阅读说明：本技术 一种基于plc控制的桁架五轴机械手的防碰撞方法 (Anti-collision method of five-axis truss manipulator based on PLC control ) 是由 潘飞 于 2021-09-01 设计创作，主要内容包括：本发明公开了一种基于PLC控制的桁架五轴机械手的防碰撞方法,包括如下步骤,S1：问题引入阶段：S11：将可编程逻辑控制器(PCL)的电源与外界的电源相连接。该基于PLC控制的桁架五轴机械手的防碰撞方法,通过计算两个引拔轴(Y1、Y2轴)之间的距离以及设置的安全距离,修改了运动轴的运行方式与距离,达到了改变轴运动目标位置的目的,保证了引拔轴即使以高速运行依然可以稳定停止在安全距离,实现了对机械手的保护,当两轴相向而行时,可进行两种目标位置的判断,如果有重合或者距离小于安全距离,会立即停止运行,触发报警,这使得操作人员即使由于自身原因,在实际工作中存在一些错误操作,也完全不会导致装机事故的发生,解决了装置的安全隐患。(The invention discloses an anti-collision method of a five-axis truss manipulator based on PLC control, which comprises the following steps of S1: a problem introduction stage: s11: the power supply of the programmable logic controller (PCL) is connected with the external power supply. According to the anti-collision method of the five-axis truss manipulator based on PLC control, the running mode and the distance of the moving shaft are modified by calculating the distance between the two pulling shafts (Y1 and Y2) and the set safe distance, the purpose of changing the moving target position of the shaft is achieved, the pulling shafts can be stably stopped at the safe distance even if running at high speed, the manipulator is protected, when the two shafts move in opposite directions, the two target positions can be judged, if the two shafts are overlapped or the distance is smaller than the safe distance, the operation can be immediately stopped, and alarm is triggered, so that even if an operator has some wrong operations in actual work due to self reasons, the occurrence of installation accidents can be completely avoided, and the potential safety hazard of the device is solved.)

1. The anti-collision method of the five-axis truss manipulator based on PLC control comprises the following steps:

s1: a problem introduction stage:

s11: connecting a power supply of a programmable logic controller (PCL) with an external power supply, and inputting various parameters of a shaft motion command into the interior of the PCL by programming and changing an internal program of the PCL;

s12: connecting a power supply of truss equipment with an external power supply, starting the truss equipment to operate, carrying out multiple tests on the five-axis truss manipulator by generally using a transverse axis (X axis), two drawing axes (Y1 and Y2 axes) and two upper and lower axes (Z1 and Z2 axes) as a mechanical structure of the five-axis truss manipulator, and finding out the problem that the axes Y1 and Y2 are collided in opposite directions due to wrong point position setting in the operation process;

s2: parameter setting and calculating stage:

s21: according to actual conditions, a lead L, a gear ratio K, a total displacement distance S (a spacing distance between a drawing shaft Y1 and a drawing shaft Y2), a safety distance F (a minimum distance between a drawing shaft Y1 and a drawing shaft Y2), a given pulse number G per revolution, a single-turn feedback pulse number H of an encoder, and a current feedback pulse number J of the encoder are set₁,J₂Acceleration a₁,a₂And the rated rotation speed of the motor;

s22: according to the known data, the maximum pulse number is calculated by the following formula:

wherein Max is the maximum pulse number, G is the given pulse number per revolution;

s23: according to the known data, calculating the current coordinates of the two shafts by a formula, wherein the specific calculation formula is as follows:

wherein S is₁- -the current position of the lead-in shaft Y1, S₂- -current position of the lead axle Y2, J₁The number of current feedback pulses, J, on the pull-out axis Y1₂-the current feedback pulse number of the drawing shaft Y2, L-lead, K-gear ratio, H-encoder single-turn feedback pulse number;

s3: point location teaching mode stage:

s31: when the point location teaching operation is carried out, two drawing shafts (Y1 and Y2 shafts) are generally in a point motion mode, the other shaft is in a static state, the assumption made in the invention is that the Y1 shaft moves and the Y2 shaft is in a static state;

s32: according to the assumed preset, when the pulling shaft Y1 starts to move, the target position is moved in the absolute movement mode, then the pulse number required by the movement is calculated through the formula and added to the command of the absolute movement of the programmable logic controller (PCL), and the calculation formula of the shaft correction corresponding to the required pulse number is as follows:

