CN112845121A - Automatic sorting system and sorting control method for waste materials in blanking workshop - Google Patents
Automatic sorting system and sorting control method for waste materials in blanking workshop Download PDFInfo
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- CN112845121A CN112845121A CN202110097138.8A CN202110097138A CN112845121A CN 112845121 A CN112845121 A CN 112845121A CN 202110097138 A CN202110097138 A CN 202110097138A CN 112845121 A CN112845121 A CN 112845121A
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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
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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
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
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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
- B07C5/344—Sorting according to other particular properties according to electric or electromagnetic properties
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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
- B07C2501/00—Sorting according to a characteristic or feature of the articles or material to be sorted
- B07C2501/0054—Sorting of waste or refuse
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Abstract
The invention provides an automatic sorting system and a sorting control method for blanking workshop waste. The sorting control method of the automatic sorting system adopts a PLC controller, an HMI touch screen and a control panel to jointly form a control device of the automatic sorting system, and comprises local control, remote control and manual and automatic operation modes. Therefore, an integrated automatic sorting and control system facing the blanking workshop waste is formed and can be used for automatically sorting and controlling the blanking workshop waste.
Description
Technical Field
The invention relates to the field of automatic sorting and control of workshop waste, in particular to an automatic sorting system and a sorting control method for blanking workshop waste.
Background
The blanking workshop is a blanking workshop section facing large-scale industrial equipment enterprises and is an important department for providing processing materials of required parts for other machining departments or carrying out primary processing on the parts. The blanking workshop mainly comprises a shearing workshop, a sawing workshop, a leveling workshop, an aligning workshop, a cutting workshop, an electric welding workshop and the like, wherein in the blanking process, leftover waste materials and waste products such as steel, iron, aluminum, glass, plastics and the like are inevitably generated. These backlogs of miscellaneous waste and waste take up significant amounts of space in the plant, squeeze plant resources, and each industrial enterprise spends significant amounts of money annually sorting, recycling, and disposing of waste.
Therefore, an integrated automatic sorting system and a sorting control method are built, waste materials from a blanking workshop are automatically sorted according to the material types of the materials, and recycling of mixed materials is achieved, so that pollution waste of the mixed materials can be reduced, and certain economic benefits can be brought to enterprises. Meanwhile, the control method of the integrated sorting monitors the sorting operation state through the upper machine configuration interface, is beneficial to more clearly knowing and adjusting the operation state of the automatic sorting system during working, reduces the fault risk and ensures the safe and stable operation of the system.
Currently, common automated sorting systems can be divided into three categories, automated sorter sorting, robotic sorting, and automated sorting conveyor sorting. The sorting system of the automatic sorting machine has better sorting precision and efficiency, is widely applied in the fields of medicine distribution and the like, but has high requirement on sorting equipment and has larger limitation on the sort of sorted goods; compared with a sorting machine, the robot automatic sorting machine has better sorting flexibility, but has higher cost and technical requirements, and is difficult to realize large-batch and long-time material sorting; the automatic sorting conveyor is the most widely applied automatic sorting system at present, can continuously sort goods in large batch, and has low management cost, high sorting efficiency and small sorting error.
Disclosure of Invention
Based on the background analysis, the invention aims to overcome the defects in the prior art, and particularly provides an automatic sorting system and a sorting control method for wastes in a blanking workshop, wherein the research contents mainly relate to electric automatic control, sensing and detection technology, electromechanical transmission and control, materials science, pneumatic transmission control, human-computer interaction design, computer technology and the like; detecting and identifying the material quality of the waste materials in the blanking workshop through a sensing detection device, outputting the material quality according to input control by a control device, and pushing and sorting the waste materials to corresponding material grooves by an execution device; meanwhile, the automatic sorting system is controlled and monitored through the control panel and the touch screen HMI, and the integrated automatic sorting system and the control method facing the waste materials in the blanking workshop are formed.
In order to achieve the technical features, the invention is realized as follows: an automatic sorting system for waste materials in a blanking workshop comprises a material device, a transmission device, a sensing detection device, an execution device and a control device; quantitatively and continuously feeding materials through a material device; the conveying device conveys and conveys the mixed materials in the blanking workshop; detecting and identifying the material of the waste material in the blanking workshop through a sensing detection device; the control device controls output according to input, and the execution device pushes and sorts the waste materials to corresponding material grooves; meanwhile, the automatic sorting system is controlled and monitored through a control panel and a touch screen of the control device, and integrated automatic sorting for the waste materials in the blanking workshop is achieved.
The material device comprises a material groove for storing waste materials in a blanking workshop, a feeding machine, materials to be sorted, a material storage area for storing various materials and a miscellaneous material storage area;
the waste materials generated by the blanking workshop comprise but are not limited to types of iron, aluminum, copper, glass and plastic materials, which are collectively called materials;
when the sorting system carries out automatic sorting, the material device can quantitatively, uniformly and continuously supply small materials stored in the trough to a conveying belt of the conveying device so as to facilitate subsequent sorting.
The conveying device comprises a conveyor belt type sorting machine and a driving motor, mixed materials given by the material device are conveyed and conveyed, and a subsequent sensing detection device can conveniently detect the materials and sort the materials through an execution device.
