CN113714789A - Thread tightening device based on visual positioning and control method - Google Patents
Thread tightening device based on visual positioning and control method Download PDFInfo
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- CN113714789A CN113714789A CN202110968755.0A CN202110968755A CN113714789A CN 113714789 A CN113714789 A CN 113714789A CN 202110968755 A CN202110968755 A CN 202110968755A CN 113714789 A CN113714789 A CN 113714789A
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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
- B23P19/04—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 for assembling or disassembling parts
- B23P19/06—Screw or nut setting or loosening machines
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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
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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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
本发明公开了一种基于视觉定位的螺纹拧紧装置及控制方法，该装置包括：机器人、控制系统、上料机构、视觉测量模块、拧紧工具，其中，控制系统分别与机器人、拧紧工具通信连接，上料机构包括机架、传送带、料盘、物料挡板、阻拦气缸、夹紧气缸和光电传感器，传送带安装于机架上，料盘放置于传送带上，物料挡板安装于传送带的两侧，阻拦气缸和夹紧气缸安装于物料挡板的同侧，光电传感器安装于阻拦气缸的对侧；视觉测量模块安装于机架上，拧紧工具安装于机器人第六轴的法兰上，且视觉测量模块位于拧紧作业区的上方。本发明可针对多个螺栓位置快速定位，并编程控制拧紧扭矩大小，提高了螺纹拧紧控制精度，使得螺纹联接能达到预期的拧紧效果。
The invention discloses a thread tightening device and control method based on visual positioning. The device comprises: a robot, a control system, a feeding mechanism, a visual measurement module, and a tightening tool, wherein the control system is respectively connected with the robot and the tightening tool for communication and connection; The feeding mechanism includes a frame, a conveyor belt, a material tray, a material baffle, a blocking cylinder, a clamping cylinder and a photoelectric sensor. The conveyor belt is installed on the frame, the material tray is placed on the conveyor belt, and the material baffle is installed on both sides of the conveyor belt. The blocking cylinder and the clamping cylinder are installed on the same side of the material baffle, and the photoelectric sensor is installed on the opposite side of the blocking cylinder; the visual measurement module is installed on the frame, the tightening tool is installed on the flange of the sixth axis of the robot, and the visual measurement is performed. The module is located above the tightening work area. The invention can quickly locate a plurality of bolt positions, and program and control the tightening torque, thereby improving the control precision of thread tightening, so that the thread connection can achieve the expected tightening effect.
Description
Technical Field
The invention relates to the technical field of thread tightening assembly, in particular to a thread tightening device based on visual positioning and a control method.
Background
At present, most production enterprises still adopt a handheld electric or pneumatic tool to assemble threaded fasteners, or use a special screw locking machine to realize a semi-automatic screw tightening function, a small part of the production enterprises adopt a tool clamp and robot mode to assemble the threaded fasteners, namely, the tool clamp is used for preliminarily positioning workpieces to be assembled, then a robot carrying a tightening tool is used for controlling a movement track and positioning in a teaching and learning mode, and the screw assembling and tightening process is completed, for example, the robot bolt tightening technology in Xiaohai is firstly inserted into a corresponding positioning hole of an engine tray through a guide pin in a jacking mechanism in the application of engine assembling, so that the positioning of an engine is realized; and processing the engine through a compression mechanism to enable all bolt holes to be in the same horizontal plane, and finally setting a robot path planning program to realize positioning and tightening processing of target bolts. In addition, a few methods of machine vision and robot are adopted to carry out connection processing on threaded fasteners, namely, positioning of bolts is achieved through vision, then the robot is guided to carry a tightening tool to carry out thread connection processing on the fasteners, for example, in the text of the ' bolt locking and tightening SCARA robot key technology research based on machine vision ' of childhood earthquake ', a vision system and the tightening tool can be simultaneously installed at the tail end of the SCARA robot through designing a clamp, the movement track of the robot is designed and planned to achieve photographing processing on threaded holes in different positions, and finally the robot is guided to carry out thread connection and assembly on LED flat lamp products.
With the continuous improvement of labor cost, the production cost of screw thread assembly of the fastener by adopting a handheld tool is high, and the screwing precision is greatly influenced by human factors; the special screw locking machine equipment can not flexibly adjust the screwing position and flexibly set or change the screwing torque according to the requirement so as to obtain higher screwing control precision; the defects that the design of a tool clamp is complex and the requirement on the repeated positioning precision of a robot is high exist when a robot teaching mode is used for carrying out thread assembly on a fastener, and the adjustment flexibility is poor; the thread tightening by using the visual positioning and guiding mode of the SCARA robot only allows carrying of a small tightening tool with light weight, and the tightening operation is generally distributed on a plane and cannot meet the thread assembling requirements of multiple directions or postures.
