CN115903710A - Generator stator core stacking robot edge control system and control method - Google Patents

Abstract

The invention provides an edge control system and a control method of a generator stator core stacking robot. The 5G network communication technology, the edge calculation technology and the informatization interaction technology are comprehensively applied, and a specific control mode is combined to construct an edge control system of the generator stator core laminated robot. The invention realizes the remote real-time control and the remote state display of the stator core lamination procedure with the control cycle less than or equal to 1 millisecond on one hand, and realizes the closed-loop control of production by constructing the interconnection and intercommunication of relevant lamination systems on the other hand, thereby effectively improving the production efficiency.

Description

Edge control system and control method of generator stator core stacking robot

technical field

The invention provides a generator stator core stacking robot edge control system and control method, which are used for remote monitoring, remote control and closed-loop control of multiple robots to realize the collaborative completion of the stacking process of magnetic punching sheets, belonging to the technical field of industrial control.

Background technique

Industrial upgrading in the industrial field is closely related to the innovation of information technology. The combination of manufacturing technology and advanced information and communication technology provides sufficient impetus for industrial upgrading and in-depth and comprehensive reform of the manufacturing industry. As the core and main direction of the five major projects, intelligent manufacturing aims to comprehensively improve the digital, networked and intelligent level of the industry through the integration and development of the new generation of information technology and industrial technology.

The stator core is the heart of large-scale power generation equipment. It is made of punched sheets with good magnetic permeability, stacked in sections, and pressurized and solidified. During the stacking process, multiple robots (manipulators) are used to grasp and position the punched sheets with the assistance of machine vision. The whole process requires real-time monitoring of the filming status, processing of image information with a large amount of data, and coordination and real-time control of multiple robots based on the filming information. Large-scale power generation equipment is custom-made according to orders, requiring stacked unit robots to have flexible and rapid redeployment capabilities. This brings great challenges to the control of stacked robots.

The current stator core stacking process is to use PLC controller on site, use field bus or industrial Ethernet, integrate the stacking workbench, industrial robot, and detection platform, and coordinate the actions of each control object by PLC to complete stacking Jobs, the continuity between jobs is realized by workers' on-site auxiliary planning. However, these technologies currently have the following technical problems:

The PLC controller is only responsible for the control process of the stacking process, and has no information interaction with other production-related systems. The entire production process must be planned by technicians on site. The interoperability between systems is poor, and there are "data islands".

Processing personnel can only operate stacked equipment and obtain various status information during the work process only at the workshop site, and cannot remotely sense the production status in real time.

In the workshop, the wired network composed of industrial Ethernet is the main one. The layout cost of the wired network is high, which affects the flexible transformation of the production line and is not conducive to the system communication across workshops. Wi-Fi-based wireless networks have poor anti-interference performance, unstable performance, and limited capacity. Due to the limitations of transmission rate, bandwidth and delay, traditional 4G networks cannot meet high real-time scenarios.

Using the cloud platform to manage the production process, the production data from the workshop terminal equipment to the cloud platform will have real-time, bandwidth, privacy, energy consumption and other issues.

Contents of the invention

In order to solve the problem of data disconnection and on-site control in the generator stator core stacking process. The present invention provides a new solution combining "5G+MEC+stator core stacking and cooperative control application", which comprehensively applies 5G network communication technology, edge computing technology and information interaction technology, and combines specific control methods to build a power generation system. Machine stator core stacking robot edge control system.

5G communication has the characteristics of high speed, low delay, and high reliability, which can realize the integration and control of workshops and factory equipment. Wireless communication can also overcome the problem that wired networks are difficult to meet the adjustment of production processes due to order changes. However, the air interface delay of 5G transmission is generally more than 5 milliseconds, while the real-time control of machine tools and robots requires a control cycle of less than or equal to 1 millisecond. Therefore, simply using 5G cannot meet the requirements of real-time control.

