CN112791967A - Abnormal part detection and flow regulation sorting method - Google Patents
Abnormal part detection and flow regulation sorting method Download PDFInfo
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- 238000003708 edge detection Methods 0.000 claims description 2
- 238000012216 screening Methods 0.000 abstract description 4
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/02—Measures preceding sorting, e.g. arranging articles in a stream orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/3412—Sorting according to other particular properties according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
- B07C5/362—Separating or distributor mechanisms
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The abnormal part detection and flow regulation sorting method marks the coordinate data and the position information of each package based on the application of an image recognition algorithm so as to identify whether abnormal parts such as overlapped parts exist or not, and then performs abnormal part elimination and normal part flow regulation operation by controlling a subsequent swinging and rotating device, thereby achieving the purposes of automatically screening the abnormal parts and directionally regulating and conveying the normal parts, providing sufficient preparation for the packages to enter a cross belt for sorting and automatic bar code scanning subsequently, and correspondingly improving the success rate of one-time single part scanning and the sorting operation efficiency. The abnormal part detecting and flow-adjusting sorting device comprises a visual identification device, an identification belt conveyor, a balance wheel sorting machine, a shunt belt conveyor and a reflux belt conveyor which are sequentially connected along the conveying direction.
Description
Technical Field
The invention relates to a device for detecting abnormal parcel and directionally conveying the abnormal parcel and a control method, belonging to the field of logistics sorting.
Background
In the logistics sorting operation field of the existing e-commerce and express delivery industries, a front-end manual piece loading operation mode is generally adopted, and a large number of packages which are piled up and enter a conveying line are manually separated so as to facilitate subsequent scanning and information input. At present, a plurality of field personnel are required to be configured in the front-end manual workpiece supply mode, sorting equipment generally runs at a high speed and cannot be stopped, accordingly, the requirement on the skill quality of manual workpiece feeding personnel is high, and the field labor intensity is high.
In case the problem that the processing speed of the upper piece of goods descends appears, a large amount of parcels can appear in the short time and concentrate and get into follow-up scanning letter sorting process and cause the phenomenon that goods overstock is serious, both scanning and letter sorting operation pressure have been increased rapidly, will directly lead to a large amount of unidentified parcels to circulate once more again and get into the upper piece and scanning process again to directly seriously influence the treatment effeciency of whole letter sorting operation, prolonged the repeated treatment time of some processes, reduced whole logistics storage efficiency and ability.
Also as a domestic prior application patent disclosing the following scheme, application number cn201910162842.x, entitled side-by-side object separation method and device. This object separator side by side includes a plurality of bar conveyer belts, a plurality of motor and the control unit that sets up side by side, the motor with bar conveyer belt one-to-one. The method comprises the steps that when a first object and a second object are detected to be side by side, the control unit obtains first position information of the first object and second position information of the second object, and the first strip-shaped conveyor belt set and the second strip-shaped conveyor belt set are controlled to run at different conveying speeds through a motor, so that the first object is separated from the second object. The separating device is provided with spacing grooves between adjacent strip-shaped conveyor belts, photoelectric sensors are arranged in the spacing grooves, the spacing grooves are located at the upstream positions of the objects on the conveying paths of the strip-shaped conveyor belts, and the photoelectric sensors are connected with the control unit. Controlling the first set of linear conveyors to transport the first object at the first speed by a first set of motors, and controlling the second set of motors to transport the second object at a third speed, the third speed being less than the first speed.
The above-mentioned prior applications have the following significant drawbacks and disadvantages: 1. how can a package being inspected and separated effectively be diverted before entering a different strip conveyor formed by adjacent compartments? How can the workload be adjusted between different conveyors simultaneously? The prior application does not provide enough technical solutions, and if manual intervention and manual scanning are still adopted, the scanning efficiency is still low, and the sorting efficiency is difficult to improve. 2. The problem that the position relation of common packages such as irregular parts, stacked parts and the like in a package queue is not effectively solved, and unnecessary workload is brought to subsequent automatic sorting and automatic scanning operations, so that the packages can only be manually sorted and scanned manually. 3. The prior art separates the disposition through sensor signal trigger mode, and processing speed is lower, is difficult to satisfy the field letter sorting operation demand of current high-speed, big batch parcel. 4. The separated parcels are still in a disordered discrete state and do not form a single queue, the subsequent single-code scanning operation is still not facilitated, the missing proportion is still large, and whether the subsequent parcels can be correctly conveyed to a cross belt cannot be guaranteed.