Meanwhile, in the process of screwing the robot, a screwing tool, namely an electric screwdriver, which is generally used in the market is generally carried, and the electric screwdriver can only set a certain torque upper limit threshold value and stops rotating when the torque upper limit threshold value is reached, so that on one hand, the torque control precision is very low, on the other hand, different screwing torque values cannot be set aiming at different threaded fasteners, and a more proper screwing process flow is planned to obtain the optimal assembling effect. Meanwhile, the tightening tool generally has no tightening process data feedback function, cannot directly judge and warn the abnormal situation of the tightening process, and cannot further trace, process and store tightening data.
Disclosure of Invention
The invention mainly aims to provide a thread tightening device based on visual positioning and a control method, aiming at adapting to various thread assembling positions and flexibly setting tightening torque, improving the thread tightening control precision and obtaining better assembling and tightening effects.
To achieve the above object, the present invention provides a thread tightening device based on visual positioning, comprising: the device comprises a robot, a control system, a feeding mechanism for conveying a module to be screwed, a vision measuring module for photographing and positioning the module to be screwed, and a screwing tool for screwing the module to be screwed according to a photographing result of the vision measuring module, wherein the control system is respectively in communication connection with the robot and the screwing tool, the feeding mechanism comprises a rack, a conveyor belt, a material tray, a material baffle plate, a blocking cylinder, a clamping cylinder and a photoelectric sensor, the conveyor belt is installed on the rack, the material tray is placed on the conveyor belt, the material baffle plate is installed on two sides of the conveyor belt, the blocking cylinder and the clamping cylinder are installed on the same side of the material baffle plate and are sequentially arranged along the running direction of the conveyor belt, the photoelectric sensor is installed on the opposite side of the blocking cylinder, the conveyor belt is positioned slightly behind the running direction of the conveyor belt; the vision measuring module is installed on the rack, the tightening tool is installed on the robot, and the vision measuring module is located above the tightening operation area.
According to a further technical scheme, the tightening tool comprises a tightening shaft connected with the robot and a tightening shaft controller connected with the tightening shaft, and the tightening shaft controller is located at the tail end of the tightening shaft and connected with the tightening shaft.
According to a further technical scheme, the tightening shaft comprises a tightening screwdriver head, an end cover, a coupler, a torque sensor, a speed reducer, a servo motor and an encoder, wherein the end cover is installed at the front end of the tightening shaft, the coupler is installed between the end cover and the torque sensor, and between the torque sensor and the speed reducer respectively, the speed reducer is connected with the servo motor, and the encoder is installed at the tail end of the servo motor.
According to a further technical scheme, the vision measuring module comprises a vision measuring component and an installation support, the top of the installation support is L-shaped, the bottom of the installation support is installed on the rack, and the vision measuring component is installed on the top of the installation support through an L-shaped installation plate.
According to a further technical scheme, the visual assembly comprises a camera, an optical lens and an annular light source which are coaxially arranged from top to bottom in sequence, wherein the camera is mounted on the L-shaped mounting plate through a camera mounting plate, the optical lens is in threaded connection with a C interface of the camera, and the annular light source is mounted on the L-shaped mounting plate through an annular light source mounting plate.
According to a further technical scheme, the material tray comprises a support plate and upright columns symmetrically arranged at two ends of the bottom of the support plate.
The technical scheme is that the module to be screwed comprises a screwed motor, a screwed motor mounting plate and mounting bolts, and a plurality of connecting bolts on the screwed motor need to be screwed.
The invention further adopts the technical scheme that the control system comprises a computer, an exchanger, a robot control cabinet and a demonstrator, wherein the exchanger is respectively connected with the vision measuring module, the robot control cabinet and the computer, and the robot control cabinet is connected with the robot.
In order to achieve the above object, the present invention also provides a visual positioning-based thread tightening device control method applied to the visual positioning-based thread tightening device as described above, the method including the steps of:
when the photoelectric sensor detects the material tray, the blocking cylinder blocks the material tray, the clamping cylinder clamps the material tray, and a clamping signal is sent to a computer in the control system;
the computer in the control system controls the vision measuring module to photograph and position the module to be screwed according to the clamping signal, and sends the position information of the bolt on the module to be screwed to the robot;
the robot drives the tightening tool to tighten a bolt, and tightening information is sent to a computer in the control system;
and the computer in the control system draws a tightening process curve according to the tightening information, and displays and stores a tightening result.
