CN112623790B

CN112623790B - Sorting control method for accurate sorting and counting of materials

Info

Publication number: CN112623790B
Application number: CN202110257257.5A
Authority: CN
Inventors: 郭阳斌; 甘国龙; 薛广库
Original assignee: Chengdu Lianxing Technology Co Ltd
Current assignee: Chengdu Lianxing Technology Co Ltd
Priority date: 2021-03-10
Filing date: 2021-03-10
Publication date: 2021-10-29
Anticipated expiration: 2041-03-10
Also published as: CN112623790A

Abstract

The invention discloses a sorting control method for accurate sorting and counting of materials, which operates based on a sorting system and comprises the following steps: the control system receives the instruction, and then the picking system is started; the sorting tray rotates fast to sort the materials, and a counting sensor at a discharge hole of the sorting tray counts the sorting quantity; when the picking number is close to the target value, the rotating speed of the picking disc is reduced, stepping rotation is carried out, each stepping rotation enables the next material selecting hole of the material selecting disc of the picking disc to be overlapped with the material discharging hole of the material discharging disc of the picking disc, then pause is carried out, if the picking number does not reach the target value, stepping rotation is continued, and if the picking number exceeds the limited time, no material is counted, and the feeding hopper carries out blanking; the sorting tray stops rotating until the counting sensor detects that the blanking quantity reaches the target number; after the picking is finished, the control system operates the next picking instruction or waits for the next picking instruction, the method is high in efficiency and accurate in picking, and the picking disc effectively prevents the materials from being clamped through forward and reverse rotation.

Description

Sorting control method for accurate sorting and counting of materials

Technical Field

The invention belongs to the technical field of material sorting, and particularly relates to a sorting control method for accurate sorting and counting of materials.

Background

With the development of times, a material conveying mode becomes one of the modes for improving the working efficiency. The material conveying is to use an aerial cableway to convey bulk materials in the United states at first; various modern configurations of conveyor belt conveyors have subsequently emerged. As early as in uk belt conveyors appeared; next to this, spiral conveyors have appeared in the united states, steel belt conveyors in switzerland, inertia conveyors in uk and germany, etc. After that, the conveyor belt is influenced by the technical progress of mechanical manufacturing, motors, chemical industry and metallurgical industry, is continuously perfect, gradually develops from the completion of the conveying inside a workshop to the completion of the material handling inside an enterprise, between enterprises and even between cities, and becomes an indispensable component part of the mechanization and automation of a material handling system.

As the industry continues to evolve, the need for conveyor belts is not limited to transferring articles, but rather to screening, counting, etc. articles. The method is mainly applied to assembly production of mechanical and electronic products, and the problems of material sorting and counting are encountered before the products are assembled.

A method for accurately sorting materials is needed to sort the materials so as to ensure the sorting to be carried out smoothly.

The inventor finds that the prior arts have at least the following technical problems in the practical use process:

1. the traditional manual sorting has low efficiency and high error rate, cannot meet production requirements, and the application of an automatic sorting technology is immature, so that manual intervention is still needed for sorting materials.

2. The existing picking mode is difficult to accurately pick and easily causes less or more picking target quantity.

Disclosure of Invention

In order to overcome the defects, the inventor of the invention continuously reforms and innovates through long-term exploration and trial and multiple experiments and efforts, and provides a sorting control method for accurate sorting and counting of materials.

In order to achieve the purpose, the invention adopts the technical scheme that: provides a sorting control method for accurate sorting and counting of materials. The method is applied to a sorting system, the sorting system comprises a feed hopper and a sorting tray, the feed hopper is positioned above the sorting tray, a discharge hole of the sorting tray is provided with a counting sensor, the feed hopper is connected with the sorting tray through a control system, and the method comprises the following steps:

