摘要
码垛机械手作为现代码垛系统中最重要的设备,对促进工业自动化起到非常重要的作用。近年来,国内许多高校和企业均对码垛机械手控制系统进行了研究和开发,但我国码垛机械手控制系统与国外相比还有很大的差距。因此,研发具有自主产权的高水平码垛机械手控制系统具有重要的意义。基于工业实时以太网总线技术,本论文设计了一种适用于多种类型码垛机械手控制系统开发的码垛机械手控制平台。
首先,本论文从码垛机械手的工作过程出发,对码垛机械手所需运动进行了分析,并对常用的混联码垛机械手结构和串联码垛机械手结构进行了分析。根据码垛机械手工作过程中的运动规律,对机械手末端类似门字形的运动轨迹进行规划,使用S曲线加减速控制方法和码垛机械手运动学正逆解对运动轨迹中各个运动轴的运动过程进行插补计算。在轨迹规划过程中,使用s曲线加减速控制方法,实现水平运动、底座旋转、手爪旋转三个运动的同步协调运行。
其次,本课题对码垛机械手控制平台进行研究。控制系统硬件平台采用基于Ether MAC (Ethernet for Manufacture Automation Control)实时以太网总线技术的e-Link接口板和IO接口板,接口板与工控机以及各接口板之间均通过屏蔽双绞线进行级联。码垛机械手控制系统软件采用模块化的设计理念,将控制软件分为运动控制模块、数据通信模块、人机交互模块等。其中,数据通信模块中包含总线通信模块,可实现控制系统软件与硬件平台之间的通信。对于不同类型的码垛机械手机械结构,只需要调用相对应的软件功能模块即可快速、准确的开发出适用于用户需求的码垛机械手控制系统。
最后,在基于实时以太网的码垛机械手控制平台上,开发设计了一种满足用户需求的码垛机械手控制系统,并应用于生产现场。试验表明,该码垛机械手控制系统能够实现所需的功能,工作情况稳定、流畅,达到了工业自动化的需求。
As the most important equipment for modern stacking system, palletizing robots make important effectiveness for industrial automation. In recent years, a number of universities and companies have paid a great deal of attention to the research and development of palletizing robot. But there is still a large gap between home and abroad in the overall development and application levels of robot controllers. Therefore, the independent research and development of the palletizing robot controller is of great significance for China's development. Based on the real-time industrial Ethernet fieldbus, this paper designs one palletizing robot control platform which uses to develop palletizing robot control systems.
First of all, the desired movement of the palletizing robot is analyzed from the working process. Then the structures of a kind of mixed-connection palletizing robot and series palletizing robot are analyzed, too. The similar door-shaped trajectory of the end of the palletizing robot is planned according to the regular pattern of motion in the palletizing robot working process. Using the S-curve acceleration and deceleration control method and robot forward and inverse kinematics, the interpolation calculation is done for the movement trajectory of all axes. Using the S-curve acceleration and deceleration control method in trajectory planning process, it achieves that the synchronized running of horizontal movement, base rotation and gripper rotation.
Secondly, the paper does some research of palletizing robot control platform. The control system hardware platform adopts e-Link interface card and IO interface card which are based on the real-time Ethernet fieldbus EtherMAC (Ethernet for Manufacture Automation Control). Connections between e-Link interface card, IO interface card and Industrial PC is through shielded twisted pair. The palletizing robot control system software using a modular design concept. The control software is divided into motion control module, data communication module, human-computer interaction module, etc. Wherein the data communications module includes a fieldbus communication module, can be realized to control the communication between the system software and hardware platform. For different types of palletizing robot mechanical structure, only need to call the corresponding software function modules can be quickly and accurately develop palletizing robot control system applicable to the user needs.
Finally, a palletizing robot control system to meet user needs is designed on the basis of the palletizing robot control platform which is based on the real-time Ethernet fieldbus, and a palletizing robot control system is used to the production line. The tests showed that the palletizing robot control system can achieve the desired functionality, work in a stable and smooth condition, and reach the needs of industrial automation.
引文
[1]赵杰.我国工业机器人发展现状与面临的挑战[J].航空制造技术,2012(12)：26-29.
[2]刘晋浩,李晓刚.码垛机器人的研究与应用现状_问题及对策[J].包装工程,2011,3(32)：96-102.
[3]胡洪国,高建华,杨汝清.码垛技术综述[J].组合机床与自动化加工技术,2000(6)：9-11.
[4]Clyde E W. Palletizing unit load:many options [J]. Material Handling Engineering,1999,54(1):99-106.
[5]Hemmingson E. Palletizing Robots Industry [J]. Industrial Robot, 1998,25(6):384-388.
[6]Spiess J. Development of high capacity bagging and palletizing lines [J]. World Cement,1995,26(12):121-132.
[7]George A, Weimer I V. New robotics technology adds value to material, handling, palletizing Material Handling Engineering [J].1998,53(7):61-65.
[8]Hemmingson E. Palletizing robots for the consumer goods industry [J]. Industrial Robot-An International Journal,1998,6(2):384-388.
[9]董忠.码垛机器人运动控制与优化[D].上海交通大学,2010.
[10]陈黎明.码垛机器人控制系统设计[D].上海交通大学,2010.
[11]Clyde E W. For speed or reliability, automatic palletizers are the right choice [J]. Material Handing Engineering,1996,4(51):13-20.
[12]Sorenti P. Rapid palletizing:simulation in the fast lane [J]. Industrial Robot, 1996,3(23):16-19.
[13]Clyde E W. Transport packaging the next frontier of cost reduction [J]. Material Handling Engineering,1995,12(50):61-62.
