Automatic positioning and shearing control system and method for lead plate machining

Abstract

The invention provides an automatic positioning and shearing control system and method for lead plate machining, and relates to the technical field of lead plate shearing, and the system comprises a feeding module, a flattening module, a sensor module, an image recognition module, a control module, a cutting module and a discharging module. All links are precisely coordinated and linked through an intelligent control module, the production efficiency and the machining precision are greatly improved, manual intervention and personal errors are reduced, meanwhile, the labor intensity and the safety risk are reduced, and through real-time monitoring and feedback control of various sensors and combination of the advanced image recognition technology, the production efficiency is improved. Parameters such as the flattening gap, the pressure, the heating temperature, the cutting path and the cutting speed of the lead plate can be accurately adjusted and controlled, it is ensured that each lead plate can achieve the ideal flattening effect and the ideal cutting precision, and the high-quality production requirement is met.

Description

Technical Field

[0001] The present invention relates to the technical field of lead plate shearing, and in particular to an automatic positioning shearing control system and method for lead plate processing. Background Art

[0002] With the continuous development of industrial technology, lead plates are increasingly used in many fields such as radiation protection and battery manufacturing. In the field of lead plate processing, the traditional processing process mainly relies on manual operation and single-function equipment to complete the flattening and cutting processes. There are many significant drawbacks, which seriously restrict the efficient development of the lead plate processing industry and the improvement of product quality.

[0003] In the flattening process, the equipment can only perform simple and rough flattening processing on the lead plate, and cannot accurately adapt to the characteristics of different lead plates. For complex situations such as subtle bends and wavy distortions on the surface of the lead plate, when entering the cutting process, the cutting equipment usually cuts according to preset fixed sizes or relies on workers to measure and mark on site. It is unable to adjust the cutting plan in real time according to the actual width and shape characteristics of the lead plate. This makes the utilization rate of the lead plate at a low level, and a large amount of scraps and excess parts caused by unreasonable cutting planning become waste, which not only causes a waste of raw materials, but also the edges and middle parts of the lead plate are prone to varying degrees of unevenness during production, transportation or early processing. If these uneven parts are not accurately identified and effectively avoided, many quality problems are likely to occur during the cutting process.

[0004] The traditional lead plate processing process is highly dependent on manual intervention. Manual loading, handling, measurement, and sorting after cutting consume a lot of manpower and time. The production efficiency is low and easily affected by human factors, resulting in unstable processing accuracy and difficulty in ensuring consistency in product quality. It is difficult to meet the needs of large-scale and standardized production in modern industry.

[0005] The present invention proposes an automatic positioning and shearing control system and method for lead plate processing to solve such problems. Summary of the Invention

[0006] To achieve the above-mentioned purpose, the present invention proposes a control system and method for automatic positioning and shearing of lead plate processing, comprising a loading module, a flattening module, a sensor module, an image recognition module, a control module, a cutting module and a blanking module, wherein:

[0007] Loading module: It adopts an automated loading conveyor belt with adjustable conveying speed to adapt to different production rhythms;

[0008] Flattening module: It consists of two sets of flattening rollers, the diameter and length of which are designed according to the maximum size of the lead plate. The gap between the flattening rollers is automatically adjusted by an electric adjustment mechanism. The heating device can moderately heat the flattening rollers according to the material and thickness of the lead plate.

[0009] Sensor module: including position sensor and speed sensor, used to monitor the position information of key components;

[0010] Image recognition module: Install a high-resolution industrial camera to fully capture the surface features, edge contours, and central concave and convex conditions of the lead plate;

[0011] Control module: processes data information from each module and generates control instructions according to preset program logic and algorithms;

[0012] Cutting module: It uses high-precision carbide blades, which are installed on the tool holder and are driven by servo motors to move precisely in the X and Y axis directions. A length detection sensor is set at the front end of the cutting tool.

