阅读说明：本技术 基于人机协作机器人的线束装配智能辅助系统 (Intelligent wire harness assembling auxiliary system based on man-machine cooperation robot ) 是由 鞠传海 龚清萍 李杰林 王大伟 于 2021-09-13 设计创作，主要内容包括：本发明公开了一种基于人机协作机器人的线束装配智能辅助系统,包含系统管理层、中央控制层、现场控制层以及现场执行层,系统管理层用于将待装配的线缆对应的安装孔位的三维坐标信息传递给中央控制层；中央控制层在接收到安装孔位的三维坐标信息后计算出机器人移动数据和机器人末端需要绕TCP点旋转的三个角度值,现场控制层的机器人移动平台控制器按机器人移动数据移动机器人,机器人控制器按机器人末端需要绕TCP点旋转的三个角度值移动机器人末端,在激光发射器对准线束的待安装孔位后控制激光发射器发射激光提示安装位置。本发明可以满足智能辅助线束安装时的指示精度、响应速度等要求。(The invention discloses a wire harness assembly intelligent auxiliary system based on a man-machine cooperation robot, which comprises a system management layer, a central control layer, a field control layer and a field execution layer, wherein the system management layer is used for transmitting three-dimensional coordinate information of an installation hole position corresponding to a cable to be assembled to the central control layer; the central control layer calculates robot moving data and three angle values of the tail end of the robot needing to rotate around a TCP point after receiving three-dimensional coordinate information of the mounting hole site, a robot moving platform controller of the field control layer moves the robot according to the robot moving data, the robot controller moves the tail end of the robot according to the three angle values of the tail end of the robot needing to rotate around the TCP point, and the laser emitter is controlled to emit laser to prompt the mounting position after the laser emitter is aligned with the to-be-mounted hole site of the wiring harness. The intelligent auxiliary wire harness installation device can meet the requirements of indication precision, response speed and the like during intelligent auxiliary wire harness installation.)

1. The utility model provides a pencil assembly intelligence auxiliary system based on man-machine cooperation robot, contains system management layer, central control layer, on-the-spot control layer and on-the-spot execution layer, its characterized in that:

the field control layer comprises a robot controller and a robot mobile platform controller;

the field execution layer comprises an end effector, a robot and a robot moving platform, the robot is arranged on the robot moving platform, the end effector is arranged at the tail end of the robot, and the robot moving platform drives the robot to move in the horizontal and vertical directions; the end effector comprises a laser emitter;

the system management layer is used for transmitting the three-dimensional coordinate information of the mounting hole positions corresponding to the cables to be assembled to the central control layer;

after receiving the three-dimensional coordinate information of the mounting hole sites, the central control layer calculates robot moving data and three angle values of the tail end of the robot needing to rotate around a TCP point by combining the current position of the robot, then sends the robot moving data to the robot moving platform controller to drive the robot to move on the robot moving platform, sends the three angle values of the tail end of the robot needing to rotate around the TCP point to the robot controller to control the tail end of the robot to point to the hole sites to be mounted, and controls the laser emitter to emit laser to prompt the mounting position after the laser emitter is aligned with the hole sites to be mounted of the wiring harness; and the central control layer receives and stores the robot moving platform position information and the robot axis position information returned by the robot controller and the robot moving platform controller.

2. The wire harness assembly intelligent auxiliary system based on the human-computer cooperative robot as claimed in claim 1, wherein the system management layer performs information interaction with the central control layer through a bus, the central control layer exchanges control information with the field control layer in an EtherCAT field bus control mode, the field execution layer is directly controlled by the central control layer through the field bus or completes control through the robot controller and the robot mobile platform controller, and the field execution layer finally completes control of the whole system under control coordination of the central control layer.

3. The intelligent auxiliary system for assembling the wire harness based on the human-machine cooperation robot is characterized in that a system management layer comprises a host and an HMI all-in-one machine;

the HMI all-in-one machine is used as a human-computer interface and is provided with an intelligent auxiliary operation page program, and the intelligent auxiliary operation page program comprises the human-computer interface and a wiring harness installation page program; the main machine is provided with a wire harness installation auxiliary program; the control software of the central control layer comprises a wire harness installation control program;

after an operator selects a wire harness installation page program on a human-computer interface, the wire harness installation page program receives and displays a cable bar code of a wire harness to be assembled, and transmits the cable bar code to a host computer after the operator confirms the cable bar code;