The sensing detection devices are classified into three types and are used for detecting whether the material tank is provided with a material detection sensor for detecting whether residual materials exist in the material tank or not; the material position proximity switch is used for counting the total number of materials; an iron detection sensor, an aluminum detection sensor, a copper detection sensor, a glass detection sensor, a black plastic detection sensor and a light-colored plastic detection sensor for detecting material quality;
the material detection sensor is arranged above the material groove and used for detecting whether materials exist in the material groove, if the materials exist, the motor is driven to rotate forwards to drive the conveyor belt to operate forwards, and if the materials do not exist, the system enters a standby state, and the motor does not operate;
the material position proximity switch is arranged at the front end of the conveyor belt, and when the materials pass by along with the operation of the conveyor belt, the material position proximity switch can count the materials, so that the total number of the materials is counted;
the various material type detection sensors are all arranged in front of the sorting execution device.
The executing device comprises a material pushing cylinder and an air compressor, and after the sensor identifies the material, the corresponding cylinder pushes and sorts the material into the corresponding material storage area;
the air compressor provides power support for the material pushing cylinder.
The control device comprises a PLC controller, a touch screen and a control panel;
the PLC is connected with a power supply module, a digital quantity input module and a digital quantity output module in an expanded manner;
the control panel comprises a state indicating area and a button switch area, and the state indicating area is provided with indicating lamps for the working and operating conditions of the automatic sorting system, and comprises an operation indicating lamp, an emergency stop indicating lamp, an alarm lamp 1, an alarm lamp 2, a local state indicating lamp, a remote state indicating lamp, a manual operation indicating lamp and an automatic operation indicating lamp; the button switch section includes a start button, a stop button, a reset button, a mode confirm button, a cylinder extend button, a cylinder retract button, a forward jog button, a reverse jog button, an on-site/remote mode select switch, a manual/automatic mode select switch, and an emergency stop button.
The sorting control method of the automatic sorting system for the waste materials in the blanking workshop comprises the steps of initializing and setting the whole system after the automatic sorting system is powered on and started; the system comprises two operation modes of local control and remote control, wherein a control panel is adopted for operation control during the local control, and a touch screen is adopted for operation control during the remote control; the system comprises a manual working mode and an automatic working mode.
The system checks whether each main device can normally work in a manual mode, so that the devices are debugged step by step, wherein a jog button is used for checking whether a motor and a conveyor belt can normally run, and a cylinder extension button and a cylinder retraction button are used for checking whether each cylinder can normally work;
the basic steps of the automated sorting system in the manual mode of operation are as follows:
step 1-1: firstly, selecting an operation mode, namely selecting a local operation mode or a remote operation mode, and selecting a manual control mode or an automatic control mode; selecting a local operation mode, selecting a manual control mode, pressing a mode confirmation button, then enabling the system to enter a local manual mode, and enabling a local indicator lamp and a manual indicator lamp to be turned on;
step 1-2: under the control mode, the forward inching button, the reverse inching button, the pushing cylinder extending button and the pushing cylinder retracting button are used for debugging the equipment; when the forward inching button is pressed down, the motor is driven to rotate forward, so that the conveyor belt is driven to operate in the forward direction, and after the conveyor belt is loosened, the motor stops and the conveyor belt stops operating; when the reverse inching button is pressed down, the driving motor reverses to drive the conveyor belt to run reversely, and after the conveyor belt is loosened, the motor stops and the conveyor belt stops running; when the cylinder extension button is pressed down, all the cylinders are pushed out, and after the cylinders are loosened, the cylinders keep an extension state; when the cylinder retraction button is pressed, all the cylinders retract, and after the cylinders are released, all the cylinders keep a retraction state; in addition, if the forward jog button and the reverse jog button are pressed at the same time, an interlock is formed and the conveyor belt does not operate.
The system can finish the automatic sorting work of the waste materials in the blanking workshop in an automatic mode, firstly, the waste materials from the blanking workshop need to be placed into a material device, and the material device can sequentially supply the materials to a transmission device; then the material moves forwards along with the transmission device, the sensing detection device judges the material type of the material in the operation process and transmits a detection signal to the control device; then, the control device can control the corresponding execution device to sort according to the signal, and meanwhile, the control device can adjust the material device and the transmission device according to the actual operation condition of the sorting system; finally, the execution device pushes the materials into the material storage area corresponding to the materials according to the signals of the control device; after the material sorting work is finished, resetting the system to prepare a good operation environment for restarting the next system;
the basic steps of the automated sorting system in the automatic operating mode are as follows:
step 2-1: firstly, selecting an operation mode, selecting a local operation mode, selecting an automatic control mode, pressing a mode confirmation button, then enabling the system to enter the local automatic mode, and enabling a local indicator light and an automatic indicator light to be constantly on;
step 2-2: the method comprises the following steps that a starting button is pressed, a production line enters a running state, corresponding indicating lamps are turned on, the number of all material grooves is reset firstly, namely, the number of all the material grooves is 0 when the reset button is pressed, the whole production line enters the running state, and materials are waited to enter to realize a sorting task;
step 2-3: if the material detection switch detects that the material is in the material groove, the motor starts to rotate forwards, the conveyor belt runs forwards, and otherwise, the conveyor belt does not run and the system is still in a standby state;
step 2-4: when the conveyor belt runs in the forward direction and materials pass through the first position proximity switch, adding 1 to the total number of the materials so as to count the total number of the materials;
step 2-5: the material continuously moves forwards along with the conveyor belt and passes through the iron detection sensor, if the iron detection sensor detects that the material is iron, the No. 1 material pushing cylinder pushes out, the No. 1 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-6: the material continuously moves forwards along with the conveyor belt and passes through the aluminum detection sensor, if the aluminum detection sensor detects that the material is aluminum, the No. 2 pushing cylinder pushes out, the No. 2 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-7: the steps are carried out in sequence, and the sorting is not finished until the materials enter the material grooves corresponding to the materials.