[0013] Unloading module: It consists of a liftable unloading tray and a conveyor belt. The unloading tray transfers the lead plate smoothly to the conveyor belt.

[0014] In one example, the feeding end of the feeding module is provided with a lead plate thickness and width detection sensor, which detects and transmits the lead plate data to the control module in real time, providing basic data for subsequent processing.

[0015] In one example, the flattening module is equipped with a pressure sensor to monitor the pressure applied during the flattening process in real time and accurately adjust the downward pressure of the flattening roller through a closed-loop control algorithm.

[0016] In one example, the image recognition module uses advanced image processing algorithms and machine learning techniques to analyze and process the collected images to assist in cutting positioning and quality control.

[0017] In one example, the cutting module combines the width data transmitted by the loading module and the analysis results of the image recognition module to calculate the optimal cutting layout plan to reduce scraps.

[0018] A method for controlling automatic positioning and shearing of lead plate processing, characterized by comprising the following steps:

[0019] Step 1: Set system parameters, start the system, and perform self-test procedures;

[0020] Step 2: Loading and testing: start the loading conveyor belt, measure the thickness and width of the lead plate, and collect image information;

[0021] Step 3: Flattening treatment, adjust the gap between the flattening rollers according to the thickness data, and heat the flattening rollers;

[0022] Step 4: Cutting process, measuring the length of the lead plate, and determining the cutting positioning point by combining image analysis;

[0023] Step 5: Unloading and quality control. The unloading tray rises to receive the cut lead plate, transfers it to the unloading conveyor belt, and conducts the final quality inspection.

[0024] In one example, the control system software sets relevant parameters, including the initial gap of the flattening roller, the flattening pressure range, the heating temperature setting value, the cutting size parameters, the conveyor belt speed, and sets relevant parameters of the cutting planning algorithm.

[0025] In one example, after receiving the data, the control module determines the specifications of the lead plate and issues an alarm signal if the specifications exceed the allowable range.

[0026] In one example, the flattening roller is driven to rotate by a servo motor, and a pressure sensor monitors the pressure in real time and feeds back to a control module, and the downforce is dynamically adjusted through a closed-loop control algorithm.

[0027] In one example, the control module calculates the optimal cutting path and parameters, drives the cutting tool to perform high-speed and precise cutting, monitors the material cutting process and performs quality inspection.

[0028] The automatic positioning and shearing control system and method for lead plate processing proposed by the present invention can bring the following beneficial effects:

[0029] 1. The present invention realizes the full process automation of lead plate from loading to unloading through this system. The various links are precisely coordinated and linked through the control module, which improves production efficiency and processing accuracy, reduces manual intervention and human errors, and reduces labor intensity and safety risks. Through real-time monitoring and feedback control of multiple sensors, combined with advanced image recognition technology, the flattening gap, pressure, heating temperature, cutting path and speed parameters of the lead plate can be accurately adjusted and controlled to ensure that each lead plate can achieve the ideal flattening effect and cutting accuracy to meet high-quality production requirements.

[0030] 2. The present invention uses an image recognition module to perform multiple inspections and analyses on the surface quality of lead plates throughout the entire production process, which can timely discover and deal with various surface defects and quality problems, improve product qualification rates and production efficiency. At the same time, the system records and stores the processing data and quality inspection results of each lead plate, which facilitates product quality traceability and management, and provides a strong basis for continuous improvement of production processes.

[0031] 3. The present invention can flexibly adjust according to lead plates of different specifications and materials through the system parameter settings, and can adapt to various production needs. Whether it is processing lead plates with large thickness variations or coping with cutting tasks of different sizes and specifications, the system can quickly adapt through simple parameter modifications or program adjustments, and has strong versatility and practicality. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0033] Figure 1 This is a schematic diagram of the architecture of an automatic positioning and shearing control system for lead plate processing according to the present invention.

