驱动电路电连接，所述的驱动电路与执行机构电连接。
优选的，所述的主程序控制模块包括：PLC控制器、图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块；
所述的PLC控制器设置在主滑车上，用于实现图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块的相应算法；
所述的图像处理与识别模块，通过图像处理获得特征数据，确定硅钢片的规格和种类、边沿位置；
所述的机械臂位姿控制模块，控制水平机械臂稳定的运行到指定位置；
所述的机械臂力控制模块，采用直接转矩控制算法，控制机械臂竖直方向运动状态，控制竖直机械臂保证稳定的输出扭矩；
所述的机器视觉定位模块，用于工作初始位置的确定和每一行最后一枚滑石片的位置摆放。
优选的，所述的信号采集模块包括：图像采集装置、位置传感器、压力传感器、电压电流传感器；
所述的位置传感器位于驱动电机处、与机械臂驱动电机同轴安装，用于反馈机械臂当前位置，实现机械臂位置的闭环控制，利用编码器采用增量方式记录当前移动距离，计算当前位置；
所述的压力传感器安装在竖直机械臂中，用于滑石片粘接放置时保证合适的压力；
所述电压电流传感器用于测量机械臂上电机上的电压电流，控制机械臂的运行；
所述的图像采集装置设置在水平机械臂上，包括：具备视觉跟踪的摄像头。
优选的，所述的执行机构包括：机械臂、移动滑车以及送料机构，所述的机械臂由竖直臂、水平臂和真空吸附器组成，所述的移动滑车包括沿工作台长度方向移动的主滑车和安装于主滑车上的沿工作台宽度方向移动的副滑车；
所述的硬件处理模块包括：高亮度均匀照明LED光源、滤光片、硬件滤波模块，所述的高亮度均匀照明LED光源和滤光片设于滑车的上部；
所述的驱动电路采用可控硅作为开关，控制电机转速从而控制机械臂的移动速度；
所述的上位机包括：显示控制屏、远程遥控装置，显示控制屏用于选择粘接方式和必要时进行手动设置滑石片粘接运动轨迹，远程遥控装置用于故障时紧急停机、暂停。
本发明的有益效果：
1)本发明的智能控制方法和***，实现了滑石片全自动粘接，保证了滑石片粘接的快速性、粘接性、准确性。
2)生产结果表明滑石片粘接符合工艺标准和规范，滑石片排列整齐，粘接质量好。
3)应用本发明生产效率极大提升，完全可以代替人工操作。
附图说明
为了更清楚地说明本发明的具体实施方式、或者现有技术中的技术方案，下面将对具体实施方式或现有技术的描述中所需要使用的附图作简单的介绍。显而易见地，下面描述中的附图是本发明的一些具体实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的属于本申请保护范围之内的附图。
图1是本发明实施例的智能控制方法流程图；
图2是本发明实施例的图像识别方法流程图；
图3是本发明实施例的一种上下边加密模式的滑石片粘接技术要求示意图；
图4是本发明实施例的全自动粘接***的原理示意图；
图5是本发明实施例的机械臂控制方法原理示意图。
具体实施方式
下面结合附图，具体说明本发明的实施方式。
如图1所示，是本发明实施例的智能控制方法流程图。如图2所示，是本发明实施例的图像识别方法流程图。如图3所示，是本发明实施例的一种上下边加密模式的滑石片粘接技术要求示意图。一种滑石片全自动粘接智能控制方法，包括以下步骤：
步骤1、前期人工准备工作：
将适量滑石片和胶液分别放入料筒和胶桶中；在工作台上铺放硅钢片(如相同规格尺寸可铺放多层)且使其上边对齐上部定位块，目的是保证硅钢片与副滑车移动方向保持垂直。