Under two working modes, when equipment has a fault, a corresponding alarm lamp 1 or 2 on an operation panel can flash as an alarm signal, and different faults can have different flash frequencies; after the fault occurs, an operator is required to perform fault response in the upper computer to indicate that the fault is noticed and solved, and the corresponding alarm lamp is turned off only after the fault is solved; if the fault is still not eliminated, the alarm lamp is kept in a normally-on state until the fault is eliminated, and the alarm lamp is not turned off; therefore, the system responds to faults and emergency situations in the system, and timely early warning and reminding of the system faults are realized;
in a touch screen HMI control mode, a human-computer interaction interface initial interface is provided with main functional interfaces of manual operation, automatic operation, parameter setting, fault alarm and user management; under the automatic operation interface, the production line is monitored through the operation state monitoring interface, so that whether the sorting normally works or not is identified, and the overall monitoring and control of the automatic material sorting process are realized; under the operation state monitoring interface, because the materials in the No. 7 material groove are not identified by various preset material monitoring sensors, the materials have two types, one is waste products caused by detection errors of the sensors, the other is non-preset sorting type materials, the materials are collectively called sorting waste products, a simple evaluation can be carried out on the sorting result of the automatic sorting system according to the sorting rejection rate which is the proportion of the number of the materials in the No. 7 material groove to the total number of the materials, the sorting rejection rate is excellent when the sorting rejection rate is 0-2%, the sorting rejection rate is good when 3-10%, the sorting rejection rate is qualified when 11-20%, and the sorting rejection rate is unqualified when 21-100%.
The automatic sorting system and the automatic sorting control method designed by the invention can achieve the following technical effects by adopting the technical scheme:
1. this automatic sorting system is applicable to and uses the kind of material as the foundation to carry out automatic classification letter sorting to unloading workshop waste material, the automatic classification letter sorting problem of the mixed material of realization that can be better. The material device is with the fritter material ration of depositing in the silo, evenly, supply with on transmission device's the conveyer belt in succession, transmission device transmits the mixed material that material device gave and transports, whether material detection sensor detects the silo in has the material, material position proximity switch statistics material total number, detect the material through all kinds of sensors, after the material is discerned to the sensor and its corresponding executive device can deposit the district with material propelling movement letter sorting to its corresponding material, from this form the integration towards the automatic sorting system of unloading workshop waste material.
2. The PLC, the HMI touch screen and the control panel are adopted to jointly form a control device part of the automatic sorting system, two control modes of local control and remote control can be realized, and two operation modes of manual operation and automatic operation are set for the system. The system can check whether each main device can work normally or not in a manual mode, so that the devices are debugged step by step; the system can finish the automatic sorting work of the waste materials in the blanking workshop in an automatic mode. In addition, the control device is preset with functions of fault alarm, running state monitoring, system evaluation and the like, can control and monitor the automatic sorting system in various modes, timely reacts to faults and emergency situations in the system, and overcomes the defects that the traditional automatic material sorting system is single in control mode, uncontrollable in working process and difficult in timely early warning of faults.
3. Through the effective integration of the designed automatic sorting system and the sorting control method, the system can be controlled and adjusted through the entity buttons in the control panel, the system can be monitored and controlled through the touch screen HMI interface in the upper computer, and compared with the traditional automatic sorting system adopting manual sorting and single control mode, the automatic sorting system for the materials under multi-channel combined control has more comprehensive functions, better reliability and higher sorting efficiency.
In summary, the automatic sorting system based on design of the invention adopts the PLC, the HMI touch screen and the control panel to jointly form a control device part, can realize two control modes of local and remote control and two operation modes of manual and automatic, realizes the functions of operation debugging, material sorting, fault early warning, state monitoring, system evaluation and the like of the system, forms an integrated automatic sorting system and control method facing to the waste material of the blanking workshop, which are constructed by 'the material device quantitatively and continuously feeding the mixed material, the transmission device transmits and transports the mixed material, the sensing detection device detects and identifies the material, the control device pushes and sorts the material to the corresponding material groove according to the input control output-execution device', and simultaneously controls and monitors the system through the control panel and the HMI touch screen, thereby avoiding the traditional material sorting method from low control reliability, low control reliability and low control reliability, The method has the advantages of being difficult to monitor the operation state, short in fault timely early warning and the like, and provides a new idea method for the design of the automatic material classifying and sorting system and the sorting control mode.