The edge computing model provides the ability to integrate computing, storage, and network resources on the edge of the network close to the source of objects or data, which can reduce the upstream pressure of terminal device data and shorten device response time. Combining 5G communication technology with edge computing technology, deploying edge computing (MEC) nodes in the lamination workshop, deploying user plane functions (UPF) in MEC equipment, and sinking the user plane functions of the 5G core network to the stator core At the edge of the stacking process, the production data is transmitted to the sinking UPF through the 5G base station, and the data is sent to the MEC node, so as to realize the transmission and unloading of business data at the edge of the production line. Business data does not need to be transmitted long-distance from the bearer network to the transmission network, which significantly reduces the transmission delay, satisfies the real-time control delay of machine tools and robots, and ensures the security of business data.

The specific technical solutions are:

Generator stator core stacking robot edge control system, including operation system, operation assistance system, 5G communication gateway, generator stator core stacking collaborative control application and remote control terminal, generator stator core stacking collaborative control application For the system brain, build a unified and effective connection.

The operation system is the executive mechanism of the stator core stacking process, which is the core data source of the edge control system. Its main body is composed of stacking workbench, industrial robot, and various position, speed, and pressure sensors. The main control PLC is used as the on-site control The core integrates on-site processing information and environmental sensing information.

Operation assistance system, including material management system, AGV system and monitoring system; the material management system digitizes the material information of the production site through seamless integration with the factory logistics, warehousing and production line resources. Through the unified management of AGV, the AGV system includes two aspects: upper scheduling of materials and positioning of AGV, environmental perception, path planning and guidance control. The monitoring system includes front-end cameras, network transmission equipment, and back-end control and display parts. Through continuous monitoring of the workshop system, intuitive perception of the target system or target processing equipment is realized. At present, various operation-related systems cannot be directly associated with the operation system, and employees are on-site to assist in the operation of each operation-related system.

The 5G communication gateway is an on-site communication device. With the help of the 5G communication capability of the gateway, the workshop equipment can be connected to the 5G network environment. Deploy the collection and distribution application inside the gateway, provide on-site computing power at the edge of the operation system, and provide services for collecting downstream operation system information and issuing upstream task information through communication with the main control PLC. By converting protocols and data types, Realize the interconnection and intercommunication of the generator stator core stacking collaborative control application and the operation system.

The stator core stacking collaborative control application, hereinafter referred to as the edge control platform, is deployed on the MEC node server, based on the B/S architecture, that is, the browser/server architecture, and is the unified interaction of the system's core computing control center to build various systems.

The cross-shop scheduling terminal is the client corresponding to the edge control platform, which directly interacts with the user to realize the user's comprehensive perception of the processing process and remote assistance.

The control method of the edge control system of the generator stator core stacking robot integrates various systems and realizes the three system functions of remote monitoring, remote control and closed-loop control based on edge computing.

1. The system builds a five-node remote monitoring chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and on-site cameras. This link is based on 5G network for transmission, and based on edge computing for nearby processing of monitoring data , which ensures real-time monitoring delay and production data security. The remote monitoring process is mainly divided into two aspects: parameterized monitoring of production status and remote video monitoring of production scenarios:

(1) The edge control platform calls the collection service of the 5G communication gateway application regularly based on the HTTP protocol at an interval of 30 ms. The address and parameters are formatted, encapsulated into JSON format data and responded to the edge control platform, so as to map the data of the production site to the network space. The edge control platform analyzes the address parameters, builds a real-time mirror image of production data inside the application, and pushes the real-time status to the remote control terminal through the WebSocket protocol, and relevant personnel can realize remote parameterized monitoring of the production process by accessing the remote control terminal interface .

(2) The edge control platform pulls the job site monitoring video stream in real time according to the video stream address, and the video stream is sent back to the edge control platform through the 5G communication gateway. The edge control platform encodes and transcodes the video, and converts video stream slices into multiple small files for storage. The remote control terminal obtains video files based on the HTTP protocol and displays them in real time, thereby realizing remote video monitoring of production scenarios.