1) the control system receives a picking quantity requirement, and the picking system is started; 2) the sorting disc rotates rapidly to sort materials, and a counting sensor at a discharge port of the sorting disc counts the sorting quantity; 3) when the picking number is close to the target value, the rotating speed of the picking disc is reduced, stepping rotation is carried out to enable the next material selecting hole of the material selecting disc of the picking disc to be overlapped with the material discharging hole of the material discharging disc of the picking disc, then stopping is carried out, the counting sensor detects whether the blanking number reaches the target value or not, and if the picking number does not reach the target value, stepping rotation is continued; 4) in the sorting process of the step 2) or the step 3), materials are not counted after the limited time is exceeded, a feed hopper performs blanking, and the step 4) and the step 2) and the step 3) operate synchronously; 5) when the counting sensor detects that the blanking quantity reaches a target value, the picking disc stops rotating; 6) when the picking is finished, the control system runs the next picking instruction or waits.

According to the invention, a further preferable technical scheme is as follows: the sorting system comprises a feed hopper and a sorting tray, the feed hopper performs supplementary blanking on the sorting tray, counting is performed through a counting sensor at a discharge hole of the sorting tray, and the control system controls the operation of the feed hopper and the sorting tray; the sorting disc is formed by assembling a sorting disc with sorting holes on a discharge disc with discharge holes, the sorting disc is connected with a motor, and a control system controls the motor to control the rotation of the sorting disc.

According to the invention, a further preferable technical scheme is as follows: the material selecting disc respectively realizes positive rotation and reverse rotation relative to the material discharging disc, positive rotation selection is adopted in the step 2) and the step 3), when the material selecting disc is blocked and difficult to rotate, the control system detects that the current consumed by a motor of the material selecting disc rises, and if the current exceeds a preset value, the control system controls the motor to rotate reversely to drive the material selecting disc to rotate reversely.

According to the invention, a further preferable technical scheme is as follows: and the forward rotation is recovered after the material selecting plate of the selecting plate rotates reversely by 20-360 degrees.

According to the invention, a further preferable technical scheme is as follows: the control system is connected with the conveyor of the feed hopper, the motor of the picking tray and the counting sensor of the picking tray.

According to the invention, a further preferable technical scheme is as follows: the control system is connected with a plurality of groups of sorting systems, and different materials are filled into feed hoppers of different sorting systems.

According to the invention, a further preferable technical scheme is as follows: the limited time in the step 4) is 3-10 s.

According to the invention, a further preferable technical scheme is as follows: the target value is approached by 1-3 differences in the step 3).

According to the invention, a further preferable technical scheme is as follows: the dwell time in the step 3) is 0.1s-0.3 s.

Compared with the prior art, the technical scheme of the invention has the following advantages/beneficial effects:

1. the picking mode of two stages of the feed hopper and the picking disc is adopted for picking, the picking disc adopts stepping rotation when approaching a picking target, and the picking quantity of materials is accurately controlled.

2. The picking disc realizes fast picking by adopting a mode of combining fast rotation and stepping rotation, and the picking speed is high.

3. The forward rotation and the reverse rotation of the sorting tray are combined to prevent the materials from being blocked, and the forward rotation and the reverse rotation are combined to effectively drive the materials to fall down, so that the normal work of the sorting tray is guaranteed.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are required to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.

Fig. 1 is a flow chart of a sorting control method for accurate sorting and counting of materials according to the invention.

Fig. 2 is a schematic structural diagram of a picking system of an embodiment of the picking control method for accurate sorting and counting of materials.

FIG. 3 is a schematic diagram of the configuration of the picker tray of FIG. 2.

Fig. 4 is a rear view of fig. 3.

FIG. 5 is an exploded view of the picker tray of FIG. 2.

The labels in the figure are respectively: 100. picking disc 101, picking disc 102, discharging disc 103, power equipment 104, retainer ring 105, chassis 106, power mounting hole 107, material selecting hole 108 and discharging hole

200. The frame 300, the counter sensor 400, the conveyor 500, the shroud 600, and the feed hopper.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are a part of the embodiments of the present invention, not all of the embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention. Thus, the detailed description of the embodiments of the present invention provided below is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention.

It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it may not be further defined and explained in subsequent figures.