A further technical solution of the present invention is that, after the step of drawing a tightening process curve according to the tightening information and displaying and storing a tightening result, the computer in the control system further comprises:
a computer in the control system judges whether an expected tightening requirement is met or not according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the tightened bolts to judge whether all the bolt tightening tasks to be tightened are completed or not, if all the bolt tightening tasks are completed, the robot moves back to the zero point, the camera measuring module stops shooting, and the process is finished;
if the expected screwing requirement is not met, judging whether the thread screwing defect exists or not;
if the tightening defect does not exist, the computer in the control system controls the tightening tool to realize secondary tightening treatment on the bolt;
and if the thread tightening defects exist, the computer in the control system displays and records tightening abnormity information.
The thread tightening device and method based on visual positioning have the beneficial effects that:
1. aiming at the problems that a handheld screwing tool is high in production cost and screwing precision is greatly influenced by human factors, the bolt is quickly screwed by adopting a mode that a robot carries the screwing tool, so that the production efficiency is improved, the production cost is reduced, and the automation degree of thread assembly is improved;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to needs when the special screw locking machine equipment and the robot teaching mode are assembled, the invention adopts vision to shoot and position the threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; (ii) a
3. Aiming at the problems of tightening assembly directions and load limitation of the SCARA robot, the invention adopts a scheme of six-axis industrial robot and vision matched with load, and solves the problems of limitation of the freedom degree of the robot on the moving space of the robot and assembly overload of the robot;
4. aiming at the problems that a common screwdriver carried by a robot cannot set different tightening processes according to different threaded fasteners in the tightening process, the torque control precision is low, and the tightening process data feedback function is absent, the tightening tool with the torque closed-loop control function is adopted, the corresponding tightening processes are set according to the material characteristics of different bolts and fasteners by a torque control-corner monitoring method, so that a good control effect is achieved, meanwhile, upper software in a computer is used for communicating with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, analysis of the tightening process and judgment of the tightening result are facilitated, the tightening process data are further stored, and the source tracing and tracking of assembly data are facilitated.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.
FIG. 1 is a schematic view of a system composition of a preferred embodiment of a thread tightening apparatus based on visual alignment according to the present invention;
FIG. 2 is a schematic view showing the structure of a conveyor belt and a module to be screwed in a preferred embodiment of the screw tightening apparatus according to the present invention based on visual alignment;
FIG. 3 is a schematic view of the overall structure of the tightening tool;
FIG. 4 is a schematic view of another angle of the overall construction of the tightening tool;
FIG. 5 is a schematic view of the overall structure of a further angle of the tightening tool;
FIG. 6 is a schematic view of the tightening tool;
FIG. 7 is a schematic structural view of a vision measurement module;
fig. 8 is a detailed flowchart of the control method of the thread tightening device based on visual positioning according to the present invention;
FIG. 9 is a schematic image processing flow diagram;
FIG. 10 is a schematic of a tightening torque-time model;
FIG. 11 is a torque-angle-time diagram of a tightening process;
FIG. 12 is an enlarged partial torque-angle-time diagram of the tightening process;
fig. 13 is a tightening curve interface diagram of the computer.
The reference numbers illustrate:
a robot 1; the module 2 to be screwed down; a vision measuring module 3; a tightening tool 4; a frame 5; a conveyor belt 6; a material tray 7; a material baffle 8; a catch cylinder 9; a clamping cylinder 10; a photosensor 11; a twisted motor 12; a twisted motor mounting plate 13; a computer 14; a switch 15; a robot control cabinet 16; a demonstrator 17; an air pump 18; a support plate 19; a column 20; a tightening shaft 21; tightening the shaft controller 22; screwing down the bit 23; an end cap 24; a coupling 25; a torque sensor 26; a speed reducer 27; a servo motor 28; an encoder 29; a mounting bracket 30; an L-shaped mounting plate 31; a camera 32; an optical lens 33; an annular light source 34; a camera mounting plate 35; an annular light source mounting plate 36.
The implementation, functional features and advantages of the objects of the present invention will be further described with reference to the accompanying drawings.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that, if directional indications (such as up, down, left, right, front, and back … …) are involved in the embodiment of the present invention, the directional indications are only used to explain the relative positional relationship between the components, the movement situation, and the like in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indications are changed accordingly.
In addition, if there is a description of "first", "second", etc. in an embodiment of the present invention, the description of "first", "second", etc. is for descriptive purposes only and is not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In addition, the meaning of "and/or" appearing throughout includes three juxtapositions, exemplified by "A and/or B" including either A or B or both A and B. In addition, the technical solutions in the embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope required by the present invention.