S_t＝S-S₂-F；

wherein S is_t-axis corrected target position, S-total displacement distance (separation distance between the lead-out axis Y1 and the lead-out axis Y2), S₂- -the current position of the lead-in shaft Y2, S_mAxial correction corresponding to the number of pulses required, F-ampereThe total distance (the minimum distance between a drawing shaft Y1 and a drawing shaft Y2), G-the given pulse number per revolution, L-the lead, H-the feedback pulse number of a single coil of an encoder;

s4: and (3) a phase of opposite movement:

s41: when the point data is not taught but directly set, or two actual point positions which collide with each other due to wrong teaching of an operator are obtained, the internal program of the programmable logic controller (PCL) judges the positions of the pull shaft Y1 and the pull shaft Y2 as follows:

S_t1+S_t2+F≥S；

wherein S is_t1-the corrected position of the drawing axis Y1, S_t2-the corrected position of the puller axis Y2, F-the safety distance (minimum distance of the puller axis Y1 from the puller axis Y2), S-the total displacement distance (separation distance between the puller axis Y1 and the puller axis Y2);

s42: once the formula is judged to be established, the truss equipment can immediately trigger an alarm, emergently stop and stop the movement of a pulling shaft (Y1 shaft and Y2 shaft), and simultaneously prompt an operator that the related point position is wrongly set;

s43: after receiving the error alarm, an operator resets the operation parameters of the mechanical structure of the manipulator, which are reported by the fault, by using a programmable logic controller (PCL), and then restarts the truss equipment to recover the normal operation of the truss equipment;

s5: and (3) safety test stage:

s51: according to the calculated data, after the positions of two drawing shafts (Y1 and Y2 shafts) of the manipulator are adjusted, the truss equipment is started to test, whether the two drawing shafts (Y1 and Y2 shafts) can be stably stopped at a safe distance under the condition of high-speed operation is observed, whether the equipment can be emergently stopped and an alarm is triggered when collision occurs when the Y1 shaft and the Y2 shaft face each other, the improvement is completed through the tested truss equipment, and the truss equipment can be put into use formally.

2. The anti-collision method of the five-axis truss manipulator based on the PLC control as claimed in claim 1, wherein: the axis motion command of the programmable logic controller (PCL) in S11 mainly includes the position, speed, axis number and other relevant parameters of the target.

3. The anti-collision method of the five-axis truss manipulator based on the PLC control as claimed in claim 1, wherein: the default rated rotating speed of the motor in the S21 is 3000r/min, so that the maximum pulse frequency is calculated, and the maximum pulse frequency is not exceeded during speed regulation.

Technical Field

The invention relates to the technical field of industrial automation, in particular to an anti-collision method of a five-axis truss manipulator based on PLC control.