Drawings
The invention is further illustrated by the following figures and examples.
Figure 1 is a schematic diagram of the installation arrangement, zone division and control scheme of the automated sorting system of the present invention.
Fig. 2 is a flow chart of the steps of the automatic sorting system for the blanking shop waste in accordance with the present invention.
Fig. 3 is a flow chart of the steps of the automatic sorting system of the present invention in a manual commissioning mode.
Fig. 4 is a flow chart of the steps of the automated sorting system of the present invention in an automated sorting mode.
Fig. 5 is a flow diagram of an embodiment of an automated sorting system control scheme according to the present invention.
Detailed Description
Embodiments of the present invention will be further described with reference to the accompanying drawings.
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function, and wherein "material" refers to "scrap from a blanking plant" unless otherwise specified. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
As shown in the attached figure 1, the automatic sorting system for the waste materials in the blanking workshop mainly comprises a material device, a transmission device, a sensing detection device, a control device and an execution device.
Further, the material device comprises a material groove for storing waste materials in a blanking workshop, a feeding machine, a material storage area for waiting to sort materials, and storing various materials, and a miscellaneous material storage area. The waste materials generated by the blanking workshop include but are not limited to iron, aluminum, copper, glass, plastics and other material types, which are collectively called materials. When the material sorting system carries out automatic sorting, the material device can quantitatively, uniformly and continuously supply small materials stored in the trough to a conveying belt of the conveying device so as to facilitate subsequent sorting. From the aspects of uniform feeding, convenient operation, low power consumption, equipment maintenance cost and the like, the invention can select the closed vibrating feeder as a material device of the automatic sorting system.
Further, transmission device mainly includes conveyer belt sorting machine and driving motor, and the function of realization is that the mixed material that gives the material device transports, makes things convenient for subsequent sensing detection device to carry out the material and detects and sort through final controlling means. Based on the speed and precision requirements of conveying materials, the conveyor belt can adopt a belt conveyor, and the driving motor can adopt a three-phase asynchronous motor.
Furthermore, the sensing detection device comprises three types, namely a material detection sensor for detecting whether residual materials exist in the material groove; the material position proximity switch is used for counting the total number of materials; a iron detects sensor, aluminium and detects sensor, copper and detect sensor, glass and detect sensor, black plastics and light colour plastics sensor for detecting the material. The material detection sensor is arranged above the material groove and used for detecting whether materials exist in the material groove, if the materials exist, the motor is driven to rotate positively to drive the conveyor belt to operate positively, if the materials do not exist, the system enters a standby state, the motor does not operate, and the specific model can adopt a cylindrical photoelectric sensor; the material position proximity switch is installed in the front end of conveyer belt, and when the material passed through along with the conveyer belt operation, material position proximity switch can make statistics of it to the realization is to the statistics of material total number. Because the materials have both conductive objects and insulators, the material position proximity switch is not suitable for adopting an inductive type, but a capacitive type proximity switch is adopted; all kinds of material type detection sensor all install before letter sorting final controlling element, iron detection sensor uses switch type hall current sensor, aluminium detection sensor can adopt electrostatic capacity type proximity switch, copper detection sensor can use inductive proximity switch, glass detection sensor uses the photoelectric sensor who takes the mirror surface reflection-type, black plastics detection sensor and light colour plastics detection sensor both can use optical fiber sensor to differentiate the letter sorting with the help of the material colour, also can realize the letter sorting with the help of the dielectric constant difference of substance through capacitanc proximity switch.
Further, the executing device comprises a material pushing cylinder and an air compressor, wherein after the sensor identifies the material, the cylinder corresponding to the sensor can push and sort the material into the material storage area corresponding to the sensor, as shown in fig. 1, the system has 6 material pushing cylinders, wherein the cylinders 1, 2 and 4 are in a material pushing and sorting state, and the cylinders 3, 5 and 6 are in a retraction state; the air compressor provides power support for the material pushing cylinder. Particularly, push away the material cylinder and can select for use double-acting single pole cylinder, air compressor can select for use three-phase air compressor.
Furthermore, the control device comprises a PLC controller, an HMI touch screen and a control panel. The PLC controller selects a Siemens S7-1500 series 1516-3 PN/DP, and is expanded with a power supply module, a 32-bit digital quantity input module and a 32-bit digital quantity output module. Specifically, the power module uses PM 70W 120/230VA, the input module uses DI 32x24VDC HF, and the output module uses DQ 32x24VDC/0.5 AST; the HMI touch screen adopts KTP700 Basic PN matched with the PLC for realizing man-machine interaction operation. The control panel comprises a state indicating area and a button switch area, and the state indicating area is provided with indicating lamps for the working and operating conditions of the automatic sorting system, and comprises an operation indicating lamp, an emergency stop indicating lamp, an alarm lamp 1, an alarm lamp 2, a local state indicating lamp, a remote state indicating lamp, a manual operation indicating lamp and an automatic operation indicating lamp; the button switch section includes a start button, a stop button, a reset button, a mode confirm button, a cylinder extend button, a cylinder retract button, a forward jog button, a reverse jog button, an on-site/remote mode select switch, a manual/automatic mode select switch, and an emergency stop button.