In order to solve the technical problems in the prior art, the invention provides a thread tightening device based on visual positioning, which utilizes a visual measurement module to provide a robot with an accurate position of a thread to be assembled on a screwed object so as to guide the robot to move to a proper position and posture, and utilizes a tightening tool to realize the tightening process of a screw by adopting a torque closed-loop control and angle monitoring method so as to achieve the purpose of controlling the axial pre-tightening force of threaded connection in a proper range. And drawing a torque-corner-time curve according to data generated in the tightening process so as to further analyze and judge the bolt tightening result and ensure that the assembling quality of the bolt meets the expected requirement. Meanwhile, by utilizing the upper software and the communication function, the computer further stores and records the data of the tightening process, so that the source tracing of the data and the problems of the tightening process can be conveniently and subsequently checked.
As shown in fig. 1 to 7, a preferred embodiment of the thread tightening apparatus based on visual positioning of the present invention comprises: the device comprises a robot 1, a control system, a feeding mechanism for conveying a module 2 to be screwed, a vision measuring module 3 for photographing and positioning the module 2 to be screwed, and a screwing tool 4 for screwing the module 2 to be screwed according to a photographing result of the vision measuring module 3, wherein the control system is respectively in communication connection with the robot 1 and the screwing tool 4, the feeding mechanism comprises a rack 5, a conveyor belt 6, a material tray 7, a material baffle plate 8, a blocking cylinder 9, a clamping cylinder 10 and a photoelectric sensor 11, the conveyor belt 6 is arranged on the rack 5, the material tray 7 is placed on the conveyor belt 6, the material baffle plate 8 is arranged on two sides of the conveyor belt 6, the blocking cylinder 9 and the clamping cylinder 10 are arranged on the same side of the material baffle plate 8 and are sequentially arranged along the running direction of the conveyor belt 6, the photoelectric sensor 11 is arranged on the opposite side of the blocking cylinder 9, at a position slightly behind the running direction of the conveyor belt 6; the vision measuring module 3 is mounted on the frame 5, the tightening tool 4 is mounted on the robot 1, and the vision measuring module 3 is located above the tightening work area.
The module to be screwed 2 may include a screwed motor 12, a screwed motor mounting plate 13, and a plurality of screwing bolts, among others. The control system comprises a computer 14, an exchanger 15, a robot control cabinet 16 and a demonstrator 17, wherein the exchanger 15 is respectively connected with the vision measuring module 3, the robot control cabinet 16 and the computer 14, and the robot control cabinet 16 is connected with the robot 1.
As an embodiment, the present embodiment further includes an air pump 18, and the air pump 18 is connected to the arresting cylinder 9 and the clamping cylinder 10, respectively.
Specifically, the computer 14 and the Vision measuring module 3 communicate with each other by using a Vision Gige protocol in ethernet, the robot 1 and the computer 14 communicate with each other by using a TCP/IP protocol in ethernet, and the tightening tool 4 and the computer 14 communicate with each other by using a specific protocol.
The charging tray 7 comprises a charging tray supporting plate 19 and upright posts 20 which are symmetrically arranged at two ends of the bottom of the supporting plate 19. The tray 7 is mainly used for carrying the module 2 to be screwed, namely the screwed motor 12, the screwed motor mounting plate 13 and the mounting bolts.
In the embodiment, the material baffle plates 8 are arranged at two sides of the conveyor belt 6 and play a role in guiding and blocking the material tray 7; the blocking cylinder 9 is arranged in front of the running direction of the conveyor belt 6 and mainly plays a role in blocking the material tray 7; the clamping cylinder 10 is arranged at a proper position behind the blocking cylinder 9 and mainly plays a role in clamping the material tray 7; the photoelectric sensor 11 is arranged at the opposite side of the blocking cylinder 9 and is slightly at a proper position behind the running direction of the conveyor belt 6, so that the photoelectric sensor mainly plays a role in detecting the material tray 7 and judging whether materials pass through the photoelectric sensor.
The embodiment can utilize the vision measuring module 3 to take pictures of target bolts with different specifications and sizes in a complex environment, and the visual origin and the reference point of the tightening position of the robot 1 are combined to be the same point on the product, so that the offset of the bolt relative to the visual origin is equal to the offset of the bolt relative to the reference point of the tightening position of the robot 1, thereby realizing the accurate positioning of the target bolt, and further guides the robot 1 to rapidly perform a tightening process for the corresponding bolt with the tightening tool 4, meanwhile, the computer in the control system draws a tightening process curve according to the tightening data sent by the tightening tool 4 and displays the tightening result, if necessary, triggers the tightening tool 4 to perform repeated tightening work so as to achieve the tightening target of the expected setting, meanwhile, the data of the tightening process is further stored and recorded, so that the data of the tightening process and the source tracing of problems can be conveniently checked subsequently.