步骤2、设备启动后进入初始化阶段，垂直臂与水平臂回到机械零位，真空吸附器移动到取片口位置。操作人员可以通过上位机选择不同的粘接方式(按产品的不同分为上下两边加密及不加密两种，默认为不加密)，配置运动轨迹，此时完成***的初始化工作。
步骤3、启动高亮度均匀LED光源对硅钢片进行图像采集，检测辨识硅钢片的种类；
将硅钢片右上角的尖角部分置入视觉识别机构的摄像头拍摄范围后，设备启动后会通过摄像头采集的图像自动判断硅钢片的种类和规格，根据硅钢片的种类和规格调用相对应的滑石片粘片的粘接轨迹规划路径；
根据图像对硅钢片进行边沿检测，确定第一个滑石片的放置位置。
此步骤中，判断所辨识的硅钢片的类型是否在已知类型中，如果是、调用已有粘接工作流程进行滑石片的自动粘接；如果否，根据硅钢片的新的边沿类型、设定新的粘接工作流程，然后调用新设定的粘接工作流程进行滑石片的自动粘接。
步骤4、自动开始第一片滑石片的粘接，直至完成第一列滑石片的粘接。
通过料筒的振动使单片滑石片经螺旋滑道、直线滑道顺次输送至取片口；垂直臂在电机作用下带动真空吸附器下压，吸嘴吸附滑石片上提，同时压缩空气带动喷胶头将适量胶液向上喷至滑石片底部，多余胶液自动吸回；水平臂水平伸出将滑石片移动到硅钢片上方，垂直臂带动真空吸附器下压到硅钢片上，并保压200毫秒后释放滑石片后提起，第一片粘接完成。
通过预先设定的运动轨迹移动到下一个放置点，重复取片、喷胶、压片的动作，如此循环往复直至第一列完成，在整个工作过程中一直进行边沿检测，当机器视觉***检测到边沿时，控制***会给出信号，PLC自动修正副滑车移动距离，保证贴片位置距离边沿为7mm。
此步骤中，根据采集的图像判断当前滑石片是否放置成功，设置最多的放置次数(比如5次)，如果超过设置的最多的放置次数、则报警停机。
步骤5、自动开始后面各列滑石片的粘接，直至完成整个硅钢片的滑石片的粘接。
完成第一列的滑石片粘接工作后，主滑车移动到第二列，副滑车自动完成此列粘接工作，循环往复完成所有滑石片粘接工作。当机器视觉***检测到结束角会停止粘接工作，蜂鸣器发出响声提醒操作者取出已完成的硅钢片，更换新片继续粘接。
为防止滑石片粘接工作出现意外情况，本智能控制方法中设置了异常情况处理模块，异常情况的种类以及相应的处理方式如下表所示。在本申请的实施例中，异常情况处理模块可以是具有通信接口能够实现通信协议的一个或多个处理器或者芯片，如有需要还可以包括存储器及相关的接口、***传输总线等；所述处理器或者芯片执行程序相关的代码实现相应的功能。
控制***异常情况处理检测项目表
异常情况 处理方式
电机过电压 报警停机
电机过电流 报警停机
装置超过硅钢片边沿 报警停机
滑石片未成功吸附或脱落 重新取料
滑石片多次脱落 报警停机
料桶内材料不足 报警停机
到达硅钢片边沿 控制滑石片放置位置距离边沿7mm
到达边角 报警停机，更换硅钢片
如图4所示，是本发明实施例的全自动粘接***的原理示意图。如图5所示，是本发明实施例的机械臂控制方法原理示意图。一种滑石片全自动粘接智能控制***，包括：硬件处理模块，所述的硬件处理模块与信号采集模块电连接，通过信号采集模块的硬件完成信号采集。所述的信号采集模块与主程序控制模块电连接，所述的主程序控制模块分别与上位机、驱动电路电连接，所述的驱动电路与执行机构电连接。通过上位机进行硅钢片类型、滑石片粘接路径等参数设定，主程序控制模块根据信号采集模块采集的实时信息，通过驱动电路控制执行机构的机械装置的动作，完成滑石片的全自动粘接工作。
所述的主程序控制模块包括：PLC控制器、图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块。其中，所述图像识别模块即为图像处理与识别模块；所述机械臂自动控制模块包括机械臂位姿控制模块、机械臂力控制模块。