Further, the work flow chart of the whole automatic sorting system facing the waste materials in the blanking workshop is shown in fig. 2, and when the automatic sorting system is powered on and started, the whole system is initialized; the system comprises two operation modes of local control and remote control, wherein a control panel is adopted for operation control during the local control, and a touch screen HMI is adopted for operation control during the remote control;
the system comprises a manual working mode and an automatic working mode.
The method comprises the following steps: manual commissioning mode for automated sorting systems
The system can check whether each main device can normally work under the manual mode, so that the devices are debugged step by step, wherein the inching button is used for checking whether the motor and the conveyor belt can normally run, and the cylinder extending and cylinder retracting button is used for checking whether each cylinder can normally work. The operation flow of the manual debugging mode is shown in fig. 3, which briefly describes the basic steps of the automatic sorting system in the manual operation mode as follows:
step 1-1: firstly, selecting an operation mode, namely selecting a local operation mode or a remote operation mode, and selecting a manual control mode or an automatic control mode; taking fig. 3 as an example, the local operation mode is selected, the manual control mode is selected, the mode confirmation button is pressed, then the system enters the local manual mode, and the local indicator light and the manual indicator light are both on;
step 1-2: under the control mode, the equipment can be debugged by using a forward inching button, a reverse inching button, a pushing cylinder extending button and a pushing cylinder retracting button. When the forward inching button is pressed down, the motor is driven to rotate forward, so that the conveyor belt is driven to operate in the forward direction, and after the conveyor belt is loosened, the motor stops and the conveyor belt stops operating. When the reverse inching button is pressed down, the driving motor rotates reversely to drive the conveying belt to run reversely, and after the conveying belt is loosened, the motor stops and the conveying belt stops running. When the cylinder extension button is pressed, the No. 1 to No. 6 cylinders are all pushed out, and after the cylinders are loosened, the cylinders are kept in an extension state. When the cylinder retraction button is pressed, the No. 1 to No. 6 cylinders are retracted, and after being released, the cylinders are kept in a retracted state. In addition, if the forward jog button and the reverse jog button are pressed at the same time, an interlock is formed and the conveyor belt does not operate.
Step two: automatic sorting mode for automatic sorting system
The system can finish the automatic sorting work of the waste materials in the blanking workshop in an automatic mode, firstly, the waste materials from the blanking workshop need to be placed into a material device, and the material device can sequentially supply the materials to a transmission device; then the material moves forwards along with the transmission device, the sensing detection device judges the material type of the material in the operation process and transmits a detection signal to the control device; then, the control system can control the corresponding execution device to sort according to the signal, and meanwhile, the control device can adjust the material device and the transmission device according to the actual operation condition of the sorting system; and finally, the executing device pushes the materials into the material storage area corresponding to the materials according to the signals of the control device. And after the material sorting work is finished, resetting the system to prepare a good operation environment for restarting the next system work. The operation flow of the automatic sorting mode is shown in fig. 4, which briefly describes the basic steps of the automatic sorting system in the automatic operation mode as follows:
step 2-1: the mode of operation is first selected, similar to the manual mode. Taking fig. 4 as an example, the local operation mode is selected, the automatic control mode is selected, the mode confirmation button is pressed, then the system enters the local automatic mode, and the local indicator light and the automatic indicator light are always on;
step 2-2: and when the starting button is pressed down, the production line enters a running state, and the corresponding indicator light is on. Resetting the quantity of all material grooves, namely pressing a reset button, wherein the quantity of all material grooves is 0, and the whole production line enters a running state and waits for the materials to enter so as to realize a sorting task;
step 2-3: if the material detection switch detects that the material is in the material groove, the motor starts to rotate forwards, the conveyor belt runs forwards, and otherwise, the conveyor belt does not run and the system is still in a standby state;
step 2-4: when the conveyor belt runs in the forward direction and materials pass through the first position proximity switch, adding 1 to the total number of the materials so as to count the total number of the materials;
step 2-5: the material continuously moves forwards along with the conveyor belt and passes through the iron detection sensor, if the iron detection sensor detects that the material is iron, the No. 1 material pushing cylinder pushes out, the No. 1 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-6: the material continuously moves forwards along with the conveyor belt and passes through the aluminum detection sensor, if the aluminum detection sensor detects that the material is aluminum, the No. 2 pushing cylinder pushes out, the No. 2 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-7: the steps are carried out in sequence, and the sorting is not finished until the materials enter the material grooves corresponding to the materials.
Further, in two working modes, when equipment has a fault, a corresponding alarm lamp 1 or 2 on the operation panel can flash as an alarm signal, and different faults can have different flashing frequencies; after a fault has occurred, the operator is required to respond to the fault in the host computer to indicate that the fault has been noticed and resolved, and the corresponding warning light is turned off only after the fault has been resolved. If the fault is still not eliminated, the alarm lamp is kept in a normally-on state until the fault is eliminated. Therefore, the system can respond to faults and emergency situations in the system, and timely early warning and reminding of the system faults are realized.