the wire harness installation auxiliary program calls the database to match the cable bar codes after receiving the transmitted cable bar codes, finds the three-dimensional coordinate information of the installation hole positions corresponding to the cable bar codes stored in the database, and then transmits the three-dimensional coordinate information of the installation hole positions to the central control layer;

after receiving the three-dimensional coordinate information of the mounting hole site transmitted by the host, the wire harness mounting control program firstly controls the robot controller to convert the three-dimensional coordinate information of the mounting hole site into coordinates under a world coordinate system of the robot according to the coordinate conversion matrix, then calculates robot moving data and three angle values of the tail end of the robot needing to rotate around a TCP point by combining the current position of the robot and the coordinate values under the world coordinate system of the hole site, then sends the robot moving data to the robot moving platform controller, sends the three angle values of the tail end of the robot needing to rotate around the TCP point to the robot controller, and finally sends a light beam emission command to the laser emitter after the laser emitter is aligned with the hole site to be mounted of the wire harness.

4. The intelligent auxiliary system for assembling the wire harness based on the man-machine cooperative robot as claimed in claim 3, wherein the intelligent auxiliary operation page program further comprises a calibration and positioning page program, the control software further comprises a calibration and positioning control program, and the end effector further comprises a monitoring camera;

when an operator selects a calibration and positioning page program on a human-computer interface, the calibration and positioning page program firstly displays a field picture shot by a monitoring camera, then sends a moving parameter given by the operator to an industrial personal computer, and sends a coordinate conversion matrix establishing command and a three-dimensional coordinate of calibration and positioning to the industrial personal computer after monitoring that the tail end of the robot reaches specified calibration and positioning;

after receiving the movement parameters issued by the calibration and positioning page program, the calibration and positioning control program respectively calculates robot movement data and robot tail end movement data according to the current position information of the robot, sends the robot tail end movement data to the robot controller and sends the robot movement data to the robot mobile platform controller; after a coordinate transformation matrix establishing command is received, a coordinate transformation matrix is obtained by analyzing the rule of the three-dimensional coordinate of calibration and positioning and the world coordinate system coordinate of the robot, and the coordinate transformation matrix is stored in the robot controller.

5. The intelligent auxiliary system for assembling the wire harness based on the man-machine cooperative robot as claimed in claim 3, wherein the intelligent auxiliary operation page program further comprises a permission control page program;

and after the operator selects the authority control page program on the human-computer interface, the authority control page program receives the input work number of the operator, displays the operator and the authority of the operator on a touch screen of the HMI all-in-one machine, and transmits the work number to the host through the bus to be stored as a character log after the operator clicks and confirms on the touch screen.

6. The intelligent auxiliary system for assembling the wire harness based on the human-computer cooperative robot as claimed in claim 3, wherein a system starting program is further installed on the host computer; the control software also comprises a self-checking control program;

the system starting program sends a self-checking command to the industrial personal computer after the intelligent auxiliary system is assembled by the wire harness; and after receiving the self-checking command from the host, the self-checking control program communicates with the field control layer and the field execution layer to drive each part of the field control layer and the field execution layer to perform self-checking work.

7. The intelligent auxiliary system for assembling the wire harness based on the man-machine cooperative robot as claimed in claim 3, wherein the host computer is further provided with an operation monitoring program; and the operation monitoring program reads and displays each part information of the field execution layer stored in the industrial personal computer for monitoring by field operators.

8. The intelligent auxiliary system for assembling the wire harness based on the human-computer cooperative robot as claimed in claim 3, wherein the end effector further comprises a three-color alarm lamp, and the control software comprises an alarm control program;

the robot and the robot moving platform stop moving when collision is detected in the movement, the robot controller and the robot moving platform controller send alarm information to an alarm control program, and command movement is continued when removal of an obstacle is detected; and the alarm control program is used for issuing an alarm command to the three-color alarm lamp after receiving alarm information returned by the robot controller and the robot mobile platform controller.

9. The intelligent auxiliary system for assembling the wire harness based on the human-computer cooperative robot is characterized in that a splicing type gear rack transmission mode is adopted in the horizontal direction of a robot moving platform; and a ball screw transmission mode is selected in the vertical direction.

Technical Field

The invention belongs to the field of automatic control, and relates to an intelligent auxiliary system for assembling a wire harness based on a human-computer cooperation robot.