Example (b):

a picking control method for accurate sorting and counting of materials is based on a picking mechanism shown in figure 1 or a similar picking mechanism, the method is applied to a picking system, the picking system comprises a feed hopper 600 and a picking tray 100, the feed hopper 600 is positioned above the picking tray 100, a discharge port of the picking tray 100 is provided with a counting sensor 300, the feed hopper 600 is connected with the picking tray 100, and the method comprises the following steps:

1) the control system receives a picking quantity requirement, and the picking system is started;

2) the sorting disc 100 rotates fast to sort materials, and a counting sensor 300 at a discharge port (combination of a material sorting hole of the sorting disc and a discharge hole of the discharge disc) of the sorting disc 100 counts the sorting quantity;

3) when the picking number is close to the target value, the rotating speed of the picking disc 100 is reduced, stepping rotation is carried out, each stepping rotation enables the next material selecting hole of the material selecting disc of the picking disc to be overlapped with the material discharging hole of the material discharging disc of the picking disc, then stopping is carried out, the counting sensor detects whether the blanking number reaches the target value, if the picking number does not reach the target value, stepping rotation is continued, the operation is stopped when the picking number reaches the target value, and the step 5 is carried out; in the step, 0 or 1 material falls from the discharge hole during each stepping rotation, and then the counting sensor counts, and the interval of 0.1s-0.3s is arranged between the two stepping rotations, so that the counting sensor can count enough to ensure that the number of the materials cannot exceed or be less than the target picking number;

4) in the sorting process of step 2) or step 3), no material is counted after the limited time is exceeded, and the feeding hopper 600 performs blanking;

5) when the counting sensor 300 detects that the blanking amount reaches the target number, the picking tray 100 stops rotating;

6) when the picking is finished, the control system runs the next picking instruction or waits.

As shown in fig. 2, the sorting system comprises a feed hopper and a sorting tray, wherein the feed hopper is positioned above the sorting tray, the feed hopper and the sorting tray are both installed on the rack 200, and a protective cover 500 is arranged at the tail end of the feed hopper to prevent the falling material of the feed hopper from splashing and play a role in guiding. The discharge gate of selecting the dish is provided with count sensor, feeder hopper and selecting the dish connection control system.

Select dish 100 including selection dish and play charging tray, the assembly of selection dish is on the play charging tray, selects the rotation that the charging tray connected motor realization goes out the dish relatively, the interval is provided with the selection hole uniformly on the selection dish, and the material falls in the selection downthehole along with the selection dish rotates in the inside of play charging tray, is provided with the discharge opening on the play charging tray, when selecting the discharge opening and discharge opening coincidence, the material can fall under the effect of self gravity, count sensor 300 is located the discharge opening department of play charging tray (also is the discharge gate play of selecting the dish). The center of the discharging disc is a plane, the periphery of the plane is an inclined plane, the shape of the discharging disc is basically the same as the structure of the chassis of the material selecting disc, and the discharging hole in the discharging disc is arranged above the discharging disc, so that the material can fall conveniently.

However, due to reasons such as irregular material shapes, materials are clamped at a discharge port, and the like, the material selecting plate is designed to respectively realize forward rotation and reverse rotation relative to the discharge plate, forward rotation is adopted for selecting in the step 2) and the step 3), when the material selecting plate is blocked and is difficult to rotate, the material selecting plate rotates reversely, the materials can be effectively driven to move towards different directions by reverse rotation, the situation that the materials are clamped is eliminated, the forward rotation is recovered after the material selecting plate of the material selecting plate rotates reversely by 20-360 degrees, and in the same way, the material selecting plate can also adopt the direct rotation for selecting, and the forward rotation is eliminated again when the materials are clamped. The basis for judging the jamming is that when the material selecting disc is jammed and difficult to rotate, the control system detects that the current consumed by the motor of the material selecting disc rises, and when the current exceeds a preset value, the control system controls the motor to rotate reversely, wherein the preset value of the current is specifically determined according to the type of the motor, and the reference basis is the current of a short circuit when the motor is jammed and the current of the motor running relatively slowly. Meanwhile, it should be noted that the forward rotation and the reverse rotation are a relative concept, and are determined according to the last rotation state of the motor, for example, if the material selecting disc rotates clockwise to forward rotation, the reverse rotation is counterclockwise, and vice versa.