所述的PLC控制器，用于实现图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块的相应算法。所述的PLC控制器设置在主滑车上，用于处理各种算法和信号，是整个控制***的核心。
所述的图像处理与识别模块，处理摄像头所采集的图像，通过图像处理获得特征数据，确定硅钢片的规格和种类、边沿位置，从而确定机械臂和滑车的作业流程和运动轨迹。
所述的机械臂位姿控制模块，用于控制水平机械臂稳定的运行到指定位置。通过确认硅钢片类型，手动设计或者查表确定对应的运动轨迹，机械臂运动分为水平方向运动和竖直方向运动，其中水平方向运动主要依靠机械臂位姿控制，保证机械臂可以准确的停留在指定位置；采用位置闭环的控制方式并采用前馈补偿的方法保证机械臂运动的快速性。
所述的机械臂力控制模块，主要用于控制机械臂竖直方向运动状态，控制竖直机械臂保证稳定的输出扭矩。采用直接转矩控制算法，保证机械臂恒转矩输出，从而保证滑石片粘接牢固，有效防止压力过小导致滑石片脱落或者压力过大导致胶液溢出的问题。
所述的机器视觉定位模块，主要用于工作初始位置的确定和每一行最后一枚滑石片的位置摆放，控制滑石片放置在距离硅钢片边沿7mm处。利用硅钢片边角的特点，确定第一个滑石片的放置位置，并在最后位置进行边沿检测，将滑石片放在距离边沿7mm处。由于不需要纵深方向的距离测算，所以仅需要单目即可实现。
所述的驱动电路采用可控硅作为开关，控制电机转速从而控制机械臂的移动速度。所述的驱动电路将PLC控制器信号、机械臂运动信号放大，将PLC控制器的控制信号转换为机械臂上驱动电机的驱动信号，进而控制电机运行状态。
所述的信号采集模块包括：图像采集装置、位置传感器、压力传感器、电压电流传感器。
所述的位置传感器位于驱动电机处、与机械臂驱动电机同轴安装，用于反馈机械臂当前位置，实现机械臂位子控制的闭环控制，利用编码器采用增量方式记录当前移动距离，计算当前位置。所述的压力传感器用于监测机械臂对硅钢片的压力，保证电机恒转矩输出。所述的压力传感器安装在竖直机械臂中，主要用于滑石片粘接放置时保证合适的压力。PLC控制器根据位置传感器、压力传感器的反馈信息，控制机械臂的运行状况，确保滑石片粘接位置的精度，保证滑石片受力均匀。
所述电压电流传感器用于测量机械臂上电机上的电压电流，控制机械臂的运行，保证机械臂工作的快速性和跟随性。所述的电压电流传感器中的电流传感器用于机械臂驱动电机实现闭环控制、过电流监测，所述的电压电流传感器中的电压传感器实现电机相电压重构以及过电压监测。
所述的图像采集装置设置在水平机械臂上，包括：具备视觉跟踪的摄像头，主要用于采集硅钢片的种类。利用高亮度均匀照明LED光源和滤光片对硅钢片进行光学处理，利用带视觉跟踪***的摄像头进行图像采集。以上所有信号采集模块均与PLC控制器相连。
所述的执行机构包括：机械臂、移动滑车以及送料机构。所述的机械臂由竖直臂、水平臂和真空吸附器组成。所述的移动滑车包括沿工作台长度方向移动的主滑车和安装于主滑车上的沿工作台宽度方向移动的副滑车。
所述的硬件处理模块包括：高亮度均匀照明LED光源、滤光片、硬件滤波模块。所述的高亮度均匀照明LED光源和滤光片设于滑车的上部，提供硬件上的光学处理，提高物体的辨识度，配合图像采集装置采集清晰的图像。