Further, as shown in fig. 1 and 5, in the touch screen HMI control mode, the human-computer interaction interface initial interface sets main function interfaces such as manual operation, automatic operation, parameter setting, fault alarm, user management, and the like. Under the automatic operation interface, the production line can be monitored through the operation state monitoring interface, so that whether the sorting normally works can be identified, and the overall monitoring and control of the automatic material sorting process can be realized; under the operation state monitoring interface, because the materials in the No. 7 material groove are not identified by various preset material monitoring sensors, the materials have two types, one is waste products caused by detection errors of the sensors, the other is non-preset sorting type materials, the materials are collectively called sorting waste products, the sorting result of the automatic sorting system can be simply evaluated according to the proportion (sorting rejection rate) of the number of the materials in the No. 7 material groove to the total number of the materials, when the sorting rejection rate is 0-2%, the sorting waste product is excellent, when the sorting rejection rate is 3-10%, the sorting waste product is qualified when the sorting rejection rate is 11-20%, and the sorting waste product is unqualified when the sorting rejection rate is 21-100%.
Thus, the whole process of the design of the automatic sorting system for the waste materials in the blanking workshop, the scheme design of the automatic sorting control system and the control method is completed.
In order to more clearly describe the flow and functions of the sorting control method of the present invention, the flow steps and the main functions of the automatic sorting control will be further described with reference to a specific example provided in the embodiment of the present application in fig. 5.
As shown in fig. 5, the manual operation interface is directly entered from the main interface of the touch screen HMI, in the manual debugging mode, the local/remote mode selection switch is first adjusted to the remote control mode, the manual/automatic mode selection switch is adjusted to the manual operation mode, and the mode confirmation button is pressed, so that it can be seen that both the remote indicator light and the manual operation indicator light are turned on; the motor drives the conveyor belt to operate in the forward direction when the forward inching button is pressed down, the motor drives the conveyor belt to operate in the direction when the reverse inching button is pressed down, the pushing cylinders No. 1-6 are all in the extending state when the cylinder extending button is pressed down, and the pushing cylinders No. 1-6 are all in the retracting state when the cylinder retracting button is pressed down, and in the process, if a certain cylinder does not execute related operation according to an instruction, the fault can be judged. The manual commissioning mode of fig. 5 shows the cylinder in an extended state and the motor running in forward direction.
The main interface of the touch screen HMI can also directly enter an automatic operation interface, and the automatic operation interface comprises a control interface and a state monitoring interface in an automatic sorting mode. The basic functions of the automatic sorting system are mainly formed by buttons, knobs, indicator lights and I/O domains in a control interface, wherein the buttons in a blue dotted line frame simulate sensor signal input during system simulation; meanwhile, the interface can enter a fault alarm interface to confirm the generated fault information. And the running state can be monitored in the running state monitoring interface, the sorting quantity in each trough can be indicated, and the whole automatic sorting system can be simply evaluated. In addition, once a fault is found or an unreasonable situation occurs in operation, all operations can be forcibly stopped by using an emergency stop button to ensure the safety of the system.
In fig. 5, in the initialization step of automatic operation in the automatic sorting mode, the system is already in operation, but since the material detection sensor detects that there is no waste left in the initial trough from the blanking workshop, the conveyor belt does not operate, and at this time, the trough does not count even if the subsequent iron sensor or the like detects the material.
In the normal operating mode of automatic operation, the system is in the automatic sorting state, and material detection sensor detects that there is the waste material that comes from the unloading workshop in the silo, and the conveyer belt operation this moment, subsequent automatic sorting part also begin to operate, and the silo begins the count.
In the fault alarm step, the system is under the control mode of remote automatic operation at this moment, so for the convenience of demonstration, the upper limit of total material is set to 5, namely when the total material reaches 5, the system can produce the fault alarm, alarm lamp 1 glimmers, pop up the overall alarm interface and reveal the reason that the alarm produced at the same time. At the moment, the fault can be eliminated step by step according to the prompted fault reason, and after the fault is eliminated and the fault response button is pressed, the fault can be responded and confirmed on the fault alarm interface.
In the scram step, a fault occurs in the system and an alarm is generated. For safety reasons, pressing the emergency stop button may be selected to prevent accidents. After the emergency stop button is pressed, only the emergency stop indicator lamp is on, and other output peripherals are all set to be zero. Without the emergency stop button, the system will not function here even if the start button is pressed. At this time, the user should return to the main interface, and after logging in, the user can enter the parameter modification interface according to the account authority to modify the preset upper limit of the material.
In the parameter setting step, a user with engineer authority should be logged in before entering the parameter setting, a keyboard is automatically called when the upper limit of the preset material is modified, and the range of the parameter is marked on the upper and lower sides of an input box, for example, the upper limit max =32767 of the preset material, the lower limit min =1 of the preset material, the parameter is successfully modified after the entry is completed, and the upper limit of the preset material is set to 531 in the figure.
