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CN-122010017-A - High-safety multifunctional transfer robot and control method thereof

CN122010017ACN 122010017 ACN122010017 ACN 122010017ACN-122010017-A

Abstract

The invention relates to a high-safety multifunctional transfer robot and a control method, wherein the robot comprises a vehicle body and a lifting fork, an industrial personal computer, a safety PLC (programmable logic controller) and a driving assembly are arranged in the vehicle body, travelling wheels are further arranged at the bottom of the vehicle body, a navigation radar and an obstacle avoidance camera are further arranged at the top of an upright post, the obstacle avoidance radar is further arranged in front of the bottom of the vehicle body, the industrial personal computer controls the vehicle body to automatically walk through monitoring data of the navigation radar, the obstacle avoidance camera and the obstacle avoidance radar, a collision plate is further arranged at the joint of the lifting fork and the vehicle body, a pallet identification camera is further arranged at the upper part of the collision plate, a bottom radar is further arranged at the lower part of the rear end of the vehicle body, a fork tip camera and a fork tip radar are respectively arranged at the rear ends of the two lifting forks, and the industrial personal computer controls the lifting fork to automatically lift through the collision plate, the pallet identification camera, the bottom radar, the fork tip camera and the monitoring data of the fork tip radar. The robot provided by the invention has the capacity of omnibearing environment sensing, high-precision autonomous operation and multiple safety redundant control.

Inventors

  • ZHANG AO
  • YANG FANGBING
  • WEN YONGXIANG
  • SHI SHENGHUA

Assignees

  • 浙江中力机械股份有限公司

Dates

Publication Date
20260512
Application Date
20260327

Claims (10)