Further, in the present embodiment, the tightening tool 4 includes a tightening shaft 21 connected to the robot 1, and a tightening shaft controller 22 connected to the tightening shaft 21, and the tightening shaft controller 22 is located at a distal end position of the tightening shaft 21 and connected to the tightening shaft 21.
The tightening shaft 21 comprises a tightening bit 23, an end cover 24, a coupler 25, a torque sensor 26, a speed reducer 27, a servo motor 28 and an encoder 29, wherein the end cover 24 is installed at the front end of the tightening shaft 21, the coupler 25 is respectively installed between the end cover 24 and the torque sensor 26, and between the torque sensor 26 and the speed reducer 27, the speed reducer 27 is connected with the servo motor 28, and the encoder 29 is installed at the tail end of the servo motor.
In this embodiment, the tightening shaft 21 control driver of the tightening tool 4 is mounted at the end of the tightening shaft 21, and is connected to the tightening shaft 21, and mainly functions as a drive control and a signal transmission for the tightening shaft 21.
In this embodiment, the vision measuring module 3 mainly takes a picture of the screwed motor 12 and the mating fastening device, so as to obtain the accurate position of the target bolt.
The vision measuring module 3 comprises a vision measuring component and a mounting bracket 30, wherein the top of the mounting bracket 30 is L-shaped, the bottom of the mounting bracket 30 is mounted on the frame 5, and the vision measuring component is mounted on the top of the mounting bracket 30 through an L-shaped mounting plate 31.
The visual assembly comprises a camera 32, an optical lens 33 and an annular light source 34 which are coaxially arranged from top to bottom in sequence, wherein the camera 32 is installed on the L-shaped installation plate 31 through a camera installation plate 35, the optical lens 33 is in threaded connection with a C interface of the camera 32, and the annular light source 34 is installed on the L-shaped installation plate 31 through an annular light source installation plate 36.
The whole working process of the thread tightening device based on visual positioning comprises the following steps:
after the system is started to operate, a material tray 7 carrying a twisted motor 12 and a matched fastening device is detected by using a photoelectric sensor 11 which is arranged on a conveyor belt 6 and is positioned below the visual field of a camera 32, when the material tray 7 touches the photoelectric sensor 11, a blocking cylinder 9 acts and extends out to block the material tray 7, meanwhile, the conveyor belt 6 stops operating and a clamping cylinder 10 is triggered to act to clamp the material tray 7, the camera 32 arranged above a bracket beside the conveyor belt 6 performs photographing processing on the twisted motor 12, a twisted motor mounting plate and a mounting bolt which are positioned below the camera 32, and the photographed processing result, namely the offset of a fastening bolt between the twisted motor and the twisted motor mounting plate relative to the visual origin is transmitted to a computer in a control system, and the computer in the control system receives the offset of the twisted motor fastening bolt relative to the visual origin and then transmits the twisted motor fastening bolt to the computer in a TCP/IP protocol mode The offset of a fastening bolt relative to a visual origin is sent to the robot 1, then the robot 1 carries a tightening tool 4 to move to the position of a corresponding bolt for tightening, tightening data is sent to a control system in a serial port communication mode, finally the control system draws a tightening curve and displays a result according to the tightening data, and meanwhile secondary tightening is carried out or the control system moves to the next bolt position for tightening according to the tightening result until the device quits the control process and enters a waiting execution state after all the bolts to be tightened are tightened.
The thread tightening device based on visual positioning has the beneficial effects that:
1. aiming at the problems that a handheld screwing tool is high in production cost and screwing precision is greatly influenced by human factors, the bolt is quickly screwed by adopting a mode that a robot carries the screwing tool, so that the production efficiency is improved, the production cost is reduced, and the automation degree of thread assembly is improved;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to needs when the special screw locking machine equipment and the robot teaching mode are assembled, the invention adopts vision to shoot and position the threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; (ii) a
3. Aiming at the problems of tightening assembly directions and load limitation of the SCARA robot, the invention adopts a scheme of six-axis industrial robot and vision matched with load, and solves the problems of limitation of the freedom degree of the robot on the moving space of the robot and assembly overload of the robot;
4. aiming at the problems that a common screwdriver carried by a robot cannot set different tightening processes according to different threaded fasteners in the tightening process, the torque control precision is low, and the tightening process data feedback function is absent, the tightening tool with the torque closed-loop control function is adopted, the corresponding tightening processes are set according to the material characteristics of different bolts and fasteners by a torque control-corner monitoring method, so that a good control effect is achieved, meanwhile, upper software in a computer is used for communicating with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, analysis of the tightening process and judgment of the tightening result are facilitated, the tightening process data are further stored, and the source tracing and tracking of assembly data are facilitated.
