CN-121973102-A - System and method for monitoring and automatically replacing consumable life of mobile polishing robot

CN121973102ACN 121973102 ACN121973102 ACN 121973102ACN-121973102-A

Abstract

The invention discloses a consumable life monitoring and automatic replacing system and method for a mobile polishing robot, and relates to intelligent manufacturing and industrial robots. The method comprises the steps of comparing the preprocessed working current with a failure threshold value through a consumable life monitoring algorithm, and judging whether the current consumable is failed. This life-span judgement based on working current carries out avoids the consumptive material extravagant and the fluctuation of processingquality. The polishing head is controlled to be contacted with the stripping mechanism based on Z-axis displacement and millstone pressure control force through a consumable replacement control algorithm, and the current consumable is torn off through the resistance of the stripping mechanism. The complex action is completed by utilizing the motion capability of the mobile polishing robot, so that the failure rate is reduced. And the movable polishing robot moves above the rigid reference surface, controls the Z-axis to downwards detect, and judges whether the current consumable material is successfully dropped off or not based on the Z-axis displacement. Consumable replacement verification is performed through negative pressure adsorption detection, visual detection or a rigid reference surface. Through the double verification steps, the reliability problem in unmanned operation is solved.

Inventors

LI JIABAO
WANG CHENGJUN
HOU XINLI
ZHANG YUEPENG
YE DONGDONG
LIU HOULI
Bao Suya
WANG BUYUN
ZHU MING

Assignees

安徽工程大学
南京绥德自动焊接装备有限公司

Dates

Publication Date: 20260505
Application Date: 20260401

Claims (10)

1. The consumable life monitoring and automatic replacing system of the mobile polishing robot is characterized by comprising the mobile polishing robot and a consumable replenishing device; the movable polishing robot comprises a controller, a force control polishing head, a tray interface, a main shaft current sensor, a displacement sensor and a pressure sensor; the force control polishing head is connected with consumable materials through a tray interface; the displacement sensor and the pressure sensor are respectively used for acquiring Z-axis displacement and millstone pressure of the force control polishing head; The consumable life monitoring algorithm is used for carrying out real-time analysis on the consumable life based on real-time working current, and the consumable replacement control algorithm is used for controlling the movable polishing robot to automatically replace consumable in the consumable supply device based on Z-axis displacement and millstone pressure; the consumable supply device comprises a stripping mechanism and a consumable supply mechanism; the consumable feeding mechanism is used for containing new consumables to be replaced, and the stripping mechanism is used for stripping old consumables through the movable polishing robot through the protruding part.
2. The mobile grinding robot consumable life monitoring and automatic replacement system of claim 1, wherein the tray interface is located on a bottom surface of the force-controlled grinding head grinding disc.
3. The system for monitoring and automatically replacing consumable parts of a mobile grinding robot of claim 1, wherein the tray interface is a velcro.
4. The mobile grinding robot consumable life monitoring and automatic replacement system of claim 1, wherein the stripping mechanism is a metal spade or a barbed rack.
5. The system for monitoring and automatically replacing consumable supplies of a mobile grinding robot according to claim 1, wherein a spring jack is arranged at the bottom of the consumable supply mechanism for keeping a new consumable to be replaced at a fixed height.
6. The system for monitoring and automatically replacing consumable parts of a mobile grinding robot according to any one of claims 1 to 5, wherein the consumable part replenishment device further comprises a rigid reference surface; and the rigid reference surface is used for judging whether the invalid consumable is successfully stripped or installed based on Z-axis displacement.
7. A method for monitoring and automatically replacing consumable life of a mobile grinding robot, which is applied to the system for monitoring and automatically replacing consumable life of a mobile grinding robot according to any one of claims 1 to 6, comprising: in the polishing process, the spindle current sensor collects real-time working current of the spindle motor in real time and uploads the real-time working current to the controller; preprocessing the real-time working current through the consumable life monitoring algorithm, comparing the preprocessed working current with a failure threshold value, and judging whether the current consumable fails; If the current consumable fails, the mobile polishing robot pauses operation, records the current breakpoint coordinates and moves to the consumable supply device; the force control polishing head is controlled to be contacted with the stripping mechanism based on Z-axis displacement and millstone pressure by the consumable replacement control algorithm, and the current consumable is torn off by the resistance of the stripping mechanism; the movable polishing robot moves to a consumable feeding mechanism, and controls the Z-axis of the force control polishing head to be pressed downwards, so that the tray interface is connected with consumable to be replaced; and returning the movable polishing robot to the previous breakpoint coordinates, and continuing polishing operation.
8. The method for monitoring the life of consumable parts and automatically replacing a movable polishing robot according to claim 7, further comprising, after tearing off the current consumable part by resistance of the peeling mechanism: the movable polishing robot moves to the position above the rigid reference surface, and the Z-axis downward detection is controlled until the pressure of the grinding disc reaches a preset value; And acquiring Z-axis displacement, and judging whether the current consumable is successfully dropped or not based on the Z-axis displacement.
9. The method for monitoring and automatically replacing consumable parts of a mobile grinding robot according to claim 7, further comprising, after the tray interface is connected to the consumable part to be replaced: The movable polishing robot lifts the force control polishing head, and consumable replacement verification is performed through negative pressure adsorption detection, visual detection or a rigid reference surface.
10. The method for monitoring and automatically replacing consumable life of a mobile grinding robot according to claim 7, wherein the consumable life monitoring algorithm performs a consumable life analysis process, comprising: And if the working current is smaller than the failure threshold value within the continuous preset time, confirming that the current consumable is failed.

