基于 PLC 电气控制智能协作机器人的 CNC 上下料系统设计

Design of a CNC Loading/Unloading System Based on PLC-Controlled Intelligent Collaborative Robots

  • 摘要: CNC上下料系统受环境复杂多变的影响,相机采集的图像中包含大量不相关的特征,使得边缘检测过程中产生较多伪边缘点,工件定位不准确,导致上下料抓取点位的匹配误差增大,难以满足高精度加工需求。为此,设计基于PLC电气控制智能协作机器人的CNC上下料系统。首先,选用小型高性能的PLC作为核心控制器,设计带有自动交换视觉测头的在线视觉采集系统硬件;其次,对协作机器人视觉采集图像进行预处理后,结合图像亚像素级边缘定位技术对图像像素边缘进行划分与精确定位;最后,结合图像亚像素边缘定位结果,利用PLC程序对机器人的运动轨迹进行控制,实现上下料整个生产流程的自动化控制。测试结果表明:应用PLC电气控制智能协作机器人进行上下料抓取的过程中,针对轴承钢套5个抓取点位的匹配误差均低于0.05mm,上下料的位置误差可以始终保持在0.1mm以下,能够满足实际应用的抓取要求,使得机械臂上下料抓取更加精准,具有较好的实用性能。

     

    Abstract: CNC loading/unloading systems are often challenged by complex and dynamic environments, where camera-captured images contain excessive irrelevant features. This leads to numerous pseudo-edge points during edge detection, inaccurate workpiece positioning, and increased matching errors in grasping points, ultimately failing to meet high-precision machining requirements. To address these issues, this study designs a CNC loading/unloading system based on PLC-controlled intelligent collaborative robots. First, a compact high-performance PLC is selected as the core controller, and an online vision acquisition system hardware with an auto-switching visual probe is designed. Second, after preprocessing images captured by the collaborative robot’s vision system, sub-pixel edge localization technology is applied to partition and precisely locate pixel edges. Finally, leveraging the sub-pixel edge localization results, the PLC program controls the robot’s motion trajectory to achieve automated control of the entire loading/unloading process. Experimental results demonstrate that, during the grasping of bearing steel sleeves at five target points, the system achieves matching errors below 0.05 mm and positional errors consistently under 0.1 mm, fulfilling practical requirements. This approach significantly enhances the precision and reliability of robotic arm operations, demonstrating strong practical applicability.

     

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