The lower end of the feed hopper 600 is provided with a conveyor 400, and the end of the conveyor 400 is positioned above the picking tray 100. The control system is connected with the conveyor 400 of the feed hopper 600, the motor of the picking tray 100 and the counting sensor 300 of the picking tray 100, the counter counts the picked materials, the counting sensor 300 is arranged at the discharge hole of the picking tray 100, and other counting modes can be adopted. The control system is a PLC, and the feed hopper 600 can be in a mode of arranging an electric inserting plate at the outlet of the hopper and the like, so long as controllable automatic blanking can be realized. The control system actually transmits the counting data to the control system according to the counting sensor 300, and then the control system controls the motor rotation of the conveyor 400 and the motor rotation of the picking tray 100 according to the feedback of the counting data, and the rotation of the two motors respectively realizes the control of the blanking and the picking.

The control system is connected with a plurality of groups of picking systems, different materials are loaded into feed hoppers 600 of different picking systems, the picking requirements of different materials are met, and the plurality of groups of picking systems can also pick the same material at the same time or partially at the same time to improve the picking speed.

In step 4) the limited time is 3-10s, and the selection is carried out according to specific picking requirements. Meanwhile, the time can be modified according to actual requirements and is not limited to 3-10 s. The target values in the step 3) are close to 1-3, and a space for controlling the material quantity in a stepping mode is reserved to ensure that the target number is not increased.

Meanwhile, the blanking number in the step 4) is controlled by the influence of the blanking speed and the blanking time, the blanking number can be roughly controlled by the blanking time after the blanking speed is preset, the blanking number needs to be determined according to actual conditions, and when the picking speed is required to be met, the materials cannot overflow the sorting tray 100 or collide with the sorting tray 100 in the rotation process of the sorting tray 100.

As shown in fig. 3, 4 and 5, the picking tray 100 includes a picking tray 101 and a discharging tray 102, the picking tray 101 is mounted on the discharging tray 102 and can rotate relative to the discharging tray 102 under the driving of a power device 103, and the picking tray 101 is attached to the discharging tray during mounting. Specifically, the material selecting disc 101 is composed of a retainer ring 104 and a base disc 105, and the retainer ring 104 is assembled on the periphery of the base disc 105. The center of the chassis 105 is a plane, the periphery of the plane is an inclined plane, a power mounting hole 106 is formed in the circle center of the chassis 105, the shape of the discharging disc 102 is basically the same as the structure of the chassis of the material selecting disc, and overlapping mounting is achieved. The discharging disc 102 is obliquely arranged on the mounting seat, and material selecting holes 107 are uniformly arranged on the material selecting disc 101 at intervals. A discharge hole 108 is arranged at the top of the discharge disc 102 corresponding to the material selecting hole 107. The material selecting holes 107 are arranged in a circular ring and are uniformly arranged on the outer edge of the chassis of the material selecting disc 101 at intervals. The diameter of the discharge hole 108 is larger than that of the material selecting hole 107, and preferably, the diameter of the discharge hole 108 is larger than that of the material selecting hole 107 and smaller than twice the diameter of the material selecting hole 107, so that blockage caused by too small discharge holes can be avoided, and the material is thrown into the discharge hole when the material selecting hole does not reach a specified position due to too large discharge holes, so that some unqualified materials are selected.

The discharging tray 102 is obliquely arranged on the mounting base 200, the installation inclination angle of the discharging tray 102 is 30-60 degrees, and the installation of the discharging tray 102 is 30 degrees, so that the situation that the materials cannot slide to the bottom due to the fact that the materials which do not meet the requirements cannot be caused by insufficient inclination angle when the material selecting tray 101 rotates, and the materials cannot be transmitted to the discharging hole due to too large angle is avoided. And the discharging disc, the material selecting disc and the mounting plate are integrally inclined. A counting sensor 300 is arranged at the discharge port of the picking disc and used for monitoring the speed of material selection and accurately monitoring the material selection amount.