Background

The general ground station of unmanned aerial vehicle is an important component in the avionics system, and is mainly used for realizing various communications and data transmission between the ground control equipment and the unmanned aerial vehicle during flight, and controlling the unmanned aerial vehicle to execute various flight tasks.

The pencil installation inefficiency of the general ground station shelter car of traditional unmanned aerial vehicle, the installation needs the manual identification process through the pencil, then seeks the installation hole site that corresponds the pencil according to wiring design drawing and wiring process file, carries out the installation operation of pencil afterwards again. Wherein, what a general ground station of unmanned aerial vehicle waited to install the pencil is maked up to hundreds of, and wiring personnel need stand on the narrow and small frock ladder of area during the pencil installation, and the work area scope is very limited, when looking for pencil installation hole site in addition, need constantly bow the inquiry and compare the pencil installation hole site on the equipment, and long-time abnormal posture operation under the limited condition in this kind of workplace very easily leads to wiring personnel tired out of and makes mistakes. And the harness installation process is not traceable. In addition, monitoring records cannot be achieved in the original wiring harness installation process, the installation process is not traceable, and once errors occur, the inspection is difficult to carry out.

Disclosure of Invention

The invention aims to provide an intelligent auxiliary system for assembling a wire harness based on a human-computer cooperation robot, which is used for intelligently and auxiliarily indicating and recording the installation process of the wire harness by means of the human-computer cooperation robot, greatly improving the installation efficiency of the wire harness, reducing the error rate and simultaneously realizing the traceability of the installation process of the wire harness.

The invention aims to be realized by the following technical scheme:

a wire harness assembly intelligent auxiliary system based on a man-machine cooperation robot comprises a system management layer, a central control layer, a field control layer and a field execution layer;

the field control layer comprises a robot controller and a robot mobile platform controller;

the field execution layer comprises an end effector, a robot and a robot moving platform, the robot is arranged on the robot moving platform, the end effector is arranged at the tail end of the robot, and the robot moving platform drives the robot to move in the horizontal and vertical directions; the end effector comprises a laser emitter;

the system management layer is used for transmitting the three-dimensional coordinate information of the mounting hole positions corresponding to the cables to be assembled to the central control layer;

after receiving the three-dimensional coordinate information of the mounting hole sites, the central control layer calculates robot moving data and three angle values of the tail end of the robot needing to rotate around a TCP point by combining the current position of the robot, then sends the robot moving data to the robot moving platform controller to drive the robot to move on the robot moving platform, sends the three angle values of the tail end of the robot needing to rotate around the TCP point to the robot controller to control the tail end of the robot to point to the hole sites to be mounted, and controls the laser emitter to emit laser to prompt the mounting position after the laser emitter is aligned with the hole sites to be mounted of the wiring harness; and the central control layer receives and stores the robot moving platform position information and the robot axis position information returned by the robot controller and the robot moving platform controller.

The invention has the beneficial effects that:

the intelligent auxiliary system for assembling the wire harness based on the man-machine cooperation robot changes the original wire harness installation mode, gets rid of the situation that a wire harness installer needs to rely on a design file and a wiring process file during wire harness installation, solves the problems of low wire harness installation efficiency, high labor intensity, high possibility of errors and the like in wire harness installation operation of a universal ground station of an unmanned aerial vehicle, and realizes high-efficiency, low-intensity and high-quality intelligent wire harness assembly. The system can meet the requirements of indication precision, response speed and the like when the intelligent auxiliary wire harness is installed. The system can be transplanted to other intelligent systems applying man-machine cooperation robot wire harness assembly without modification on a principle framework, has wide application range and has obvious market prospect and economic benefit.

Drawings

Fig. 1 is a schematic structural diagram of an intelligent auxiliary system for assembling a wire harness based on a human-computer cooperative robot according to an embodiment.

Fig. 2 is a schematic diagram of a robot moving platform.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings and examples.