  1. 1. The utility model provides a multifunctional transfer robot of high security, includes automobile body (1) and sets up lift fork (3) at automobile body (1) rear portion, the both sides of automobile body (1) still are equipped with stand (2), be equipped with steering indicator lamp (23), reset button (24), scram button (25) and touch-sensitive screen (27) on stand (2), still be equipped with operating handle (11) on automobile body (1), be equipped with industrial computer, safe PLC controller and drive assembly in automobile body (1), the bottom of automobile body (1) still is equipped with walking wheel (19), through operating handle (1) manual control automobile body (1) and lift fork (3) action, wherein the top of stand (2) still is equipped with navigation radar (21) and obstacle avoidance camera (22), the both sides of automobile body (1) still are equipped with ultrasonic radar (17), two bights in front of automobile body (1) bottom still are equipped with obstacle avoidance radar (13), start automatic task through touch-sensitive screen (27), industrial computer (21), obstacle avoidance camera (17), automobile body (1) and automatic obstacle avoidance camera (17) are connected with ultrasonic wave (13) in order to monitor that the lift fork (3) move, the upper portion of striking board (33) still is equipped with pallet identification camera (34), the lower part of automobile body (1) rear end still is equipped with bottom radar (35), and the rear end of two lift forks (3) is equipped with fork point camera (31) and fork point radar (32) respectively, industrial computer is through the monitoring data who strikes board (33), pallet identification camera (34), bottom radar (35), fork point camera (31) and fork point radar (32), and control lift fork (3) is automatic to go up and down.
  2. 2. The multifunctional transfer robot with high safety according to claim 1, wherein the driving assembly comprises a driving installation seat (100), a traveling motor (101) and a steering motor (104), the traveling motor (101) is rotatably arranged on the driving installation seat (100), the steering motor (104) is fixed on the driving installation seat (100) and drives the traveling motor (101) to rotate through gear engagement, the output end of the traveling motor (101) drives the traveling wheel (19) to rotate, an encoder (102) is further arranged on the traveling motor (101), and a rotary proximity switch (103) is further arranged on the driving installation seat (100).
  3. 3. The multifunctional transfer robot with high safety according to claim 1, wherein a power switch (12) is further arranged on one side of the vehicle body (1) positioned on the operating handle (11), an automatic charging port (15) is further arranged on the lower portion of one side of the vehicle body (1), an anti-collision strip (18) is further arranged on the lower portion of the vehicle body (1), and a turnover pedal (16) is further arranged on the rear portion of the vehicle body (1).
  4. 4. The multifunctional transfer robot with high safety according to claim 1, wherein the top of the upright post (2) is further provided with a voice module (26) and a warning lamp (28), and the industrial personal computer provides warning signals in an acousto-optic mode through the voice module (26) and the warning lamp (28).
  5. 5. The method for controlling a high-safety multifunctional transfer robot according to claim 2, comprising the steps of: The industrial personal computer receives tasks to control the robot to carry out carrying work, the robot runs to a loading area through a navigation track, pallet identification is carried out through a pallet identification camera (34) above the lifting fork (3) after the preset purpose is achieved, the lifting fork (3) can be accurately inserted into a tray to be carried, the tray is triggered to collide with a plate (33), and the robot runs to a destination according to a planned path after acquiring a goods loading in-place state; In the robot conveying process, the moving direction, the speed and the turning direction of the robot are monitored through an encoder (102) of a walking motor (101) and a rotary proximity switch (103), speed limiting and switching of radar obstacle avoidance areas are carried out according to safety requirements, turning stability is guaranteed, meanwhile, 360-degree obstacle avoidance of the robot is achieved through an obstacle avoidance camera (22), an obstacle avoidance radar (13), a bottom radar (35), a fork tip camera (31) and a fork tip radar (32), the robot also carries out space-filling identification of a bin through the obstacle avoidance radar (13) in front, autonomous sensing of the bin is achieved, and idle bin automatic unloading is selected according to the actual space-filling condition of the bin.
  6. 6. The method for controlling a high-safety multifunctional transfer robot according to claim 5, wherein the pallet recognition process is as follows: Firstly, a robot synchronously acquires RGB images and depth point cloud data of a target area through a pallet identification camera (34) above a lifting fork (3), an industrial personal computer adopts a depth learning target detection and posture estimation model to extract characteristic points of a pallet in real time, and the six-degree-of-freedom space posture of the pallet under a camera coordinate system is calculated by combining the depth ranging data; Then, the industrial personal computer converts and maps the calculated tray pose data under the coordinate system of the pallet recognition camera (34) to the base coordinate system of the robot in real time through a pre-calibrated hand-eye relation matrix to generate target docking coordinates; And finally, the industrial personal computer receives the deviation value of the target coordinate and the current vehicle body (1) coordinate, a dynamic track planning algorithm is adopted to generate an approximation route, a pallet recognition camera (34) continuously tracks the target in the moving and lifting fork action process of the robot, and a fine adjustment compensation instruction is issued in real time to drive the vehicle body (1) and the lifting fork (3) to adjust the posture, so that the lifting fork (3) is accurately inserted into the pallet.
  7. 7. The method for controlling a high-safety multifunctional transfer robot according to claim 5, wherein the library empty-full recognition process is as follows: Firstly, a robot approaches a target warehouse area according to a set navigation track, 2 obstacle avoidance radars (13) at the front bottom of a vehicle body (1) are activated, an industrial personal computer performs space-time synchronization and splicing fusion on point cloud/two-dimensional profile data scanned by double radars, a blind area of a single radar is eliminated, and then, a region of interest of a current warehouse position to be detected is dynamically defined in a fused data frame according to a priori global map coordinate of the warehouse area; Then, the industrial personal computer carries out filtering denoising on the scanning data in the interested area, eliminates interference noise points such as ground reflection and the like, counts effective reflection points in the interested area through a set obstacle clustering algorithm or a scanning line density threshold judgment mechanism, judges that the bin state is full if the size of an effective clustered object or the point cloud density exceeds a set full load threshold; And finally, after the robot completes the state calculation locally, packaging the library ID and the empty/full state label into a simplified state message, reporting the simplified state message to the global scheduling system in real time through a wireless communication network, updating a background library state matrix by the scheduling system according to the state matrix, and dynamically redirecting the robot searching for the unloading point to the nearest real idle library according to the optimal path allocation principle.
  8. 8. The method for controlling a high-safety multifunctional transfer robot according to claim 5, wherein the obstacle avoidance camera (22) is in communication with an industrial personal computer through a USB, when an obstacle enters a warning area set by a point cloud, the industrial personal computer transmits an audible alarm and visual alarm reminding to an I/O control board module, meanwhile, the industrial personal computer transmits a light deceleration command to a CURTIS F a controller through a CAN communication, the CURTIS F a controller performs light deceleration through a torque braking function control mode, when the obstacle enters the deceleration area set by the point cloud, the industrial personal computer transmits a clear deceleration command to a CURTIS F a controller through the CAN communication, the CURTIS F a controller performs clear deceleration through a torque braking function control mode, and when the obstacle enters a parking area set by the point cloud, the industrial personal computer transmits a parking command to the CURTIS F a controller through the CAN communication, and the CURTIS F a controller performs deceleration and braking through a torque braking function.
  9. 9. The method for controlling a highly safe multifunctional transfer robot according to claim 5, wherein the two obstacle avoidance radars (13) and the one bottom radar (35) of the vehicle body (1) respectively access point cloud data to an industrial personal computer, the industrial personal computer performs safety logic processing according to the point cloud distance data fed back by the radars in real time, and the vehicle automatically runs, When the obstacle enters the warning area set by the point cloud, the industrial personal computer transmits the warning information to the voice alarm and the I/O control board module through CAN communication to carry out audible and visual alarm reminding, when the obstacle enters the deceleration area set by the point cloud, the industrial personal computer transmits a speed reducing command to the CURTIS F A controller through CAN communication, the CURTIS F A controller decelerates in a torque braking function control mode, and when the obstacle enters the parking area set by the point cloud, the industrial personal computer transmits a parking command to the CURTIS F A controller through CAN communication, and the CURTIS F A controller decelerates through a torque braking function and brakes; Simultaneously, three radars respectively take two paths OSSID of normally closed signals as input signals to be connected into a safety PLC controller, the safety PLC controller detects OSSID signals in real time, when a vehicle runs automatically and an obstacle enters a safety protection area set by point cloud, the radars disconnect the output of two paths OSSID, the safety PLC controller cuts off two paths of main contactors of a bottom layer controller, the normally closed auxiliary contacts of the main contactors are detected in real time to form closed loop control as feedback signals, then power supplies of CURTIS F A and 1220E controllers are cut off through the main contactors to cut off a brake, and when the obstacle leaves a red protection area, the radars release a triggering state, delay 3S and carry out audible and visual alarm prompt, and the vehicle starts and continues to execute tasks.
  10. 10. The method for controlling a high-safety multifunctional transfer robot according to claim 5, wherein the fork point camera (31) and the fork point radar (32) perform safety detection of the running direction during reversing, the coverage area is larger than the maximum width of the vehicle body (1) and cargoes, the fork point camera (31) and the fork point radar (32) detect surrounding object information, the detection range is a plane horizontal to the ground, the industrial personal computer performs safety logic processing according to the real-time feedback point cloud distance data, the point cloud data is divided into a warning area, a deceleration area and a parking area, and corresponding actions are executed.