2. The system has established a five-node remote control chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and stacked robot controllers. The remote control process is:

The remote control terminal has the authority to set stacking tasks, control the loading and unloading of on-site equipment, adjust the processing status of the robot controller, and emergency stop. In the initial state of production, after the employees edit the processing tasks on the remote control terminal, they send the task data to the edge control platform through the HTTP protocol, and the edge control platform verifies the task parameters. Tasks are automatically optimized. On the premise of ensuring the complete execution of the current task and the original task, the calculation of the shortest operation time of all tasks is performed, so as to construct the optimal mapping between the station and the task. After the task assignment calculation is completed, the global robot trajectory Optimizing for the lowest overall energy consumption. According to the optimization results, the edge control platform sends the control parameters to the 5G gateway application through the 5G network, and the gateway application performs protocol and data type conversion to set the PLC controller and robot controller parameters, that is, the stator core is stacked every 50 milliseconds Collaborative control uses the edge control platform to perform a parameter optimization, the PLC controller updates the status and control output of each device on site every 2 milliseconds, and the robot controller performs position closed-loop control every 0.5 milliseconds. When the stacking operation is in progress, the remote control terminal only has the authority to stop emergency and adjust processing tasks.

3. The system has built a closed-loop control chain of four system nodes: the operating system, the edge control platform, the material management system, and the AGV system. The closed-loop control process is:

When there are production stoppage scenarios such as material shortage and return at designated stations in the production process, the control right of the equipment is transferred to the edge control platform. The edge control platform uses multi-threading technology to perform multi-dimensional analysis and calculation on the production image, integrating business continuity conditions and According to the current task requirements, standard business continuity parameters are formulated, and the decision-making data is sent to the material management system. The material management system integrates the materials, and then sends the task parameters to the AGV system responsible for material transportation, and the AGV system transports the materials to the stacker. After the designated station of the assembly system, the ready state of the material is captured by the edge control platform, which controls the stacking system to perform loading or unloading operations, so that the production continues to run, and the control of the equipment is transferred to the on-site PLC controller and the stacking machine again. Install the robot controller. Through the background computing and system communication of the edge control platform, it replaces the on-site manual operation of employees and effectively breaks the "data island" of the stacking system.

In addition to the above control process, in order to consider the safety of stacking operations, an automatic remote control switch is set on site, and the system administrator with system control rights sends instructions to the on-site PLC controller through the edge control platform, and at the same time, the processing personnel set the PLC input on site Signal to realize the switch between on-site operation and remote automatic control. The system administrator has the priority, and the input signal of the on-site personnel will be valid only if the switch command is issued by him. When the switch is turned on, closed-loop control and real-time control can be realized on the remote control terminal through the application. When the switch is turned off, the remote control is turned off, and the processing personnel can control it on site.

The invention combines 5G technology, edge computing technology and stator core stacking collaborative control application to build a generator stator core stacking robot edge control system. On the one hand, the remote real-time control and remote status display with a control cycle of less than or equal to 1 millisecond for the stacking process of the stator core is realized. On the other hand, the closed-loop control of production is realized through the interconnection of stacking-related systems, which effectively improves production efficiency.

Description of drawings

Fig. 1 is the system interaction model of the present invention;

Fig. 2 is a remote monitoring control block diagram of the present invention;

Fig. 3 is a flowchart of the remote control and closed-loop control of the present invention.

Detailed ways

The specific technical solutions of the present invention are described in conjunction with the accompanying drawings.

The interaction model of each node of the generator stator core stacking robot edge control system is shown in Figure 1. The overall system is mainly composed of the operation system, the operation assistance system, the 5G communication gateway, the generator stator core stacking collaborative control application, and the remote control The terminal configuration uses the generator stator core stacking collaborative control application as the system brain to build a unified and effective connection. Each structural node is introduced as follows:

The operation system is the executive mechanism of the stator core stacking process, which is the core data source of the edge control system. Its main body is composed of stacking workbench, industrial robot, and various position, speed, and pressure sensors. The main control PLC is used as the on-site control The core integrates on-site processing information and environmental sensing information.