[0034] Figure 2 The present invention is a flowchart of a method for automatically positioning and shearing control of lead plate processing. DETAILED DESCRIPTION

[0035] In order to more clearly and completely illustrate the technical solution of the present invention, the present invention will be further described below with reference to the accompanying drawings.

[0036] Please refer to Figure 1 and Figure 2 The present invention proposes an automatic positioning and shearing control system for lead plate processing. The system is mainly composed of several key parts: loading module, flattening module, sensor module, image recognition module, control module, cutting module and unloading module. The modules work closely together to ensure the efficiency and accuracy of lead plate processing.

[0037] The loading module, as the starting point of the entire system, adopts an automated loading conveyor belt. The conveying speed is not fixed and can be flexibly adjusted according to the actual production rhythm. By adjusting the conveyor belt speed, the best loading effect can be achieved, thereby providing a stable and orderly supply of lead plates for subsequent processing procedures.

[0038] The flattening module is a key part to ensure the flatness of the lead plate. It consists of two sets of flattening rollers, upper and lower. In terms of design, the diameter and length of the flattening rollers are determined according to the maximum size of the lead plate. This design can ensure that even the largest lead plate can be evenly flattened. The adjustment method of the flattening roller gap adopts an advanced electric adjustment mechanism, which can realize automatic adjustment and improve the convenience and accuracy of operation. The heating device also has intelligent characteristics. According to the material and thickness of the lead plate, the flattening roller is moderately heated. Lead plates of different materials and thicknesses have different temperature requirements during the flattening process.

[0039] The sensor module plays a perception role in the entire system. It includes various types of sensors such as position sensors and speed sensors. These sensors can monitor the position information of key components and important parameters such as operating speed in real time and accurately. By accurately grasping this information, the system can timely understand the working status of each component and provide reliable data support for subsequent control and decision-making.

[0040] The image recognition module uses a high-resolution industrial camera to conduct a comprehensive and detailed observation of the lead plate, capturing various features on the lead plate surface, including subtle surface textures and possible defects, and clearly obtaining the edge contour information of the lead plate, as well as the concave and convex conditions in the middle. The rich image information provides an important basis for subsequent cutting positioning and quality control, making the cutting process more accurate and product quality more guaranteed.

[0041] The control module is the brain of the entire system, responsible for processing data information from each module. With its powerful computing power and preset program logic and algorithms, the control module can quickly and accurately analyze and process this data and generate corresponding control instructions.

[0042] The cutting module is responsible for accurately cutting the lead plate. It uses a high-precision carbide blade. The blade is installed on a sturdy tool holder and is driven by a servo motor. It can move precisely in the X and Y axis directions. A length detection sensor is set at the front end of the cutting tool. The sensor can monitor the length information of the lead plate in real time.

[0043] The unloading module is mainly composed of a liftable unloading tray and a conveyor belt. When the cut lead plate needs to be unloaded, the unloading tray will rise smoothly, hold the lead plate, and then transfer the lead plate to the designated position through the conveyor belt. This design ensures the stability of unloading and improves the efficiency of unloading.

[0044] In order to further improve the performance of the system and product quality, lead plate thickness and width detection sensors are set at the loading end of the loading module. These sensors can detect the thickness and width data of the lead plate in real time and accurately, and transmit these data to the control module in a timely manner. Based on these basic data, the control module can more accurately control and adjust the subsequent processing flow to ensure that each lead plate can receive the most appropriate treatment.

[0045] The flattening module is equipped with a pressure sensor. During the flattening process, this sensor can monitor the pressure applied to the lead plate in real time. Through the closed-loop control algorithm, the system can accurately adjust the downward pressure of the flattening roller according to the data feedback from the pressure sensor. This dynamic pressure adjustment method ensures that the lead plate is effectively flattened and avoids damage to the lead plate due to excessive pressure.

[0046] The image recognition module uses advanced image processing algorithms and machine learning technologies. After collecting the image information of the lead plate, these technologies can perform in-depth analysis and processing of the image, and can accurately identify the various features and defects of the lead plate. By learning from a large amount of image data, the system can continuously optimize its own recognition capabilities and quality control level, further improving product quality and production efficiency.