[14]Blomdell A, Dressler I, Nilsson K. Flexible Application Development and High-performance Motion Control Based on External Sensing and Reconfiguration of ABB Industrial Robot Controllers[J]. ICRA 2010 Workshop on Innovative Robot Control Architectures for Demanding (Research) Applications.,2010:62-66.
[15]李刚.工业用码垛机器人[J].现代制造,2005(24)：42-43.
[16]潘炼东.开放式机器人控制器及相关技术研究[D].华中科技大学,2007.
[17]Ford W E. What is an Open Architecture Robot Controller[C]. Proceedings of the 1994 IEEE International Symposium on Intelligent Control,1994.
[18]安彦波.工业机器人开放式控制系统的研究[D].哈尔滨工业大学,2010.
[19]http://www.abb.com.cn/robotics.
[20]http://www.kuka-robotics.com/zh.
[21]蓝培钦.码垛机器人控制器系统软件的设计和研究[D].上海交通大学,2010.
[22]苏海新,韩宝玲,罗庆生,等.基于PMAC的工业码垛机器人控制特性研究[J].机械与电子,2009(9)：57-60.
[23]刘扬,高志慧,负超,等.混联码垛机器人运动学分析与仿真[J].机械与电子,2010(3)：57-60.
[24]张志强,臧冀原,负超.混联码垛机器人运动学分析及仿真[J].机械设计,2010(11)：47-51.
[25]刘兴磊.基于现场总线的码垛机器人控制系统研究[D].东华大学,2010.
[26]梁园,罗庆生,石琳,等.CAN总线技术在工业码垛机器人控制系统中的应用研究[J].今日电子,2009(6)：54-55.
[27]Guan X, Wang J. Mechanical design and kinematic analysis of a new kind of palletizing robot[C]. Mechanic Automation and Control Engineering (MACE), 2011 Second International Conference on,2011.
[28]李成伟,贠超.码垛机器人机构设计与运动学研究[J].机械设计与制造,2009(6)：181-183.
[29]李成伟,负超.码垛机器人控制系统的设计与实现[J].机电产品开发与创新,2008(5)：9-10.
[30]李成伟,朱秀丽,负超.码垛机器人机构设计与控制系统研究[J].机电工程,2008(12)：81-84.
[31]芮执元,刘涛.码垛机器人运动学分析与仿真[J].机械制造,2010(4)：7-10.
[32]把明儒.CNC系统中几种加减速算法研究与比较[J].兰州工业高等专科学校学报,2010(5)：36-40.
[33]胡磊,林示麟,徐建明,等.S曲线加减速速度控制新方法[J].组合机床与自动化加工技术,2010(1)：22-26.
[34]陈友东,魏洪兴,王琦魁.数控系统的直线和S形加减速离散算法[J].中国机械工程,2010(5)：567-570.
[35]张碧陶,高伟强,沈列,等.S曲线加减速控制新算法的研究[J].机床与液压,2009(10)：27-29.
[36]李晓辉,邬义杰,冷洪滨.S曲线加减速控制新方法的研究[J].组合机床与自动化加工技术,2007(10)：50-53.
[37]石川,赵彤,叶佩青,等.数控系统S曲线加减速规划研究[J].中国机械工程,2007(12)：1421-1425.
[38]朱晓春,屈波,孙来业,等.S曲线加减速控制方法研究[J].中国制造业信息化,2006(23)：38-40.
[39]郭新贵,李从心.S曲线加减速算法研究[J].机床与液压,2002(5)：60-62.
[40]张丰华,韩宝玲,罗庆生,等.基于PLC的新型工业码垛机器人控制系统设计[J].计算机测量与控制,2009(11)：2191-2193.
[41]刘相权,负超,张志强,等.基于PMAC运动控制卡的混联码垛机器人研制[J].机械设计,2009(5)：49-52.
[42]Hunt J A. Ethernet cuts fieldbus costs in industrial automation [J]. Assembly Automation,2008,1(28):18-26.
[43]Felser M. Real-Time Ethernet-Industry Prospective [J]. Proceedings of the IEEE, 2005,93(6):1118-1129.
[44]Pfeiffer A. Making real-time Ethernet a reality [J]. Computing & Control Engineering Journal,2004,1(15):12-15.
[45]Neumann P. Communication in industrial automation—What is going on? [J]. Control Engineering Practice,2007(15):1332-1347.
[46]Decotignie J D. Ethernet-Based Real-Time and Industrial Communications [J]. Proceedings of the IEEE,2005(93):1102-1117.
[47]IEC,2004a.IEC 65C/359/NP[S],Real-time Ethernet:PROFINETIO.
[48]IEC,2004e.IEC 65C/358/NP[S].Real-time Ethernet:SERCOS Ⅲ..
[49]IEC,2004f.IEC 65C/356/NP[S].Real-time Ethernet:POWERLINK
[50]IEC,2004g.IEC 65C/355/NP[S].Real-time Ethernet:ETHERCAT.
[51]张承瑞.基于标准以太网的实时同步网络及其工作方法.张承瑞,王金江.中国.发明专利.CN101018115.2007.
[52]山东大学.一种实现以太网链状网络节点间同步的装置和方法.张承瑞,王金江.中国.发明专利.CN101039173.2007.
[53]刘远静.电路板雕刻机数据处理及控制系统研发[D].山东大学,2011.
[54]桑志谦.基于Windows CE的实时以太网运动控制平台研究及应用[D].山东大学,2011.
[55]杨林.基于工业以太网的运动控制系统关键技术研究[D].山东大学,2011.
[56]Karen A. Ergonomic aids ease manual palletizing [J]. Modern Material Handling, 1995,10.
[57]Liangan Z, Jiangping M, Xueman Z, et al. Layout analysis and path planning of a robot palletizing production line [C]. Proceedings of the IEEE, International Conference on Automation and Logistics,2008.