The operation assistance system is mainly composed of material management system, AGV system and monitoring system. The material management system digitizes the material information on the production site through seamless integration with resources such as factory logistics, warehousing and production lines. Through the unified management of AGV, the AGV system includes two aspects: upper scheduling of materials and positioning of AGV, environmental perception, path planning and guidance control. The monitoring system is mainly composed of three parts: front-end camera, network transmission equipment, and back-end control and display part. Through continuous monitoring of the workshop system, the intuitive perception of the target system or target processing equipment is realized. At present, various operation-related systems cannot be directly associated with the operation system, and employees are on-site to assist in the operation of each operation-related system.

The 5G communication gateway is an on-site communication device. With the help of the 5G communication capability of the gateway, the workshop equipment can be connected to the 5G network environment. Deploy the collection and distribution application inside the gateway, provide on-site computing power at the edge of the operation system, and provide services for collecting downstream operation system information and issuing upstream task information through communication with the main control PLC. By converting protocols and data types, Realize the interconnection and intercommunication of the generator stator core stacking collaborative control application and the operation system.

The generator stator core stacking collaborative control application (hereinafter referred to as the edge control platform) is deployed on the MEC node server. Based on the B/S architecture, that is, the browser/server architecture, it is the core computing control center of the system. This application makes full use of the MEC Computing, storage, and network resources of nodes encapsulate functions such as data collection, data conversion, data storage, log recording, and network interaction into applications to build a unified interaction of various systems.

The cross-shop scheduling terminal is the client corresponding to the edge control platform, which directly interacts with the user and can realize the user's comprehensive perception of the processing process and remote assistance.

By integrating various systems, the system realizes the three major system functions of remote monitoring, remote control and closed-loop control based on edge computing. The control process method is shown in Figure 2 remote monitoring control block diagram and Figure 3 remote control and closed-loop control flow chart.

(1) The system has built a five-node remote monitoring chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and on-site cameras. This link is based on 5G network for transmission, and based on edge computing for nearby monitoring data processing, ensuring real-time monitoring delay and production data security. The remote monitoring process is mainly divided into two aspects: parameterized monitoring of production status and remote video monitoring of production scenes, as shown in Figure 2.

(2) The edge control platform calls the collection service of the 5G communication gateway application regularly at intervals of 30 ms based on the HTTP protocol. The address and parameters are formatted, encapsulated into JSON format data and responded to the edge control platform, so as to map the data of the production site to the network space. The edge control platform analyzes the address parameters, builds a real-time mirror image of production data inside the application, and pushes the real-time status to the remote control terminal through the WebSocket protocol, and relevant personnel can realize remote parameterized monitoring of the production process by accessing the remote control terminal interface .

The edge control platform pulls the job site monitoring video stream in real time according to the video stream address, and the video stream is sent back to the edge control platform through the 5G communication gateway. The edge control platform encodes and transcodes the video, and converts video stream slices into multiple small files for storage. The remote control terminal obtains video files based on the HTTP protocol and displays them in real time, thereby realizing remote video monitoring of production scenarios.

In order to meet the real-time control of 1 millisecond or less and ensure the reliable operation of the system, the system has established a five-node remote control chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and stacked robot controllers. The link is transmitted based on the 5G network, and the task data is processed nearby based on edge computing. The remote control process is shown in steps 1 to 5 in Figure 3 .

The remote control terminal has the authority to set stacking tasks, control the loading and unloading of on-site equipment, adjust the processing status of the robot controller, and emergency stop. In the initial state of production, after the employees edit the processing tasks on the remote control terminal, they send the task data to the edge control platform through the HTTP protocol, and the edge control platform verifies the task parameters. Tasks are automatically optimized. On the premise of ensuring the complete execution of the current task and the original task, the calculation of the shortest operation time of all tasks is performed, so as to construct the optimal mapping between the station and the task. After the task assignment calculation is completed, the global robot trajectory Optimizing for the lowest overall energy consumption. According to the optimization results, the edge control platform sends the control parameters to the 5G gateway application through the 5G network, and the gateway application performs protocol and data type conversion to set the PLC controller and robot controller parameters, that is, the stator core is stacked every 50 milliseconds Collaborative control uses the edge control platform to perform a parameter optimization, the PLC controller updates the status and control output of each device on site every 2 milliseconds, and the robot controller performs position closed-loop control every 0.5 milliseconds. When the stacking operation is in progress, the remote control terminal only has the authority to stop emergency and adjust processing tasks.