In view of this, the present patent application is specifically proposed.
Disclosure of Invention
The abnormal part detection and flow regulation sorting method is characterized in that the problems in the prior art are solved, coordinate data and position information of each package are marked based on an image recognition algorithm, whether abnormal parts such as overlapped parts exist or not is identified, and then abnormal part removing and normal part flow regulation operation is carried out by controlling a subsequent swing device, so that the purposes of automatically screening abnormal parts and directionally regulating and conveying normal parts are achieved, sufficient preparation is provided for package subsequent entering of cross belt sorting and automatic bar code scanning, and the success rate of one-time single part scanning and the sorting operation efficiency are correspondingly improved.
In order to achieve the design purpose, the abnormal part detection and flow regulation sorting method comprises the following implementation steps:
1) visual recognition
The method comprises the steps of entering packages of a recognition belt conveyor, photographing one by one through a visual recognition device to generate image information, and acquiring three-dimensional size data and real-time position coordinates of each package;
2) type mark
Identifying abnormal pieces according to the package images, marking the abnormal pieces to be subjected to subsequent rejection processing if the abnormal pieces belong to the normal pieces, sequentially numbering the normal pieces one by one if the normal pieces belong to the normal pieces, and counting the number of the normal packages in each conveying channel;
all the package information generated at the stage is sent to a PLC of the balance wheel sorting machine;
3) sorting flow regulation
After the parcels enter the balance wheel sorting machine, the parcels marked as abnormal pieces are directly swung and reversed to be conveyed to the backflow belt conveyor, and the parcels of normal pieces are continuously conveyed forward to the diversion belt conveyor;
according to the counted number of the parcels in each conveying channel in unit time, the flow is regulated among 2 independent conveying belt devices of the shunt belt conveyor through the swinging and rotating reversing of the balance wheel unit.
In summary, the abnormal part detecting and flow-adjusting sorting method has the following advantages:
1. can satisfy big batch parcel need not manual intervention and can carry out abnormal part screening automatically with handling in advance, be applicable to the full automatic operation demand of high-speed sorting machine, need not original artifical manual screening link and reduce artifical input in a large number.
2. The image recognition algorithm is adopted to simultaneously recognize, mark and calculate the coordinate and position information of a plurality of adjacent packages, and then counting and directional flow regulation are carried out before the packages enter different conveyor belts, so that the balanced distribution of the workload among the different conveyor belts is realized, and the package sorting efficiency and accuracy are improved integrally.
3. The system is favorable for realizing high-speed sorting and queue conveying of the batch packages, realizing the maximum speed of subsequent single-scanning operation, reducing the missing rate and improving the sorting operation efficiency.
Drawings
The invention will now be further described with reference to the following figures.
FIG. 1 is a schematic view of a separation and flow guiding device using an abnormal part detection and flow regulation sorting device according to the present application;
FIG. 2 is a top view of FIG. 1;
FIG. 3 is a schematic view of the structure of the conveying and detecting device;
fig. 4 is a schematic structural view of a balance sorter;
FIG. 5 is a schematic flow chart illustrating a method for detecting abnormal parts and sorting abnormal parts according to the present application;
FIG. 6 is a schematic diagram of a system module for implementing the method of the present application;
FIGS. 7-1 to 7-4 are schematic diagrams of the judgment criteria and examples of whether a parcel is abnormal or not, respectively;
Detailed Description
Embodiment 1, as shown in fig. 1 to 4, a separation and diversion apparatus including an abnormal component detection and flow adjustment sorting device according to the present application includes an online conveying device 1, a package separation device 2, a scattering separation device 3, a single piece separation device 4, a visual recognition device 5, a recognition belt conveyor 6, a balance wheel sorting machine 7, a diversion belt conveyor 8, and a return belt conveyor 9, which are sequentially connected in a conveying direction.
The parcel separation device 2 is provided with a plurality of belt conveyors connected in sequence along the gradient, a vertical height drop is formed between every two adjacent belt conveyors, and each belt conveyor is driven by an independent servo motor.
The scattering and separating device 3 comprises a plurality of belt conveyors arranged in a divergent state along the conveying direction, and each belt conveyor is driven by a separate servo motor.
The single-piece separating device 4 comprises a plurality of belt conveyors arranged in a matrix along the conveying direction, each belt conveyor is driven by a single servo motor, and the belt conveyor matrix forms 1 longitudinally extending middle isolation area and 2 transversely arranged and longitudinally extending conveying channels.