In the step of monitoring the automatic sorting state, the running state detection interface mainly comprises a corresponding configuration of the automatic sorting system, related buttons and indicator lamps, wherein the buttons in the blue dotted line frame simulate the signal input of a sensor during the simulation of the system. After the parameter modification of the previous step, the upper limit of the material is changed to 531, and the total number of the material in the figure is 56 and no alarm is generated, thereby verifying that the parameter is successfully modified. The entire sorting system is in a state of automatically sorting materials, and the sorting processes of each material are independent of each other.
The flow and the main functions of the automatic sorting control of the specific case in the embodiment of the present application have been completed. Meanwhile, the above description of the specific embodiments is intended to describe and illustrate the technical solutions of the present invention, and the above specific embodiments are only illustrative and not restrictive.
Claims (10)
1. The utility model provides an automatic sorting system towards unloading workshop waste material which characterized in that: the device comprises a material device, a transmission device, a sensing detection device, an execution device and a control device; quantitatively and continuously feeding materials through a material device; the conveying device conveys and conveys the mixed materials in the blanking workshop; detecting and identifying the material of the waste material in the blanking workshop through a sensing detection device; the control device controls output according to input, and the execution device pushes and sorts the waste materials to corresponding material grooves; meanwhile, the automatic sorting system is controlled and monitored through a control panel and a touch screen of the control device, and integrated automatic sorting for the waste materials in the blanking workshop is achieved.
2. The automatic sorting system and the sorting control method for the waste materials of the blanking workshop as claimed in claim 1, characterized in that: the material device comprises a material groove for storing waste materials in a blanking workshop, a feeding machine, materials to be sorted, a material storage area for storing various materials and a miscellaneous material storage area;
the waste materials generated by the blanking workshop comprise but are not limited to types of iron, aluminum, copper, glass and plastic materials, which are collectively called materials;
when the sorting system carries out automatic sorting, the material device can quantitatively, uniformly and continuously supply small materials stored in the trough to a conveying belt of the conveying device so as to facilitate subsequent sorting.
3. The automatic sorting system for the blanking plant waste according to claim 1, characterized in that: the conveying device comprises a conveyor belt type sorting machine and a driving motor, mixed materials given by the material device are conveyed and conveyed, and a subsequent sensing detection device can conveniently detect the materials and sort the materials through an execution device.
4. The automatic sorting system for the blanking plant waste according to claim 1, characterized in that: the sensing detection devices are classified into three types and are used for detecting whether the material tank is provided with a material detection sensor for detecting whether residual materials exist in the material tank or not; the material position proximity switch is used for counting the total number of materials; an iron detection sensor, an aluminum detection sensor, a copper detection sensor, a glass detection sensor, a black plastic detection sensor and a light-colored plastic detection sensor for detecting material quality;
the material detection sensor is arranged above the material groove and used for detecting whether materials exist in the material groove, if the materials exist, the motor is driven to rotate forwards to drive the conveyor belt to operate forwards, and if the materials do not exist, the system enters a standby state, and the motor does not operate;
the material position proximity switch is arranged at the front end of the conveyor belt, and when the materials pass by along with the operation of the conveyor belt, the material position proximity switch can count the materials, so that the total number of the materials is counted;
the various material type detection sensors are all arranged in front of the sorting execution device.
5. The automatic sorting system for the blanking plant waste according to claim 1, characterized in that: the executing device comprises a material pushing cylinder and an air compressor, and after the sensor identifies the material, the corresponding cylinder pushes and sorts the material into the corresponding material storage area;
the air compressor provides power support for the material pushing cylinder.
6. The automatic sorting system for the blanking plant waste according to claim 1, characterized in that: the control device comprises a PLC controller, a touch screen and a control panel;
the PLC is connected with a power supply module, a digital quantity input module and a digital quantity output module in an expanded manner;
the control panel comprises a state indicating area and a button switch area, and the state indicating area is provided with indicating lamps for the working and operating conditions of the automatic sorting system, and comprises an operation indicating lamp, an emergency stop indicating lamp, an alarm lamp 1, an alarm lamp 2, a local state indicating lamp, a remote state indicating lamp, a manual operation indicating lamp and an automatic operation indicating lamp; the button switch section includes a start button, a stop button, a reset button, a mode confirm button, a cylinder extend button, a cylinder retract button, a forward jog button, a reverse jog button, an on-site/remote mode select switch, a manual/automatic mode select switch, and an emergency stop button.
7. The sorting control method of the automatic sorting system for the waste materials in the blanking workshop as claimed in any one of claims 1 to 6, wherein the automatic sorting system is initially set after being powered on and started up; the system comprises two operation modes of local control and remote control, wherein a control panel is adopted for operation control during the local control, and a touch screen is adopted for operation control during the remote control; the system comprises a manual working mode and an automatic working mode.