在本申请的实施例中，所述硬件处理模块为包括高亮度均匀照明LED光源、滤光片、硬件滤波模块的硬件装置，其中所述硬件滤波模块可以是具有通信接口能够实现通信协议的一个或多个处理器或者芯片，所述处理器或者芯片执行程序相关的代码实现相应的功能。所述信号采集模块为包括图像采集装置、位置传感器、压力传感器、电压电流传感器的硬件装置。所述主程序控制模块为包括PLC控制器、图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块的硬件装置，具体可以是一个具有通信接口能够实现通信协议的控制器。其中，所述图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块集成于PLC控制器，所述PLC控制器执行程序相关的代码实现相应的功能。考虑到所述图像识别模块即为图像处理与识别模块；所述机械臂自动控制模块包括机械臂位姿控制模块、机械臂力控制模块，则所述图像识别模块、所述机械臂自动控制模块可以集成为一个具有通信接口能够实现通信协议的控制器。所述控制器执行程序相关的代码实现相应的功能。
所述的上位机包括：显示控制屏，远程遥控装置，显示控制屏主要用于选择粘接方式和必要时进行手动设置运动轨迹。远程遥控装置用于故障时紧急停机、暂停。所述的上位机与PLC控制器分离，方便操作人员对控制***下达命令，规划粘接的运动轨迹。
最后需要说明的是：以上实施例，仅为本发明的具体实施方式，用以说明本发明的技术方案，而非对其限制，本发明的保护范围并不局限于此。本领域技术人员应该理解：任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，其可以对前述实施例所记载的技术方案进行修改或可轻易想到变化，或者对其中部分技术特征进行等同替换；而这些修改、变化或者替换，并不使相应技术方案的本质脱离本发明实施例技术方案的精神和范围，都应涵盖在本发明的保护范围之内。

Claims (10)

  1. 一种滑石片全自动粘接智能控制方法，其特征在于，包括：
    利用图像识别模块，自动识别待加工的硅钢片的规格和种类；根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径，通过机械臂自动控制模块按照粘接轨迹规划路径自动将滑石片粘接到硅钢片的相应位置。
  2. 根据权利要求1所述的一种滑石片全自动粘接智能控制方法，其特征在于，所述利用图像识别模块，自动识别待加工的硅钢片的规格和种类；根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径，通过机械臂自动控制模块按照粘接轨迹规划路径自动将滑石片粘接到硅钢片的相应位置具体包括以下步骤：
    步骤1、前期人工准备工作，将滑石片和胶液、硅钢片摆放到位；
    步骤2、全自动粘接智能控制***的设备启动后完成***的初始化工作；
    步骤3、启动高亮度均匀LED光源对硅钢片进行图像采集，检测辨识硅钢片的规格和种类，根据硅钢片的规格和种类调用相对应的滑石片粘片的粘接轨迹规划路径；根据采集的图像对硅钢片进行边沿检测，确定第一个滑石片的放置位置；
    步骤4、自动开始第一片滑石片的粘接，直至完成第一列滑石片的粘接；
    步骤5、自动开始后面各列滑石片的粘接，直至完成整个硅钢片的滑石片的粘接。
  3. 根据权利要求2所述的一种滑石片全自动粘接智能控制方法，其特征在于，步骤3中还包括：判断所辨识的硅钢片的规格和种类是否在已知规格和种类中，如果是、调用已有的粘接工作流程进行滑石片的自动粘接；如果否，根据硅钢片的新的规格和种类、设定新的粘接工作流程，调用新设定的粘接工作流程进行滑石片的自动粘接。
  4. 根据权利要求3所述的一种滑石片全自动粘接智能控制方法，其特征在于，步骤4中还包括：通过料筒的振动使单片滑石片经螺旋滑道、直线滑道顺次输送至取片口；垂直臂在电机作用下带动真空吸附器下压，吸嘴吸附滑石片上提；压缩空气带动喷胶头将定量胶液向上喷至滑石片底部，多余胶液自动吸回；水平臂水平伸出将滑石片移动到硅钢片上方，垂直臂带动真空吸附器下压到硅钢片上，并保压200毫秒后释放滑石片后，第一片粘接完成。