In order to achieve the above object, the present invention also provides a visual positioning-based thread tightening device control method applied to the visual positioning-based thread tightening device as described above, the method including the steps of:
when the photoelectric sensor detects the material tray, the blocking cylinder blocks the material tray, the clamping cylinder clamps the material tray, and a clamping signal is sent to a computer in the control system;
the computer in the control system controls the vision measurement module to photograph and position the module to be screwed according to the clamping signal, and sends the position information of the module to be screwed to the robot;
the robot drives the tightening tool to tighten a bolt, and tightening information is sent to a computer in the control system;
and the computer in the control system draws a tightening process curve according to the tightening information, and displays and stores a tightening result.
Further, the step of drawing a tightening process curve according to the tightening information and displaying and storing the tightening result by the computer in the control system further comprises:
a computer in the control system judges whether an expected tightening requirement is met or not according to the tightening information;
if the expected tightening requirement is met, the computer in the control system counts the number of the tightened bolts to judge whether all the bolt tightening tasks are completed or not, if all the bolt tightening tasks are completed, the robot moves back to the zero point, the camera measuring module stops photographing, and the process is ended;
if the expected screwing requirement is not met, judging whether the thread screwing defect exists or not;
if the tightening defect does not exist, the computer in the control system controls the tightening tool to realize secondary tightening treatment on the bolt;
and if the thread tightening defect exists, the control system displays and records tightening abnormity information.
The method of controlling the screw tightening apparatus based on visual alignment according to the present invention will be further described with reference to fig. 8 to 13.
As shown in fig. 8, the specific process of the thread tightening device control method based on visual positioning according to the present invention is as follows:
step 1: the following preparatory work is performed before the system enters initialization:
1) finishing model selection work of a camera, a robot, an experimental object and the like according to the requirements of a system scheme, and finally determining a black-and-white industrial camera with 600 ten thousand pixels of Haekwover, a common optical lens, an annular light source, a controller, a tightening tool and a six-axis robot with the model of ABB-1410 as the experimental object;
2) installing a calibration needle at the head of a screwing tool batch arranged at the tail end of the robot to complete the establishment work of a tool coordinate system;
3) completing the programming of a robot motion control program and the design work of a tightening process of a tightening tool;
4) connecting the computer, the camera and the robot controller cabinet by a network cable through a switch of a gigabit network card, and setting network addresses of the computer, the camera and the robot controller cabinet in the same network segment;
5) the method comprises the steps of finishing the compiling of a visual image processing program, wherein the compiling comprises the steps of calibrating a camera, calibrating hands and eyes, matching a template, establishing a template coordinate system and the like, and fitting a circle on a nut of a bolt by utilizing a circle finding tool and the like so as to confirm the position of a circle center;
6) the upper software is written, and the functions of the upper software comprise:
a) the computer and the robot have a communication function, and the function is used for receiving a robot readiness signal sent by the robot from the computer and sending the nut center point position information of the bolt and a tightening tool tightening completion signal to the robot by the computer;
b) the computer and the camera have a communication function, and the function is used for sending an operation instruction to the camera in real time by the computer and receiving a real-time image or a single image fed back by the camera in real time by the computer for subsequent image processing;
c) the computer and the tightening tool have a communication function, and the function is used for sending an operation instruction and a tightening process parameter to the tightening tool in real time by the computer and receiving real-time tightening data fed back by the tightening tool in real time by the computer for subsequent curve drawing;
d) the function of displaying the shot picture of the camera in real time is used for displaying the image of the shot picture of the camera in real time, so that the shot picture of the camera can be more intuitively understood;
e) the function of calling the image processing program is used for calling the image shot by the camera for processing and outputting the coordinate value of the nut center point of the bolt in the image after the processing of the image processing program;
f) the function is used for displaying the coordinate value of the nut center point of the bolt in a robot tool coordinate system;
g) the function of drawing a torque-corner-time curve in real time according to tightening data can intuitively know the torque variation trend in the tightening process;
h) a function to save and view tightening data that can save real-time tightening data and view historical tightening data as needed.