[0047] When the cutting module is working, it will combine the width data transmitted by the loading module and the analysis results of the image recognition module. Through comprehensive analysis of these data, the system can calculate the optimal cutting layout plan. This optimized cutting layout plan can minimize the generation of scrap materials, improve the utilization rate of raw materials, and reduce production costs.

[0048] Based on the above-mentioned automatic positioning and shearing control system for lead plate processing, an automatic positioning and shearing control method for lead plate processing is derived. The specific steps of this method are as follows: First, set the system parameters. Before starting the system, the operator needs to set relevant parameters in the control system software according to the specific production tasks and the specifications of the lead plate. The parameters cover the initial gap of the flattening roller, the flattening pressure range, the heating temperature setting value, the cutting size parameters, the conveyor belt speed, and the relevant parameters of the cutting planning algorithm. Reasonable parameter setting is the key to ensuring the normal operation of the system and product quality. After the setting is completed, start the system, and the system will automatically execute the self-test program. The self-test program will conduct a comprehensive inspection of each component of the system to ensure that each component is in normal working condition. If there is any abnormality, the system will promptly issue an alarm and prompt fault information so that the operator can check and repair it.

[0049] Enter the loading and inspection link, start the loading conveyor belt, and transport the lead plate to be processed to the system. During the loading process, the lead plate thickness and width detection sensor of the loading module will measure the thickness and width of the lead plate in real time, and transmit these data to the control module. At the same time, the high-resolution industrial camera of the image recognition module will capture the image of the lead plate to obtain the surface features, edge contours and central convexity information of the lead plate. These data and information provide important basis for subsequent flattening, cutting and other processing steps.

[0050] During the flattening process, the control module automatically adjusts the gap between the flattening rollers according to the thickness data transmitted from the loading module, so that it reaches the spacing that best suits the current lead plate thickness. At the same time, the heating device will moderately heat the flattening roller according to the material and thickness of the lead plate. During the flattening process, the flattening roller rotates driven by the servo motor, and the pressure sensor monitors the pressure in real time and feeds back to the control module. The control module dynamically adjusts the downward pressure of the flattening roller according to the data fed back by the pressure sensor through a closed-loop control algorithm to ensure that the lead plate is evenly flattened at appropriate pressure and temperature.

[0051] During cutting, the length detection sensor of the cutting module measures the length of the lead plate, and combines the analysis results of the lead plate image by the image recognition module to determine the cutting positioning point. The control module calculates the optimal cutting path and parameters based on this information, and then drives the cutting tool to perform high-speed and precise cutting. During the cutting process, the cutting tool is driven by the servo motor and moves precisely in the X and Y axis directions according to the predetermined path and parameters. The carbide blade can ensure the cutting accuracy and quality of the incision.

[0052] Carry out unloading and quality control. When the unloading tray rises to take over the cut lead plate, the lead plate is transferred to the unloading conveyor belt. During the transfer process, the system will monitor the unloading situation and conduct a final quality inspection. The quality inspection content includes the flatness, dimensional accuracy, and cutting quality of the lead plate. If quality problems are found, the system will issue an alarm in time and remove unqualified products. Qualified lead plates are transported to the designated location via the unloading conveyor belt to complete the entire processing flow.

[0053] During the entire control process, after receiving the data, the control module will judge the specifications of the lead plate. If the thickness, width, length and other specifications of the lead plate exceed the range allowed by the system, the system will immediately issue an alarm signal and stop the subsequent processing process to avoid damage to the equipment or affect product quality due to the processing of inappropriate lead plates.

[0054] In short, this automatic positioning and shearing control system for lead plate processing and its processing method, through the collaborative work of various modules and intelligent control, can achieve efficient and precise processing of lead plates, improve product quality and production efficiency, reduce production costs, and have important practical application value.