Description

High-safety multifunctional transfer robot and control method thereof Technical Field The invention relates to the technical field of logistics storage automation equipment, in particular to a high-safety multifunctional transfer robot and a control method thereof. Background With the vigorous development of electronic commerce and the deep advancement of the industrial 4.0 strategy, intelligent logistics and automatic warehousing systems have become key to improving the core competitiveness of enterprises. As core equipment for realizing automatic material handling, AGVs (Automated Guided Vehicle, automated guided vehicles) and AMR (Autonomous Mobile Robot, autonomous mobile robots) are widely used in manufacturing lines, warehouse centers, port terminals, and other scenarios. The automatic logistics system can replace manual work to finish heavy and repeated carrying tasks, so that logistics efficiency is remarkably improved, and operation cost is reduced. The conventional transport robots in the market are various in types, and can be classified into magnetic stripe navigation, two-dimensional code navigation, laser navigation, natural navigation and the like in the navigation mode, and can be classified into a latent type, a traction type, a forklift type and the like in the function. The forklift type carrying robot can be directly abutted to the standard pallet without modifying a goods shelf, and takes the dominant role in pallet carrying scenes. However, the conventional forklift-type transfer robot still has the following drawbacks in practical application: 1. The safety protection of the existing products is mostly dependent on a single type of sensor (such as laser radar), and dead zones exist in a protection area, particularly short obstacles (such as scattered cartons and pallet fragments on the ground), suspended obstacles (such as protrusions below fork tips) and insufficient protection of the rear part of a vehicle body. In a complex environment with high dynamic state and personnel and vehicles mixed, 360-degree dead angle-free safety protection in the true sense cannot be realized, and collision accidents are easy to occur, so that goods are damaged or personnel are injured. In addition, the traditional safety measures such as emergency stop and reset are mostly independent electric elements, and intelligent safety logic deeply integrated with a control system is lacked. 2. The intelligent degree of autonomous operation is not high, and the traditional automatic pallet carrying is often required to accurately limit the pallet placement position or carry out large-scale modification on a warehouse (such as labeling a two-dimensional code on a goods shelf). When the robot is in butt joint with the tray, if the position of the tray is slightly deviated, the position of the tray cannot be accurately identified, so that the picking is failed. In the unloading link, the robot can only put goods into a specified bin position according to a preset instruction, can not autonomously sense whether the bin position is occupied, and can cause task failure or even cause system confusion once the bin position is misoccupied or information is input error, manual intervention is required, and the handling efficiency is seriously affected. 3. The integration level and the synergy of the control system are insufficient, in the prior art, the functions of walking control, safety monitoring, task scheduling and the like of the robot are often realized by splicing a plurality of scattered controllers (such as independent motion controllers, safety relays and industrial personal computers), the communication protocol between the controllers is complex, and the cooperative response speed is low. Especially when the sensor detects the response of the controller and then the link from the action of the actuator is long when the sensor faces the sudden obstacle, and the quick response of the high safety level requirement is difficult to meet. Meanwhile, the information interaction between the robot and an upper scheduling system (WMS/WCS) is not real-time and rich enough, the scheduling system cannot learn the real-time state of the library position, so that the path planning is stiff, and the overall operation efficiency of the system is difficult to optimize. 4. The human-computer interaction and teaching operation are inconvenient, namely, under the scene of needing manual intervention or manual operation, the traditional operation handle has single function and lacks an intuitive state display and convenient parameter setting interface. The operation flows of debugging, task issuing, state monitoring and the like of the robot are complex, and the technical requirements on operators are high, so that the rapid deployment and maintenance are not facilitated. In summary, the existing transfer robot still has a large lifting space in terms of safety, intelligence and usability, and is difficult to completely meet th