And visual recognition devices 5 are arranged vertically above the single piece separating device 4 and the recognition belt conveyor 6, each visual recognition device 5 comprises a plurality of 3D cameras 51, and the 3D cameras 51 are installed vertically downwards along the conveying direction of the packages.
The identification conveyor belt 6 corresponds to the individual separating device 4, which is also divided into 1 longitudinally extending intermediate separating zone and 2 transversely arranged and longitudinally extending conveyor paths.
The balance wheel sorting machine 7 is provided with a plurality of sorting modules 70 distributed in rows and columns, each sorting module 70 is provided with a plurality of balance wheel units 71 arranged in a row, and each sorting module 70 is driven by a single servo motor 72 to uniformly control the swinging angle and speed of the balance wheel units 71.
The shunt belt conveyor 8 is provided with 2 belt devices for independent conveying, 2 belt devices for the shunt belt conveyor 8 are distributed in parallel along the transverse direction corresponding to 2 conveying channels which are transversely arranged and longitudinally extend and are used for identifying the conveying belt conveyors 6, so that 2 wrapping conveying channels which respectively run are realized.
The backflow belt conveyor 9 is arranged at the side part of the balance wheel sorting machine 7, and abnormal parts marked by detection on the identification belt conveyor 6 wrap the backflow belt conveyor 9 through the swinging and reversing of the balance wheel sorting machine 7, so that the abnormal parts flow back to the initial online conveying device 1 again to be manually intervened and processed.
Based on the design of the abnormal part detection and flow regulation sorting device, packages which are respectively conveyed in 2 rows are divided into a recognition conveyor belt 6 through a single piece separation device 4, 2 package queues in 2 conveying channels are photographed and recognized one by one through a visual recognition device 5, and coordinate data of each package are obtained to correspondingly generate the three-dimensional size and real-time position coordinates of the edge of the package image;
judging whether abnormal parts such as stacked parts exist or not based on the image recognition result, and marking the abnormal parts such as the stacked parts; meanwhile, the normal pieces are numbered one by one in sequence so as to count the number of the packages in each conveying channel; all the parcel information generated in the image recognition stage is sent to a PLC of the balance wheel sorting machine 7;
after entering the balance wheel sorting machine 7 along 2 conveying channels, the packages marked as abnormal parts are directly swung and reversed to be conveyed to the backflow belt conveyor 9, the abnormal parts flow back to the initial part loading position, namely the on-line conveying device 1, and finally manual intervention treatment is carried out;
the PLC of the balance wheel sorting machine 7 respectively counts the number of the parcels in each conveying channel, compares the parcels after a period of operation time, and diverts the parcels in the conveying channels with a small number to the conveying channels with a large number by the swinging and rotating direction of the balance wheel unit 71 so as to realize that the number of the parcels finally passing through the 2 single conveying belt devices of the diversion belt conveyor 8 is approximately equal, thereby providing sufficient preparation for the subsequent parcels entering the cross belt sorting and automatic bar code scanning.
As shown in fig. 6, the abnormal component detecting and flow-adjusting sorting method described in the present application mainly includes the following implementation steps:
1) visual recognition
The parcels entering the identification conveyor belt 6 are photographed one by one through the visual identification device 5 to generate image information, and the three-dimensional size data and the real-time position coordinates of each parcel are obtained;
2) type mark
Identifying abnormal pieces according to the package images, marking the abnormal pieces to be subjected to subsequent rejection processing if the abnormal pieces belong to the normal pieces, sequentially numbering the normal pieces one by one if the normal pieces belong to the normal pieces, and counting the number of the normal packages in each conveying channel;
all the parcel information generated at this stage is sent to the PLC of the balance wheel sorting machine 7;
3) sorting flow regulation
After the parcels enter the balance wheel sorting machine 7, the parcels marked as abnormal pieces are directly swung and reversed to be conveyed to the backflow belt conveyor 9, and the normal pieces of parcels are continuously conveyed forward to the diversion belt conveyor 8;
according to the counted number of the parcels in each conveying channel in unit time, the flow is regulated among 2 single conveying belt devices of the shunt belt conveyor 8 by the swinging and rotating direction change of the balance wheel unit 71.
As shown in fig. 5, the control module applied to the abnormal component detection and flow adjustment sorting method includes an upper computer, a PLC, a visual controller, and a servo driver. The servo driver drives the servo motor 72 in each of the set of sorting modules 70 of the balance sorter 7.