[0055] Example: Comparison of production efficiency and precision of a lead plate processing company

[0056] In order to verify the effectiveness of the present invention, a traditional production line (before improvement) of a lead plate processing enterprise and a production line using this system (after improvement) were selected for comparative testing. The test indicators included production efficiency (pieces / hour), processing accuracy (cutting size error rate), manual intervention frequency (times / hour) and scrap rate (%).

[0057] Production efficiency: Traditional production lines rely on manual loading, manual adjustment of the flattening roller gap, and manual positioning and cutting, with an average efficiency of 50 pieces / hour. After adopting this system, through the automation of the loading module, closed-loop control of the flattening module, and intelligent planning of the cutting module, the efficiency is increased to 120 pieces / hour, an increase of 140%.

[0058] Processing accuracy: Due to manual measurement and fixed cutting parameters, the dimensional error rate of traditional production lines is as high as 8%. This system uses the image recognition module to accurately locate the edge contour and the sensor to adjust the real-time feedback, reducing the error rate to 1.5%, meeting the requirements of high-precision processing.

[0059] Frequency of manual intervention: Traditional production lines require manual monitoring of flattening pressure and manual input of cutting dimensions, with more than 20 interventions per hour. This system automatically coordinates various modules through the control module, reducing the frequency of manual intervention to less than 3 times, and only requires regular inspections, greatly reducing labor intensity.

[0060] Scrap rate of corners: Traditional cutting relies on a fixed layout, with a scrap rate of about 15%. This system combines lead plate width detection data with image recognition results to optimize the cutting path, reducing the scrap rate to 6%, increasing raw material utilization by 9%, and saving approximately RMB 800,000 in annual costs (calculated based on an annual processing capacity of 100,000 tons of lead plates).

[0061]

[0062]

[0063] As can be seen from the chart, this system achieves efficient collaboration through the following technologies:

[0064] Multi-sensor fusion: thickness / width sensors, pressure / temperature sensors, and industrial cameras provide real-time data.

[0065] Intelligent algorithm control: closed-loop adjustment of flattening parameters, dynamic planning of cutting paths, and reduction of waste.

[0066] Full process automation: No manual intervention is required from loading to unloading, increasing efficiency by 62.5%.

[0067] In this embodiment, the loading module realizes efficient loading of lead plates through an automated loading conveyor belt, and its conveying speed can be adjusted to adapt to different production rhythms. In addition, the loading end is also equipped with a lead plate thickness and width detection sensor, which can detect and transmit the lead plate data to the control module in real time, providing basic data for subsequent processing. The flattening module consists of two sets of upper and lower flattening rollers. The diameter and length of the flattening rollers are designed according to the maximum size of the lead plate to ensure that the lead plate of the largest size can also be flattened evenly. The gap between the flattening rollers is automatically adjusted by an electric adjustment mechanism, and the heating device moderately heats the flattening rollers according to the material and thickness of the lead plate to meet the flattening requirements of different lead plates. The sensor module includes position sensors and speed sensors, etc., which are used to monitor the position information and operating speed of key components in real time to provide accurate data support for the system. The image recognition module A high-resolution industrial camera is installed to fully capture the surface features, edge contours and central convexity of the lead plate. Advanced image processing algorithms and machine learning technologies are used to analyze and process the collected images to assist in cutting positioning and quality control. The control module, as the brain of the system, is responsible for processing data information from each module and generating control instructions according to preset program logic and algorithms to ensure the orderly operation of the entire system. The cutting module uses high-precision carbide blades installed on the tool holder and is driven by a servo motor to move precisely in the X and Y axis directions. Combined with the width data transmitted by the loading module and the analysis results of the image recognition module, the optimal cutting layout plan is calculated to reduce waste corners. The unloading module consists of a liftable unloading tray and a conveyor belt. The unloading tray transfers the cut lead plate smoothly to the conveyor belt to complete the unloading process.