Step 2: after completing the preparation before initialization, the system enters an initialization state, which includes: the robot performs return movement, detects whether the functions of all parts are normal or not, confirms whether the circuit and the communication are normal or not, and sends corresponding screwing process parameters according to the type of the bolt;
and step 3: placing a material tray provided with a twisted motor, a mounting plate and a fastening bolt on the conveying belt and starting the conveying belt to run, wherein the motor and the fastening device above the material tray move along with the conveying belt; simultaneously starting a photoelectric sensor to detect the material tray;
and 4, step 4: when the charging tray triggers the photoelectric sensor, the blocking cylinder acts and extends out to block the charging tray, and meanwhile, the conveyor belt stops running and the clamping cylinder is triggered to act to clamp the charging tray;
and 5: the computer receives the signal that the clamping cylinder from the robot acts in place, triggers the camera to photograph the screwed motor on the conveyor belt, the mounting plate and the fastening bolt of the screwed motor, calls an image processing program to process the photographed image, and finally sends the processing result, namely the position of the central point of the bolt to be screwed to the robot;
step 6: the robot drives the tightening tool to move to a corresponding bolt for tightening and sends tightening process data to a computer in a serial port communication mode;
and 7: drawing a tightening process curve and displaying a tightening result by the computer according to the tightening data;
and 8: judging whether the current screwing task meets the expected screwing requirement or not according to the screwing data, and if the expected screwing requirement is met, skipping to the step 13 to judge whether the current screwing task is finished or not; if the expected screwing requirement is not met, the process jumps to step 9 to judge whether the thread screwing defect exists;
and step 9: judging whether a thread tightening defect exists according to the torque variation trend in the tightening data, and if the thread tightening defect exists, skipping to the step 12, and displaying and recording tightening abnormal information; if the thread tightening defect does not exist, the process jumps to step 10, and the tightening tool performs secondary tightening treatment on the bolt;
step 10: the computer sends a re-tightening signal, and the tightening tool realizes secondary tightening treatment on the bolt;
step 11: judging whether the screwing frequency exceeds 3 times, if so, determining that the screwing frequency is abnormal, and skipping to the step 12 to display and record the abnormal screwing information; if the screwing times do not exceed 3, the process jumps to step 8, and whether the expected screwing requirement is met is judged again;
step 12: displaying the abnormal screwing result and recording corresponding abnormal screwing information;
step 13: judging whether all the bolt tightening tasks are finished according to the statistics of the number of the bolts which are subjected to tightening processing by the computer, and if all the bolt tightening tasks are finished, skipping to a step 14; if the tightening tasks of all the bolts are not finished, the flow jumps to the step 3, and the conveyor belt is restarted;
step 14: and when the screwing task is completed, the robot moves back to the zero point, the camera stops shooting, and the process is finished.
As shown in fig. 9, the image processing flow is a process flow of images, and the operations such as camera calibration, hand-eye calibration, and the like are required before the image processing flow, so as to ensure that the vision measurement system can be directly applied to the experiment of the present invention, wherein the image processing flow includes image acquisition, template matching, template coordinate system establishment, image filtering, image dynamic threshold segmentation, expansion corrosion, and determination of the position of the center point of the bolt by using a rounding tool, and the image acquisition is performed by triggering the camera through upper software to take a picture and acquiring the picture to the upper software for image processing; the template matching is to establish a matching template according to the shape characteristics of the tail part of the screwed motor, and is used for confirming a photographing processing object of the camera; establishing a template coordinate system is to establish a coordinate system according to the characteristics of template matching, and is mainly used for determining and reducing an image processing area; the image filtering processing is mainly used for suppressing the noise of a target image and selectively enhancing or suppressing the noise, so that the required image characteristics are highlighted and the visual identification effect is enhanced; the dynamic threshold segmentation processing mainly comprises the steps of obtaining a binary image capable of reflecting the whole and local images, further improving the outline contrast of captured features and reducing the complexity of later-stage image processing; the expansion corrosion treatment mainly highlights the characteristics of the nut and reduces the interference factors of the background at the same time, so that the shape of the nut is clearer in the image; the main purpose of using the rounding tool is to find the circle of the nut head and determine the center point position thereof.