In order to promote the interconnection of various production-related systems and reduce the impact of employee efficiency on production continuity, a closed-loop control chain of four system nodes, including the operating system, edge control platform, material management system, and AGV system, was constructed. The closed-loop control process is shown in steps 6 to 11 in Figure 3 .

When there are production stoppage scenarios such as material shortage and return at designated stations in the production process, the control right of the equipment is transferred to the edge control platform. The edge control platform uses multi-threading technology to perform multi-dimensional analysis and calculation on the production image, integrating business continuity conditions and According to the current task requirements, standard business continuity parameters are formulated, and the decision-making data is sent to the material management system. The material management system integrates the materials, and then sends the task parameters to the AGV system responsible for material transportation, and the AGV system transports the materials to the stacker. After the designated station of the assembly system, the ready state of the material is captured by the edge control platform, which controls the stacking system to perform loading or unloading operations, so that the production continues to run, and the control of the equipment is transferred to the on-site PLC controller and the stacking machine again. Install the robot controller. Through the background computing and system communication of the edge control platform, it replaces the on-site manual operation of employees and effectively breaks the "data island" of the stacking system.

In addition to the above control process, in order to consider the safety of stacking operations, an automatic remote control switch is set on site, and the system administrator with system control rights sends instructions to the on-site PLC controller through the edge control platform, and at the same time, the processing personnel set the PLC input on site Signal to realize the switch between on-site operation and remote automatic control. The system administrator has the priority, and the input signal of the on-site personnel will be valid only if the switch command is issued by him. When the switch is turned on, closed-loop control and real-time control can be realized on the remote control terminal through the application. When the switch is turned off, the remote control is turned off, and the processing personnel can control it on site.

Claims (6)