Referring to fig. 1, in order to ensure that the harness installation hole locations are quickly positioned and the harness installation work is orderly performed, the intelligent harness assembly auxiliary system based on the human-computer cooperative robot shown in this embodiment has four layers from top to bottom, namely, a system management layer, a central control layer, a field control layer and a field execution layer, and the four layers of the architecture complete the coordination work of the whole intelligent harness assembly auxiliary system, the instruction input of an operator, the external display of the system state and the like through real-time information interaction. The system management layer comprises a host and an HMI (human machine interface) all-in-one machine, the central control layer comprises an industrial personal computer and the like, the field control layer comprises a robot controller, a robot moving platform controller (a robot is arranged on the robot moving platform and can move in the horizontal and vertical directions) and the like, the field execution layer comprises an end effector, a robot moving platform, a safety protection system and the like, and the end effector comprises a laser emitter, a monitoring camera, a reference probe and the like. The host and the HMI all-in-one machine carry out information interaction with the industrial personal computer through a bus, the industrial personal computer exchanges control information with a field control layer in an EtherCAT field bus control mode, the field execution layer is directly controlled by the industrial personal computer through the field bus or is controlled by the robot controller and the robot mobile platform controller, and the field execution layer finally completes the control of the whole system under the control coordination of the industrial personal computer.

System management layer

And the system management layer bears the tasks of overall system authority control management, man-machine cooperative interaction, event log management and the like, and the top-level management and control of the intelligent auxiliary system for wire harness assembly are realized.

The HMI all-in-one machine is used as a human-computer interface to install an intelligent auxiliary operation page program, the intelligent auxiliary operation page program is realized by Java, and the Java has high portability and is more convenient for later debugging iteration. The intelligent auxiliary operation page program comprises a man-machine interface, a permission control page program, a calibration and positioning page program, a wire harness installation page program and other page programs. The operator can operate the page program at the man-machine interface.

And after the operator selects the authority control page program on the human-computer interface, the authority control page program receives the input work number of the operator, displays the operator and the authority of the operator on a touch screen of the HMI all-in-one machine, and transmits the work number to the host through the bus to be stored as a character log after the operator clicks and confirms on the touch screen.

When an operator selects a calibration and positioning page program on a human-computer interface, the calibration and positioning page program firstly displays a field picture shot by a monitoring camera, then sends a moving parameter given by the operator to an industrial personal computer, and sends a storage instruction and a three-dimensional coordinate of calibration and positioning to the industrial personal computer after monitoring that the tail end of the robot reaches specified calibration and positioning. And after a plurality of pieces of calibration positioning information are stored, sending a coordinate transformation matrix establishing command.

After an operator selects a wire harness installation page program on a human-computer interface, the wire harness installation page program receives and displays a cable bar code of a wire harness to be assembled, and transmits the cable bar code to a host computer after the operator confirms the cable bar code.

The work number of an operator and the cable bar code of the wire harness to be assembled can be input in a manual input mode, or the work number bar code of the operator and the cable bar code of the wire harness to be assembled can be scanned on site by devices such as a code scanning gun and the like, and then the work number bar code, the cable bar code and the vehicle body bar code information of the operator are transmitted to the HMI all-in-one machine through the USB.

The host computer is provided with a system starting program, an operation monitoring program, a wire harness installation auxiliary program and other back-end programs.

And the system starting program sends a self-checking command to the industrial personal computer after the intelligent auxiliary system for beam assembling is started.

And the operation monitoring program is used for reading and displaying each part information of the field execution layer stored in the industrial personal computer, so that field operators can monitor the information. Wherein, each part information comprises the position information of the robot moving platform, alarm information, the position information of the robot axis, and the like.

The wire harness installation auxiliary program calls the database to match the cable bar codes after receiving the cable bar codes transmitted by the HMI all-in-one machine, finds the three-dimensional coordinate information of the installation hole positions corresponding to the cable bar codes stored in the database, and then transmits the three-dimensional coordinate information of the installation hole positions to the central control layer. The database comprises three-dimensional coordinate information of the mounting hole sites, auxiliary display two-dimensional drawing coordinate information and name information of cables corresponding to the hole sites.

(II) Central control layer

And after receiving the related instructions of the system management layer, the central control layer sends the instructions to the robot controller, the robot mobile platform controller and the field execution layer of the field control layer.

The control software embedded in the industrial personal computer adopts TwinCAT3, and the real-time control of the assembly field is completed through the control software. The control software comprises a self-checking control program, a calibration and positioning control program, a wiring harness installation control program, an alarm control program and the like.

And after receiving the self-checking command from the host, the self-checking control program communicates with the field control layer and the field execution layer to drive each part of the field control layer and the field execution layer to perform self-checking work.