Background

The PLC is a digital operation electronic system designed specially for industrial environment, and it adopts a programmable memory, in which the instructions for executing logical operation, sequence control, timing, counting and arithmetic operation are stored, and utilizes digital or analog input and output to control various mechanical equipments or production processes. After decades of development, industrial robots are controlled to be used in more industrial fields based on a PLC, truss manipulators have a long development history in China, and from the traditional industries such as machine tools and injection molding to the industries such as stacking and loading and unloading of various industries, along with continuous development, the efficiency, operability and safety of truss equipment are greatly improved, however, the safety of most of the existing systems is better protected on personal safety, but compared with the truss equipment, the system basically depends on the quality of operators and the performance of hardware equipment, so that accidents caused by collision of the manipulators due to misoperation can not be avoided all the time, for example, the mechanical structure of a five-axis truss manipulator generally comprises a transverse axis (X axis), two pulling and pulling axes (Y1 and Y2 axes), and two upper and lower axes (Z1 and Z2 axes), in the process of teaching point alignment, particularly Y1 and Y2 need to enter equipment such as an injection molding machine, a machine tool and the like, and collision occurs between Y1 and Y2 shafts in opposite directions due to wrong point position setting, so that hidden danger exists in the use of the device all the time, and the personal safety of operators cannot be really guaranteed.

In order to solve the above problems, innovative design based on the original anti-collision method is urgently needed.

Disclosure of Invention

The invention aims to provide an anti-collision method of a five-axis truss manipulator based on PLC control, and aims to solve the problems that due to the fact that an accident that the manipulator collides due to misoperation is caused in the background art, hidden dangers exist in the use of the device all the time, and the personal safety of operators cannot be really guaranteed.

In order to achieve the purpose, the invention provides the following technical scheme: an anti-collision method of a truss five-axis manipulator based on PLC control comprises the following steps,

s1: a problem introduction stage:

s11: connecting a power supply of a programmable logic controller (PCL) with an external power supply, and inputting various parameters of a shaft motion command into the interior of the PCL by programming and changing an internal program of the PCL;

s12: connecting a power supply of truss equipment with an external power supply, starting the truss equipment to operate, carrying out multiple tests on the five-axis truss manipulator by generally using a transverse axis (X axis), two drawing axes (Y1 and Y2 axes) and two upper and lower axes (Z1 and Z2 axes) as a mechanical structure of the five-axis truss manipulator, and finding out the problem that the axes Y1 and Y2 are collided in opposite directions due to wrong point position setting in the operation process;

s2: parameter setting and calculating stage:

s21: according to actual conditions, a lead L, a gear ratio K, a total displacement distance S (a spacing distance between a drawing shaft Y1 and a drawing shaft Y2), a safety distance F (a minimum distance between a drawing shaft Y1 and a drawing shaft Y2), a given pulse number G per revolution, a single-turn feedback pulse number H of an encoder, and a current feedback pulse number J of the encoder are set₁,J₂Acceleration a₁,a₂And the rated rotation speed of the motor;

s22: according to the known data, the maximum pulse number is calculated by the following formula:

wherein Max is the maximum pulse number, G is the given pulse number per revolution;

s23: according to the known data, calculating the current coordinates of the two shafts by a formula, wherein the specific calculation formula is as follows:

wherein S is₁- -the current position of the lead-in shaft Y1, S₂- -current position of the lead axle Y2, J₁The number of current feedback pulses, J, on the pull-out axis Y1₂-the current feedback pulse number of the drawing shaft Y2, L-lead, K-gear ratio, H-encoder single-turn feedback pulse number;

s3: point location teaching mode stage:

s31: when the point location teaching operation is carried out, two drawing shafts (Y1 and Y2 shafts) are generally in a point motion mode, the other shaft is in a static state, the assumption made in the invention is that the Y1 shaft moves and the Y2 shaft is in a static state;

s32: according to the assumed preset, when the pulling shaft Y1 starts to move, the target position is moved in the absolute movement mode, then the pulse number required by the movement is calculated through the formula and added to the command of the absolute movement of the programmable logic controller (PCL), and the calculation formula of the shaft correction corresponding to the required pulse number is as follows:

S_t＝S-S₂-F；

wherein S is_t-axis corrected target position, S-total displacement distance (separation distance between the lead-out axis Y1 and the lead-out axis Y2), S₂- -the current position of the lead-in shaft Y2, S_m-axis correction corresponds to the number of pulses required, F-safety distance (minimum distance between the pullout axis Y1 and the pullout axis Y2), G-given number of pulses per revolution, L-lead, H-encoder single-turn feedback number of pulses;

s4: and (3) a phase of opposite movement:

s41: when the point data is not taught but directly set, or two actual point positions which collide with each other due to wrong teaching of an operator are obtained, the internal program of the programmable logic controller (PCL) judges the positions of the pull shaft Y1 and the pull shaft Y2 as follows:

S_t1+S_t2+F≥S；

wherein S is_t1-the corrected position of the drawing axis Y1, S_t2-the corrected position of the puller axis Y2, F-the safety distance (minimum distance of the puller axis Y1 from the puller axis Y2), S-the total displacement distance (separation distance between the puller axis Y1 and the puller axis Y2);

s42: once the formula is judged to be established, the truss equipment can immediately trigger an alarm, emergently stop and stop the movement of a pulling shaft (Y1 shaft and Y2 shaft), and simultaneously prompt an operator that the related point position is wrongly set;

s43: after receiving the error alarm, an operator resets the operation parameters of the mechanical structure of the manipulator, which are reported by the fault, by using a programmable logic controller (PCL), and then restarts the truss equipment to recover the normal operation of the truss equipment;

s5: and (3) safety test stage:

s51: according to the calculated data, after the positions of two drawing shafts (Y1 and Y2 shafts) of the manipulator are adjusted, the truss equipment is started to test, whether the two drawing shafts (Y1 and Y2 shafts) can be stably stopped at a safe distance under the condition of high-speed operation is observed, whether the equipment can be emergently stopped and an alarm is triggered when collision occurs when the Y1 shaft and the Y2 shaft face each other, the improvement is completed through the tested truss equipment, and the truss equipment can be put into use formally.

Preferably, the axis movement command of the programmable logic controller (PCL) in S11 mainly includes the position, speed, axis number and other relevant parameters of the target.

Preferably, the default rated rotation speed of the motor in S21 is 3000r/min, so as to calculate the maximum pulse frequency, and the maximum pulse frequency is not exceeded during speed regulation.

Compared with the prior art, the invention provides the anti-collision method of the five-axis truss manipulator based on PLC control, which has the following advantages:

the invention modifies the operation mode and distance of the motion shaft by calculating the distance between the two pulling shafts (Y1 and Y2 shafts) and the set safety distance, achieves the purpose of changing the shaft motion target position, ensures that the pulling shafts can be stably stopped at the safety distance even if running at high speed, realizes the protection of the mechanical arm, can judge the two target positions when the two shafts are in opposite directions, and can immediately stop running and trigger alarm if the two shafts are overlapped or the distance is less than the safety distance, so that operators can not cause the occurrence of installation accidents at all even if some error operations exist in the actual work due to self reasons, thereby solving the safety hidden danger of the use of the device and really ensuring the personal safety of the operators.

Detailed Description

The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all 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.

The invention provides a technical scheme that: an anti-collision method of a truss five-axis manipulator based on PLC control comprises the following steps,

s1: a problem introduction stage:

s11: connecting a power supply of a programmable logic controller (PCL) with an external power supply, and inputting various parameters of a shaft motion command into the interior of the PCL by programming and changing an internal program of the PCL;

s12: connecting a power supply of truss equipment with an external power supply, starting the truss equipment to operate, carrying out multiple tests on the five-axis truss manipulator by generally using a transverse axis (X axis), two drawing axes (Y1 and Y2 axes) and two upper and lower axes (Z1 and Z2 axes) as a mechanical structure of the five-axis truss manipulator, and finding out the problem that the axes Y1 and Y2 are collided in opposite directions due to wrong point position setting in the operation process;

s2: parameter setting and calculating stage:

s21: according to actual conditions, a lead L, a gear ratio K, a total displacement distance S (a spacing distance between a drawing shaft Y1 and a drawing shaft Y2), a safety distance F (a minimum distance between a drawing shaft Y1 and a drawing shaft Y2), a given pulse number G per revolution, a single-turn feedback pulse number H of an encoder, and a current feedback pulse number J of the encoder are set₁,J₂Acceleration a₁,a₂And the rated rotation speed of the motor;