As shown in fig. 10, a torque control model diagram of a tightening process is shown, wherein the tightening process includes the following stages: the method comprises a cap searching stage, a thread defect detecting stage, a screwing maintaining stage and a back screwing stage, and the specific process comprises the following steps:
1. cap seeking stage (0-t)1): the screwdriver head or the sleeve rotates for a circle at a slow speed to combine the screwdriver head or the sleeve with the bolt;
2. thread defect detection phase (t)1–t2): the electric screwdriver rotates to enable the bolt to rotate downwards, whether abnormal increase of the torque occurs is detected, and if the abnormal increase occurs, the thread has defects;
3. bonding point detection stage (t)2–t3): the joint torque is detected at this stage, and the lower end of the bolt and the nut is at t3Attached to a coupling body, called t3At the fitting moment, the corresponding point is a fitting point;
4. tightening phase (t)3–t4): in the stage, the binding point is screwed up by a torque method according to the set target torque, and the next stage is switched to when the set torque value is reached, wherein different target torques can be set for different bolts in the stage;
5. screw-up holding period (t)4–t5): in the stage, the tightening torque is kept for a period of time from reaching the set torque, and the keeping time can be set according to requirements;
6. back-screwing phase (t)5–t6): proper reverse control is carried out to screwing up the batch head in this stage, and the bolt is carried out the anti-pine (unload the nail) and is handled not in the practical meaning, mainly in order to unload holding torque and reduce the frictional force between batch head and the bolt, does not influence original screwing up effect simultaneously in the extraction of batch head of being convenient for, and the anti-angle of screwing up scope can set up according to on-the-spot actual conditions between 1 to 10 degrees.
In order to make the objects, technical solutions and advantages of the control model clearer, the model will be further described with reference to the accompanying drawings.
As shown in fig. 11, the graph is a graph of the practical effect of the control model, wherein a triangle is used to identify an angle curve during tightening, a circle is used to identify a torque curve during tightening, the two curves respectively correspond to a left angle scale mark and a right torque scale mark, the horizontal axis is a time axis, and the collection interval of each data point is 50ms on average.
As can be seen from fig. 11, the tightening tool successfully seeks the nut from the beginning of approximately half a turn, and in this stage, the torque measured by the torque sensor gradually rises from zero to a certain value, and the process is switched to the thread defect detection stage; in the thread defect detection stage, the tightening tool is rapidly rotated to enable the bolt to rotate downwards, the torque value is monitored in real time, and the tightening stage is switched when the torque reaches the set binding point torque value; in the tightening stage, the tightening tool controls the electric batch according to a torque method, so that the tightening torque gradually rises to a set value, and when the tightening torque reaches the set value, the tightening holding stage is switched; in the tightening and holding stage, the tightening tool holds the target torque in the previous stage for a period of time according to the set holding time, and switches to the back-tightening stage when the holding time is reached; the tightening tool is properly reverse-controlled according to the position pattern in the back-screwing stage, where the back-screwing angle is 8 degrees in fig. 11, and a partial enlarged view of the back-screwing stage in fig. 11 is shown in fig. 12, to remove the holding torque and reduce the frictional force between the bit and the bolt, without affecting the previous tightening effect.
Fig. 13 shows a screw-up curve display interface in the upper level software developed by the present invention, which is developed in Visual Studio based on the Net language and includes functions of communication, image display, image processing, screw-up curve display, screw-up process setting, and the like. The image processing function is to call an image processing file generated by VisionPro software under the heading of Cognex corporation in the United states to process the shot image.
The thread tightening method based on visual positioning has the beneficial effects that:
1. aiming at the problems that a handheld screwing tool is high in production cost and screwing precision is greatly influenced by human factors, the bolt is quickly screwed by adopting a mode that a robot carries the screwing tool, so that the production efficiency is improved, the production cost is reduced, and the automation degree of thread assembly is improved;
2. aiming at the problems that the screwing position cannot be flexibly adjusted and the screwing torque cannot be flexibly set or changed according to needs when the special screw locking machine equipment and the robot teaching mode are assembled, the invention adopts vision to shoot and position the threaded holes with various shapes and layouts, can accurately set different torque target values, can obtain higher screwing control precision and has stronger universality; (ii) a
3. Aiming at the problems of tightening assembly directions and load limitation of the SCARA robot, the invention adopts a scheme of six-axis industrial robot and vision matched with load, and solves the problems of limitation of the freedom degree of the robot on the moving space of the robot and assembly overload of the robot;
4. aiming at the problems that a common screwdriver carried by a robot cannot set different tightening processes according to different threaded fasteners in the tightening process, the torque control precision is low, and the tightening process data feedback function is absent, the tightening tool with the torque closed-loop control function is adopted, the corresponding tightening processes are set according to the material characteristics of different bolts and fasteners by a torque control-corner monitoring method, so that a good control effect is achieved, meanwhile, upper software in a computer is used for communicating with the tightening tool, tightening data are collected in real time, a tightening curve is drawn, analysis of the tightening process and judgment of the tightening result are facilitated, the tightening process data are further stored, and the source tracing and tracking of assembly data are facilitated.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the contents of the present specification and the accompanying drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.
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