Description

System and method for monitoring and automatically replacing consumable life of mobile polishing robot Technical Field The invention relates to the field of intelligent manufacturing and industrial robots, in particular to a system and a method for monitoring and automatically replacing consumable materials of a mobile polishing robot. Background In the surface treatment of large-sized workpieces such as roughening of high-speed railway floors, polishing of wind power blades and the like, a robot needs to continuously operate for a long time. The polishing consumable (sand paper/scouring pad) belongs to a high-frequency vulnerable part, and the state of the polishing consumable directly influences the operation quality. The following pain points currently exist: 1. The life judgment is based on guessing that the prior art adopts a fixed time method or a fixed area method to replace consumable materials. If the consumable is worn, the consumable is replaced, so that waste is caused, and if the consumable is worn (if the hard spot fails in advance), the consumable is still worn, the workpiece can be slipped or burned. 2. The manual replacement efficiency is low, the AGV moves in a wide workshop, if the AGV needs to be manually replaced, the AGV needs to be stopped to wait for workers to walk, and the OEE (equipment comprehensive efficiency) is extremely low. After the robot changes the sand paper, the robot does not know that the sand paper is stuck to the bottom and is not stuck firmly, or the old sand paper is torn cleanly, and the accidents of paper stacking or paper falling often occur. Disclosure of Invention In view of the above, the invention provides a system and a method for monitoring and automatically replacing consumable materials of a mobile polishing robot, which are used for solving the problems of inaccurate consumable material life monitoring and low efficiency of manually replacing consumable materials in the conventional consumable material life monitoring and replacing method of the polishing robot. In order to achieve the above object, the following schemes are proposed: a consumable life monitoring and automatic replacement system of a mobile polishing robot comprises the mobile polishing robot and a consumable supply device; the movable polishing robot comprises a controller, a force control polishing head, a tray interface, a main shaft current sensor, a displacement sensor and a pressure sensor; the force control polishing head is connected with consumable materials through a tray interface; the displacement sensor and the pressure sensor are respectively used for acquiring Z-axis displacement and millstone pressure of the force control polishing head; The consumable life monitoring algorithm is used for carrying out real-time analysis on the consumable life based on real-time working current, and the consumable replacement control algorithm is used for controlling the movable polishing robot to automatically replace consumable in the consumable supply device based on Z-axis displacement and millstone pressure; the consumable supply device comprises a stripping mechanism and a consumable supply mechanism; the consumable feeding mechanism is used for containing new consumables to be replaced, and the stripping mechanism is used for stripping old consumables through the movable polishing robot through the protruding part. Preferably, the tray interface is positioned on the bottom surface of the grinding disc of the force control grinding head. Preferably, the tray interface is a magic tape. Preferably, the stripping mechanism is a metal shovel or a barbed rack. Preferably, a spring jacking device is arranged at the bottom of the consumable feeding mechanism and used for keeping the to-be-replaced new consumable at a fixed height. Preferably, the consumable supply device further comprises a rigid reference surface; The rigid datum plane is used for the mobile polishing robot to judge whether old consumables are successfully stripped or not. A consumable life monitoring and automatic replacement method for a mobile polishing robot is applied to the consumable life monitoring and automatic replacement system of the mobile polishing robot, and comprises the following steps: in the polishing process, the spindle current sensor collects real-time working current of the spindle motor in real time and uploads the real-time working current to the controller; preprocessing the real-time working current through the consumable life monitoring algorithm, comparing the preprocessed working current with a failure threshold value, and judging whether the current consumable fails; If the current consumable fails, the mobile polishing robot pauses operation, records the current breakpoint coordinates and moves to the consumable supply device; the force control polishing head is controlled to be contacted with the stripping mechanism based on Z-axis displacement and millstone pressure by the consumable re