In the control communication of the whole parcel detection and flow regulation sorting process, the upper computer and the visual controller send instructions to the PLC, the PLC sends instructions to the servo driver to drive and control the swing angle and speed of the balance wheel unit 71 in each group of sorting modules 70, and meanwhile, the PLC also sends instructions to the visual controller to trigger the 3D camera 51 to shoot so as to identify abnormal parts.
In the step 3), according to the package mark or the number statistical result received by the PLC of the balance wheel sorter 7, different swing angles and speeds of the balance wheel unit 71 are adjusted to remove the abnormal parts to the backflow belt conveyor 9 to flow back to the initial part feeding position, i.e. the on-line conveying device 1, and finally manual intervention processing is forwarded; or the normal parts are diverted to any one of 2 independent conveying belt devices of the diversion belt conveyor 8.
In the step 1), as shown in fig. 7-1, the upper left corner of the conveyor 6 is calibrated and identified as the origin of coordinates, the conveying direction is the X axis, and the vertical direction is the Y axis, so that the conveyor 6 (including 1 longitudinally extending middle isolation area and 2 transversely arranged and longitudinally extending conveying channels) forms a coordinate system, and each parcel thereon can acquire specific three-dimensional size and position coordinate data, that is, the 3D camera 51 of the visual recognition device 5 can recognize the real-time coordinates of any point in the coordinate system and the size information of the outermost peripheral edge of the parcel. For example, by taking the coordinates of the center of the package, having several corners, and the coordinates of each corner, the length, width, height, etc. of the outermost peripheral edge of the package can be calculated.
Based on the application of the image recognition algorithm technology, the three-dimensional size (including volume), the position coordinates and the adjacent relation of the outermost periphery image of each package are recognized, so that information such as the distance between the adjacent packages and the position relation is determined, the detection and the marking of abnormal parts are finally completed, and a judgment basis is provided for the subsequent sorting and flow adjustment of the packages.
In order to improve the accuracy of the identification information and improve the identification result to reflect the real-time state and the physical parameter data of the package more truly and effectively, the visual identification device 5 further performs edge detection on the package image, and screens out the outermost peripheral edge information of the package to correspondingly generate three-dimensional size and position coordinate information.
In order to expand the range of the viewing angle required for information collection and calculation of the identification area, further, in step 1), a visual recognition device 5 is arranged vertically above the identification belt conveyor 6, and the visual recognition device 5 comprises a 3D camera 51; the 3D camera 51 recognizes the package information vertically downward in the package conveying direction. In this embodiment, 1 3D camera 51 is arranged above the vertical direction of the recognition belt conveyor 6, the visual range of the 3D camera 51 is a rectangular area along the X axis 1000mm and along the Y axis 1560mm, and 2 parcels conveyed along 2 transverse conveying channels can be photographed and recognized in this area.
In the above step 2), as an example of the normal piece package shown in fig. 7-2, the definition for the normal piece package is as follows: the packages are cuboid, and the vertical height of the same package is within 3 mm; the distance between two adjacent packages is not less than 200 mm.
In the figure, it can be judged that 2 parcels entering the detection visual field range of the 3D camera 51 all have 4 vertex angles, that is, all are cuboids; according to the coordinate data of 4 corners of each of 2 packages, for example, the coordinate data of four corners of the outermost peripheral edge of the first package are respectively U21, U22, U23 and U24, and the coordinate data of four corners of the outermost peripheral edge of the second package are respectively U11, U12, U13 and U14. And selecting the minimum X-axis value point in the coordinate points of the first parcel and the maximum X-axis coordinate point in the second parcel to perform data comparison, namely L is | X21-X14 |. As shown in the figure, if the distance L > between the first parcel and the second parcel is 200, the 2 parcels are determined to have normal space, and each parcel is a normal piece. The two packages are respectively numbered in sequence so as to count the total quantity of all packages in the conveying channel in the unit conveying time.
As shown in fig. 7-3, in the abnormal piece example, 2 adjacent parcels in the figure are in a stacked state, i.e. the difference L between the maximum value points of the X axis in the coordinate points of the first parcel and the second parcel is less than 200, the distance between the two parcels is judged to be too small, the parcels are directly marked as a stacked piece, i.e. an abnormal piece, and the mark is simultaneously sent to the PLC of the balance wheel sorting machine 7. When the subsequent packages reach the balance wheel sorting machine 7, the packages are reversed through the swing rotation of the balance wheel unit 71 to be rejected to the return belt conveyor 9.