  5. 根据权利要求4所述的一种滑石片全自动粘接智能控制方法，其特征在于，步骤4中还包括：根据采集的图像判断当前滑石片是否放置成功，设置最多的放置次数，如果超过设置的最多的放置次数、则报警停机；步骤5中还包括：当检测到硅钢片的结束角时停止粘接工作，蜂鸣器发出响声提醒操作者取出已完成的硅钢片，更换新硅钢片继续粘接。
  6. 根据权利要求5所述的一种滑石片全自动粘接智能控制方法，其特征在于，设置异常情况处理模块，如果电机过电压、或电机过电流、或机械装置超过硅钢片边沿、或滑石片多次脱落、或料桶内 材料不足，则报警停机；如果滑石片未成功吸附或脱落，则重新取料；如果到达硅钢片边沿，则控制滑石片的放置符合距离边沿的距离值。
  7. 一种滑石片全自动粘接智能控制***，其特征在于，应用如权利要求1－6任一项所述的滑石片全自动粘接智能控制方法，包括：硬件处理模块，所述的硬件处理模块与信号采集模块电连接；所述的信号采集模块与主程序控制模块电连接，所述的主程序控制模块分别与上位机、驱动电路电连接，所述的驱动电路与执行机构电连接。
  8. 根据权利要求7所述的一种滑石片全自动粘接智能控制***，其特征在于，所述的主程序控制模块包括：PLC控制器、图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块；
    所述的PLC控制器设置在主滑车上，用于实现图像处理与识别模块、机械臂位姿控制模块、机械臂力控制模块、机器视觉定位模块的相应算法；
    所述的图像处理与识别模块，通过图像处理获得特征数据，确定硅钢片的规格和种类、边沿位置；
    所述的机械臂位姿控制模块，控制水平机械臂稳定的运行到指定位置；
    所述的机械臂力控制模块，采用直接转矩控制算法，控制机械臂竖直方向运动状态，控制竖直机械臂保证稳定的输出扭矩；
    所述的机器视觉定位模块，用于工作初始位置的确定和每一行最后一枚滑石片的位置摆放。
  9. 根据权利要求8所述的一种滑石片全自动粘接智能控制***，其特征在于，所述的信号采集模块包括：图像采集装置、位置传感器、压力传感器、电压电流传感器；
    所述的位置传感器位于驱动电机处、与机械臂驱动电机同轴安装，用于反馈机械臂当前位置，实现机械臂位置的闭环控制，利用编码器采用增量方式记录当前移动距离，计算当前位置；
    所述的压力传感器安装在竖直机械臂中，用于滑石片粘接放置时保证合适的压力；
    所述电压电流传感器用于测量机械臂上电机上的电压电流，控制机械臂的运行；
    所述的图像采集装置设置在水平机械臂上，包括：具备视觉跟踪的摄像头。
  10. 根据权利要求9所述的一种滑石片全自动粘接智能控制***，其特征在于，所述的执行机构包括：机械臂、移动滑车以及送料机构，所述的机械臂由竖直臂、水平臂和真空吸附器组成，所述的移动滑车包括沿工作台长度方向移动的主滑车和安装于主滑车上的沿工作台宽度方向移动的副滑车；
    所述的硬件处理模块包括：高亮度均匀照明LED光源、滤光片、硬件滤波模块，所述的高亮度均匀照明LED光源和滤光片设于滑车的上部；
    所述的驱动电路采用可控硅作为开关，控制电机转速从而控制机械臂的移动速度；
    所述的上位机包括：显示控制屏、远程遥控装置，显示控制屏用于选择粘接方式和必要时进行手动设置滑石片粘接运动轨迹，远程遥控装置用于故障时紧急停机、暂停。
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