1. The edge control system of the generator stator core stacking robot is characterized in that it includes an operation system, an operation assistance system, a 5G communication gateway, a collaborative control application for the generator stator core stacking, and a remote control terminal. The core stacking collaborative control application is the brain of the system to build a unified and effective connection. The operation system is the executive mechanism of the stator core stacking process, which is the core data source of the edge control system. Its main body is composed of stacking workbench, industrial robot, and various position, speed, and pressure sensors. The main control PLC is used as the on-site control Core, integrating on-site processing information and environmental sensing information; The operation assistance system is mainly composed of material management system, AGV system and monitoring system; the material management system digitizes the material information on the production site through seamless integration with resources such as factory logistics, warehousing and production lines; the AGV system conducts unified management of AGV , including the upper scheduling of materials and the positioning of AGVs, environmental perception, path planning, and guidance control; the monitoring system is mainly composed of three major parts: front-end cameras, network transmission equipment, and back-end control and display parts. Conduct continuous monitoring to achieve intuitive perception of the target system or target processing equipment; The 5G communication gateway is an on-site communication device. With the help of the 5G communication capability of the gateway, the workshop equipment can be connected to the 5G network environment; the collection and delivery application is deployed inside the gateway, and on-site computing power is provided at the edge of the operating system. By communicating with the main control PLC, Provide services for collecting downstream operating system information and issuing upstream task information, and realize the interconnection between the generator stator core stacking collaborative control application and the operating system through the conversion of protocols and data types; The stator core stacking collaborative control application, hereinafter referred to as the edge control platform, is deployed on the MEC node server, based on the B/S architecture, that is, the browser/server architecture, as the core computing control center of the system, and builds the unified interaction of each system; The cross-shop scheduling terminal is the client corresponding to the edge control platform, which directly interacts with the user to realize the user's comprehensive perception of the processing process and remote assistance. 2. The control method of the generator stator core stacking robot edge control system according to claim 1, characterized in that it includes remote monitoring, remote control and closed-loop control. The system builds a five-node remote monitoring chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and on-site cameras. The link is based on 5G network for transmission and edge computing for nearby processing of monitoring data; The system has established a five-node remote control chain consisting of remote control terminals, edge control platforms, 5G communication gateways, on-site PLC controllers, and stacked robot controllers. deal with; The system builds a closed-loop control chain of four system nodes: operating system, edge control platform, material management system, and AGV system. 3. The control method of the generator stator core stacking robot edge control system according to claim 2, characterized in that the remote monitoring process includes two aspects: parametric monitoring of production status and remote video monitoring of production scenes : (1) The edge control platform calls the collection service of the 5G communication gateway application regularly based on the HTTP protocol at an interval of 30 ms. The address and parameters are formatted, encapsulated into JSON format data and responded to the edge control platform to realize the mapping of the data on the production site to the network space; the edge control platform parses the address parameters and builds a real-time mirror image of the production data inside the application, through WebSocket The protocol pushes the real-time status to the remote control terminal, and relevant personnel can realize remote parameterized monitoring of the production process by accessing the remote control terminal interface; (2) The edge control platform pulls the job site monitoring video stream in real time according to the video stream address, and the video stream is sent back to the edge control platform through the 5G communication gateway; the edge control platform encodes and transcodes the video, and converts the video stream slices into multiple Small files are saved; the remote control terminal obtains video files based on the HTTP protocol and displays them in real time, thereby realizing remote video monitoring of production scenarios. 4. The control method of the edge control system of the generator stator core stacking robot edge control system according to claim 2, characterized in that, the described remote control process is: The remote control terminal has the authority to set stacking tasks, control the loading and unloading of on-site equipment, adjust the processing status of the robot controller, and emergency stop authority; in the initial state of production, after the employees edit the processing tasks on the remote control terminal, they send the task data through the HTTP protocol It is sent to the edge control platform, and the edge control platform verifies the task parameters. Under the premise of satisfying the legality, the task is automatically optimized in combination with real-time production mirroring. On the premise of ensuring that the current task and the original task can be fully executed, all Calculation of the shortest task operation time, so as to construct the optimal mapping between the station and the task. After the task allocation calculation is completed, the overall energy consumption of the global robot trajectory is optimized; the edge control platform uses the 5G network to download the control parameters according to the optimization results Send it to the 5G gateway application, and the gateway application performs protocol and data type conversion to set the parameters of the PLC controller and robot controller, that is, every 50 milliseconds, the edge control platform of the stator core stacking collaborative control application performs parameter optimization, and the PLC controller The status update and control output of each equipment on site is performed every 2 milliseconds, and the robot controller performs position closed-loop control every 0.5 milliseconds; when stacking operations are in progress, the remote control terminal only has the authority to stop emergency and adjust processing tasks. 5. The control method of the edge control system of the generator stator core stacking robot according to claim 2, characterized in that, the closed-loop control process is: When there is a shortage of materials at a designated station or production halts in the production process, the control of the equipment is transferred to the edge control platform. The edge control platform uses multi-threading technology to perform multi-dimensional analysis and calculation of the production image, and integrates business continuity conditions and current conditions. Task requirements, formulate standard business continuity parameters, send the decision data to the material management system, and the material management system will integrate the materials, and then send the task parameters to the AGV system responsible for material transportation, and the AGV system will transport the materials to stacking After the station is designated by the system, the ready state of the material is captured by the edge control platform, and the edge control platform controls the stacking system to perform loading or unloading operations, so that the production continues to run, and the control of the equipment is transferred to the on-site PLC controller and the stacking machine again. Robot controller; through the background computing and system communication of the edge control platform, it replaces the on-site manual operation of employees. 6. The control method of the edge control system of the generator stator core stacking robot according to claim 2, characterized in that it also includes setting an automatic remote control switch on site, and the system administrator with the system control right, through the edge The control platform sends instructions to the on-site PLC controller, and at the same time, the processing personnel set the PLC input signal on the spot to realize the switching between on-site operation and remote automatic control. Effective; when the switch is turned on, the application can realize closed-loop control and real-time control on the remote control terminal; when the switch is turned off, the remote control is turned off, and the processing personnel can control it on site.

Images