s22: according to the known data, the maximum pulse number is calculated by the following formula:

wherein Max is the maximum pulse number, G is the given pulse number per revolution;

s23: according to the known data, calculating the current coordinates of the two shafts by a formula, wherein the specific calculation formula is as follows:

wherein S is₁- -the current position of the lead-in shaft Y1, S₂- -current position of the lead axle Y2, J₁The number of current feedback pulses, J, on the pull-out axis Y1₂-the current feedback pulse number of the drawing shaft Y2, L-lead, K-gear ratio, H-encoder single-turn feedback pulse number;

s3: point location teaching mode stage:

s31: when the point location teaching operation is carried out, two drawing shafts (Y1 and Y2 shafts) are generally in a point motion mode, the other shaft is in a static state, the assumption made in the invention is that the Y1 shaft moves and the Y2 shaft is in a static state;

s32: according to the assumed preset, when the pulling shaft Y1 starts to move, the target position is moved in the absolute movement mode, then the pulse number required by the movement is calculated through the formula and added to the command of the absolute movement of the programmable logic controller (PCL), and the calculation formula of the shaft correction corresponding to the required pulse number is as follows:

S_t＝S-S₂-F；

wherein S is_t-axis corrected target position, S-total displacement distance (separation distance between the lead-out axis Y1 and the lead-out axis Y2), S₂- -the current position of the lead-in shaft Y2, S_mThe shaft correction corresponds to the number of pulses required, F- -the safety distance (minimum distance between the pullout shaft Y1 and the pullout shaft Y2), G- -the given number of pulses per revolution, L- -lead, H- -encoder single turn reverseFeeding a pulse number;

s4: and (3) a phase of opposite movement:

s41: when the point data is not taught but directly set, or two actual point positions which collide with each other due to wrong teaching of an operator are obtained, the internal program of the programmable logic controller (PCL) judges the positions of the pull shaft Y1 and the pull shaft Y2 as follows:

S_t1+S_t2+F≥S；

wherein S is_t1-the corrected position of the drawing axis Y1, S_t2-the corrected position of the puller axis Y2, F-the safety distance (minimum distance of the puller axis Y1 from the puller axis Y2), S-the total displacement distance (separation distance between the puller axis Y1 and the puller axis Y2);

s42: once the formula is judged to be established, the truss equipment can immediately trigger an alarm, emergently stop and stop the movement of a pulling shaft (Y1 shaft and Y2 shaft), and simultaneously prompt an operator that the related point position is wrongly set;

s43: after receiving the error alarm, an operator resets the operation parameters of the mechanical structure of the manipulator, which are reported by the fault, by using a programmable logic controller (PCL), and then restarts the truss equipment to recover the normal operation of the truss equipment;

s5: and (3) safety test stage:

s51: according to the calculated data, after the positions of two drawing shafts (Y1 and Y2 shafts) of the manipulator are adjusted, the truss equipment is started to test, whether the two drawing shafts (Y1 and Y2 shafts) can be stably stopped at a safe distance under the condition of high-speed operation is observed, whether the equipment can be emergently stopped and an alarm is triggered when collision occurs when the Y1 shaft and the Y2 shaft face each other, the improvement is completed through the tested truss equipment, and the truss equipment can be put into use formally.

The axis motion command of the programmable logic controller (PCL) in S11 mainly comprises the relevant parameters of the position, the speed, the axis number and the like of the target;

the default rated rotating speed of the motor in the S21 is 3000r/min, the maximum pulse frequency is calculated according to the default rated rotating speed, the maximum pulse frequency is not exceeded in speed regulation, and a data value is provided for calculating the safety distance of the drawing shaft through the set default rotating speed.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.