The working principle is as follows: progress of selecting is fed back through photoelectric counting sensor, thereby control the opportunity of feeder hopper to selecting the inside interpolation material of dish, control the high-speed rotation and the step-by-step rotation of selecting the dish simultaneously, work at a high speed when great apart from the target data gap, it is fast to select, when comparatively approaching apart from the target data, adopt step-by-step rotation, it reduces to select the speed, the precision can be controlled easily, assist simultaneously with just reversing, the blanking time, parameter such as blanking figure is controlled and can be realized that high-speed material is selected in succession.

In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", and the like, indicate orientations and positional relationships based on those shown in the drawings, and are used only for convenience of description and simplicity of description, and do not indicate or imply that the equipment or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be considered as limiting the present invention.

In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

The above is only a preferred embodiment of the present invention, and it should be noted that the above preferred embodiment should not be considered as limiting the present invention, and the protection scope of the present invention should be subject to the scope defined by the claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and these modifications and adaptations should be considered within the scope of the invention.

Claims

1. A sorting control method for accurate sorting and counting of materials is characterized in that the method is operated based on a sorting system, and the method comprises the following steps:

1) the control system receives the picking quantity requirement, the picking system is started, the control system is connected with a plurality of groups of picking systems, and different materials are filled into feed hoppers of different picking systems;

2) the sorting disc rotates rapidly to sort materials, and a counting sensor at a discharge port of the sorting disc counts the sorting quantity;

3) when the picking number is close to the target value, the rotating speed of the picking disc is reduced, stepping rotation is carried out to enable the next material selecting hole of the material selecting disc of the picking disc to be overlapped with the material discharging hole of the material discharging disc of the picking disc, then stopping is carried out, the counting sensor detects whether the blanking number reaches the target value or not, and if the picking number does not reach the target value, stepping rotation is continued;

4) in the sorting process of the step 2) or the step 3), materials are not counted after the limited time is exceeded, a feed hopper performs blanking, and the step 4) and the step 2) and the step 3) run synchronously;

5) when the counting sensor detects that the blanking quantity reaches a target value, the picking disc stops rotating;

2. The sorting control method for precise sorting and counting of materials as claimed in claim 1, wherein the sorting system comprises a feeding hopper and a sorting tray, the feeding hopper performs supplementary blanking on the sorting tray, counting is performed through a counting sensor at the discharge port of the sorting tray, and the control system controls the operation of the feeding hopper and the sorting tray; the sorting disc is formed by assembling a sorting disc with sorting holes on a discharge disc with discharge holes, the sorting disc is connected with a motor, and a control system controls the motor of the sorting disc to control the rotation of the sorting disc.

3. The sorting control method for precise sorting and counting of materials according to claim 2, wherein the sorting tray respectively realizes forward rotation and reverse rotation relative to the discharging tray, forward rotation sorting is adopted in the step 2) and the step 3), when the sorting tray is jammed and difficult to rotate, the control system detects that the current consumed by the motor of the sorting tray rises, and when the current exceeds a preset value, the control system controls the motor to reversely rotate to drive the sorting tray to reversely rotate.

4. A sorting control method for accurate sorting and counting of materials as claimed in claim 3, wherein the forward rotation of the sorting tray is resumed after 20 ° -360 ° of reverse rotation.

5. The sorting control method for precise sorting and counting of materials as claimed in claim 1, wherein the control system is connected with and controls the conveyor of the feed hopper to control the falling of the materials, the control system is connected with and controls the motor of the sorting tray to rotate the sorting tray, and the control system is connected with the counting sensor of the sorting tray to obtain the data of the number of the dropped materials.

6. The method for controlling the sorting of the accurate sorting and counting of the materials according to claim 1, wherein the limited time in the step 4) is 3-10 s.

7. The method as claimed in claim 1, wherein the target value in step 3) is close to 1-3.

8. The sorting control method for accurate sorting and counting of materials as claimed in claim 1, wherein the pause time in step 3) is 0.1s-0.3 s.