8. The sorting control method of an automatic sorting system according to claim 7, wherein the system checks whether each main apparatus can be normally operated in a manual mode, thereby debugging the apparatus step by step, wherein a jog button is used to check whether a motor and a conveyor belt can be normally operated, and a cylinder extend and cylinder retract button is used to check whether each cylinder can be normally operated;
the basic steps of the automated sorting system in the manual mode of operation are as follows:
step 1-1: firstly, selecting an operation mode, namely selecting a local operation mode or a remote operation mode, and selecting a manual control mode or an automatic control mode; selecting a local operation mode, selecting a manual control mode, pressing a mode confirmation button, then enabling the system to enter a local manual mode, and enabling a local indicator lamp and a manual indicator lamp to be turned on;
step 1-2: under the control mode, the forward inching button, the reverse inching button, the pushing cylinder extending button and the pushing cylinder retracting button are used for debugging the equipment; when the forward inching button is pressed down, the motor is driven to rotate forward, so that the conveyor belt is driven to operate in the forward direction, and after the conveyor belt is loosened, the motor stops and the conveyor belt stops operating; when the reverse inching button is pressed down, the driving motor reverses to drive the conveyor belt to run reversely, and after the conveyor belt is loosened, the motor stops and the conveyor belt stops running; when the cylinder extension button is pressed down, all the cylinders are pushed out, and after the cylinders are loosened, the cylinders keep an extension state; when the cylinder retraction button is pressed, all the cylinders retract, and after the cylinders are released, all the cylinders keep a retraction state; in addition, if the forward jog button and the reverse jog button are pressed at the same time, an interlock is formed and the conveyor belt does not operate.
9. The sorting control method of an automatic sorting system according to claim 7, wherein in the automatic mode the system is able to perform an automatic sorting of the scrap from the blanking shop, first requiring the scrap from the blanking shop to be placed in a material device which will supply them in turn to the transfer device; then the material moves forwards along with the transmission device, the sensing detection device judges the material type of the material in the operation process and transmits a detection signal to the control device; then, the control device can control the corresponding execution device to sort according to the signal, and meanwhile, the control device can adjust the material device and the transmission device according to the actual operation condition of the sorting system; finally, the execution device pushes the materials into the material storage area corresponding to the materials according to the signals of the control device; after the material sorting work is finished, resetting the system to prepare a good operation environment for restarting the next system;
the basic steps of the automated sorting system in the automatic operating mode are as follows:
step 2-1: firstly, selecting an operation mode, selecting a local operation mode, selecting an automatic control mode, pressing a mode confirmation button, then enabling the system to enter the local automatic mode, and enabling a local indicator light and an automatic indicator light to be constantly on;
step 2-2: the method comprises the following steps that a starting button is pressed, a production line enters a running state, corresponding indicating lamps are turned on, the number of all material grooves is reset firstly, namely, the number of all the material grooves is 0 when the reset button is pressed, the whole production line enters the running state, and materials are waited to enter to realize a sorting task;
step 2-3: if the material detection switch detects that the material is in the material groove, the motor starts to rotate forwards, the conveyor belt runs forwards, and otherwise, the conveyor belt does not run and the system is still in a standby state;
step 2-4: when the conveyor belt runs in the forward direction and materials pass through the first position proximity switch, adding 1 to the total number of the materials so as to count the total number of the materials;
step 2-5: the material continuously moves forwards along with the conveyor belt and passes through the iron detection sensor, if the iron detection sensor detects that the material is iron, the No. 1 material pushing cylinder pushes out, the No. 1 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-6: the material continuously moves forwards along with the conveyor belt and passes through the aluminum detection sensor, if the aluminum detection sensor detects that the material is aluminum, the No. 2 pushing cylinder pushes out, the No. 2 material groove counts and adds 1, otherwise, the material continuously moves forwards;
step 2-7: the steps are carried out in sequence, and the sorting is not finished until the materials enter the material grooves corresponding to the materials.
10. The sorting control method of the automatic sorting system according to claim 7, wherein in two operating modes, when the equipment is out of order, the corresponding alarm lamp 1 or 2 on the operating panel will flash as an alarm signal, and different faults will have different flash frequencies; after the fault occurs, an operator is required to perform fault response in the upper computer to indicate that the fault is noticed and solved, and the corresponding alarm lamp is turned off only after the fault is solved; if the fault is still not eliminated, the alarm lamp is kept in a normally-on state until the fault is eliminated, and the alarm lamp is not turned off; therefore, the system responds to faults and emergency situations in the system, and timely early warning and reminding of the system faults are realized;
in a touch screen HMI control mode, a human-computer interaction interface initial interface is provided with main functional interfaces of manual operation, automatic operation, parameter setting, fault alarm and user management; under the automatic operation interface, the production line is monitored through the operation state monitoring interface, so that whether the sorting normally works or not is identified, and the overall monitoring and control of the automatic material sorting process are realized; under the operation state monitoring interface, because the materials in the No. 7 material groove are not identified by various preset material monitoring sensors, the materials have two types, one is waste products caused by detection errors of the sensors, the other is non-preset sorting type materials, the materials are collectively called sorting waste products, a simple evaluation can be carried out on the sorting result of the automatic sorting system according to the sorting rejection rate which is the proportion of the number of the materials in the No. 7 material groove to the total number of the materials, the sorting rejection rate is excellent when the sorting rejection rate is 0-2%, the sorting rejection rate is good when 3-10%, the sorting rejection rate is qualified when 11-20%, and the sorting rejection rate is unqualified when 21-100%.
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