As the anomaly example shown in fig. 7-4, in addition to stacks, there are also anomaly situations such as non-rectangular packages, such as polygons, cylinders, circles, etc., that are in the field of view of the 3D camera 51. These abnormal packages are marked together and sent to the PLC of the balance sorter 7 to be subjected to a subsequent rejection process.
The non-rectangular parcel is judged on the basis that the parcel has more or less than 4 top angles and the vertical height of the parcel is more than 3 mm.
In the step 3), in order to match the number of parcels between 2 individual conveying belts of the diversion belt conveyor 8 to achieve relative balance, a unit conveying time is defined, for example, 5 minutes, and according to the counted number of parcels in each conveying channel, the direction, speed and time of oscillation of the balance wheel unit 71 of the balance wheel sorting machine 7 are controlled, so that parcel flow regulation can be accurately achieved.
After the wrapping number among the 2 single conveying belt devices of the flow-adjusting and flow-dividing belt conveyor 8 tends to be equal, the balance wheel unit 71 is restored to the original state to wait for the next abnormal part removal or flow-adjusting swing motion.
In summary, the embodiments presented in connection with the figures are only preferred. Those skilled in the art can derive other alternative structures according to the design concept of the present invention, and the alternative structures should also fall within the scope of the solution of the present invention.
Claims (5)
1. An abnormal part detection and flow regulation sorting method is characterized by comprising the following steps: comprises the following implementation steps of the method,
1) visual recognition
The method comprises the steps of entering packages of a recognition belt conveyor, photographing one by one through a visual recognition device to generate image information, and acquiring three-dimensional size data and real-time position coordinates of each package;
2) type mark
Identifying abnormal pieces according to the package images, marking the abnormal pieces to be subjected to subsequent rejection processing if the abnormal pieces belong to the normal pieces, sequentially numbering the normal pieces one by one if the normal pieces belong to the normal pieces, and counting the number of the normal packages in each conveying channel;
all the package information generated at the stage is sent to a PLC of the balance wheel sorting machine;
3) sorting flow regulation
After the parcels enter the balance wheel sorting machine, the parcels marked as abnormal pieces are directly swung and reversed to be conveyed to the backflow belt conveyor, and the parcels of normal pieces are continuously conveyed forward to the diversion belt conveyor;
according to the counted number of the parcels in each conveying channel in unit time, the flow is regulated among 2 independent conveying belt devices of the shunt belt conveyor through the swinging and rotating reversing of the balance wheel unit.
2. The abnormal component detecting and flow-adjusting sorting method according to claim 1, characterized in that: in the step 3), according to the package marks or the number statistical results received by the PLC of the balance wheel sorting machine, adjusting different swing angles and speeds of the balance wheel units so as to remove abnormal parts to a backflow belt conveyor to flow back to an initial part feeding position, namely an on-line conveying device; or the normal parts are diverted to any one of 2 independent conveying belt devices of the split belt conveyor.
3. The abnormal component detecting and flow-adjusting sorting method according to claim 1, characterized in that: in step 1), the visual recognition device performs edge detection on the parcel image, and screens out the outermost peripheral edge information of the parcel to correspondingly generate three-dimensional size and position coordinate information.
4. The abnormal component detecting and flow-adjusting sorting method according to claim 1, characterized in that: in the step 1), a visual recognition device is arranged vertically above the recognition belt conveyor, the visual recognition device comprises a 3D camera, and the 3D camera recognizes the package information vertically downwards along the package conveying direction.
5. The abnormal component detecting and flow-adjusting sorting method according to claim 1, characterized in that: in step 3), defining unit conveying time, and performing parcel flow regulation among 2 conveying channels by controlling the swinging direction, speed and time of a balance wheel unit of the balance wheel sorting machine according to the counted number of parcels in each conveying channel.
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Cited By (7)
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| CN111921873A (en) * | 2020-07-31 | 2020-11-13 | 杭州海康机器人技术有限公司 | Package sorting method and system |
| CN112845111A (en) * | 2020-12-25 | 2021-05-28 | 南京铁道职业技术学院 | Sorting device for logistics transportation in response to emergency |
| CN114130673A (en) * | 2021-10-14 | 2022-03-04 | 浙江菜鸟供应链管理有限公司 | Control method, device and equipment of sorting equipment and storage medium |
| CN114377969A (en) * | 2021-12-28 | 2022-04-22 | 科捷智能科技股份有限公司 | Automatic workpiece feeding sorting control method |
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| CN115744049A (en) * | 2022-11-03 | 2023-03-07 | 青岛孚鼎泰智能技术有限公司 | Multi-product whole-layer unstacking conveying system equipment and method |
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