After receiving the movement parameters issued by the calibration and positioning page program (the parameters are obtained from an intelligent auxiliary operation page program installed in an HMI (human machine interface) all-in-one machine of a system management layer), the calibration and positioning control program respectively calculates the robot movement data and the robot moving platform movement data according to the current position information of the robot, sends the robot movement data to a robot controller (a field control layer, namely the third layer), and sends the movement data of the robot moving platform to the robot moving platform controller (the field control layer, namely the third layer). And after receiving a storage command, storing the three-dimensional coordinate of the calibration and positioning and the coordinate value of the world coordinate system of the robot. After a coordinate transformation matrix establishing command is received, a coordinate transformation matrix is obtained by analyzing the rules of a plurality of three-dimensional coordinates and the world coordinate system coordinates of the robot, and the coordinate transformation matrix is stored in the robot controller.

After the wiring harness installation control program receives the three-dimensional coordinate information of the installation hole site transmitted by the host computer, the robot controller converts the three-dimensional coordinate information of the installation hole site into coordinates under a world coordinate system of the robot according to the conversion matrix, and then calculates the current position of the robot by combining the movement data of the robot moving platform (the data is calculated and provided by an industrial personal computer of a central control layer), then, three angle values (the process is completed by an industrial personal computer of a central control layer) of the tail end of the robot which needs to rotate around the TCP point are calculated by utilizing the current position of the robot and the coordinate values under the world coordinate system of the hole sites, the industrial personal computer sends the rotation angle value of the robot body to a robot controller, after a laser transmitter (the equipment is arranged at the tail end of a robot body and belongs to a field execution layer) is aligned with a hole position to be installed of a wire harness, an industrial personal computer sends a light beam transmitting command to the laser transmitter; and meanwhile, the industrial personal computer receives and stores the robot moving platform position information, the robot axis position information and the like returned by the robot controller and the robot moving platform controller, and the robot axis position information and the like are read and displayed by an operation monitoring program of the host.

And the alarm control program is used for issuing an alarm command to the three-color alarm lamp after receiving alarm information returned by the robot controller and the robot mobile platform controller.

(III) field control layer and field execution layer

Referring to fig. 2, the robot moving platform (mounted on the gantry structure) is used to drive the robot to move horizontally and vertically along the gantry and to lock after the robot reaches the operating position. The length of an X-axis (horizontal direction) walking structure of the portal frame is 14m, and due to the influence of a large stroke, the robot moving platform cannot use a common ball screw for transmission, but selects a splicing type gear rack transmission mode more suitable for the large stroke; the Z axis (vertical direction) selects a ball screw transmission mode because the stroke is small. Travel switches are arranged at two ends of the portal frame structure to realize the control of the moving range of the motor in the X-axis direction.

The control of the robot moving platform is realized by adopting a motor driver, and the functions of translation, guiding, positioning, locking, safety protection and the like of the robot moving platform are completed by the motor driver. The motor driver mainly receives the movement data from the industrial personal computer and transmits the movement data to the mobile platform motor of the field execution layer, and meanwhile, the motor driver also records the position information of the mobile platform of the robot and transmits the position information to the central control layer. The motor driver can also transmit the current state signals of translation or positioning locking and the like of the mobile platform to the central controller, and the central controller determines whether the system meets the working conditions or not according to the state signals.

The stator winding of the mobile platform motor receives the ground current signal output from the motor driver through the power conversion element to change the magnetic field change inside the motor, thereby controlling the torque, the motion direction, the speed and the position of the motor shaft.

The robot controller is a controller KUKA Sunrise cabin special for the KUKA robot, and the robot controller completes the functions of motion control of a robot body, safety protection of the robot and the like. The robot controller controls the robot body to complete the position and posture adjustment of the robot after receiving the robot moving data transmitted by the industrial personal computer, so that an emission beam of a laser emitter at the tail end of the robot points to a wiring harness to-be-installed hole site.

The robot body and the robot moving platform stop moving when collision is detected in the moving process, the robot controller and the robot moving platform controller send alarm information to an alarm control program, and command movement can be continued when the obstacle removal is detected.

The laser generator emits laser beams after receiving an installation command issued by a beam installation control program, and the laser beams just fall on the beam installation holes to prompt an operator of the installation position of the beams.

The three-color warning lamp is in an open state after receiving an alarm command issued by the alarm control program.

It should be understood that equivalents and modifications of the technical solution and inventive concept thereof may occur to those skilled in the art, and all such modifications and alterations should fall within the scope of the appended claims.