[0068] System parameter setting and self-test. Before starting the system, the operator needs to set relevant parameters in the control system software according to the specific production tasks and lead plate specifications, such as the initial gap of the flattening roller, the flattening pressure range, the heating temperature setting value, the cutting size parameters, and the conveyor belt speed. After the settings are completed, the system will automatically execute the self-test program to ensure that all components are in normal working condition. The production process includes loading and testing, flattening, cutting, unloading and quality control. Each step depends on the intelligent control and collaborative work of the system to achieve efficient and accurate processing of lead plates. In order to further improve system performance and product quality, the system has also been optimized in many aspects, such as dynamic pressure regulation, calculation of the optimal cutting layout plan, etc. Through comparative testing with traditional production lines, the system has achieved significant improvements in production efficiency, processing accuracy, manual intervention frequency and scrap rate, verifying the effectiveness of the invention.

[0069] Of course, the present invention may have many other implementations. Based on this implementation, other implementations obtained by ordinary technicians in this field without any creative work are all within the scope of protection of the present invention.

Claims

1. An automatic positioning and shearing control system for lead plate processing, characterized in that: It includes a loading module, a flattening module, a sensor module, an image recognition module, a control module, a cutting module and a blanking module, among which: Loading module: It adopts an automated loading conveyor belt with adjustable conveying speed to adapt to different production rhythms; Flattening module: It consists of two sets of flattening rollers, the diameter and length of which are designed according to the maximum size of the lead plate. The gap between the flattening rollers is automatically adjusted by an electric adjustment mechanism. The heating device can moderately heat the flattening rollers according to the material and thickness of the lead plate. Sensor module: including position sensor and speed sensor, used to monitor the position information of key components; Image recognition module: Install a high-resolution industrial camera to fully capture the surface features, edge contours, and central concave and convex conditions of the lead plate; Control module: processes data information from each module and generates control instructions according to preset program logic and algorithms; Cutting module: It uses high-precision carbide blades, which are installed on the tool holder and are driven by servo motors to move precisely in the X and Y axis directions. A length detection sensor is set at the front end of the cutting tool. Unloading module: It consists of a liftable unloading tray and a conveyor belt. The unloading tray transfers the lead plate smoothly to the conveyor belt.

2. The automatic positioning and shearing control system for lead plate processing according to claim 1, characterized in that: The feeding end of the feeding module is provided with a lead plate thickness and width detection sensor, which detects and transmits the lead plate data to the control module in real time, providing basic data for subsequent processing.

3. The automatic positioning and shearing control system for lead plate processing according to claim 1, characterized in that: The flattening module is equipped with a pressure sensor to monitor the pressure applied during the flattening process in real time and accurately adjust the downward pressure of the flattening roller through a closed-loop control algorithm.

4. The automatic positioning and shearing control system for lead plate processing according to claim 1, characterized in that: The image recognition module uses advanced image processing algorithms and machine learning technology to analyze and process the collected images to assist in cutting positioning and quality control.

5. The automatic positioning and shearing control system for lead plate processing according to claim 1, characterized in that: The cutting module combines the width data transmitted by the feeding module and the analysis results of the image recognition module to calculate the optimal cutting layout plan to reduce scraps.

6. A method for controlling automatic positioning and shearing of lead plate processing, applied to the automatic positioning and shearing control system of lead plate processing according to claims 1 to 5, characterized in that: The following steps are involved: Step 1: Set system parameters, start the system, and perform self-test procedures; Step 2: Loading and testing: start the loading conveyor belt, measure the thickness and width of the lead plate, and collect image information; Step 3: Flattening treatment, adjust the gap between the flattening rollers according to the thickness data, and heat the flattening rollers; Step 4: Cutting process, measuring the length of the lead plate, and determining the cutting positioning point by combining image analysis; Step 5: Unloading and quality control. The unloading tray rises to receive the cut lead plate, transfers it to the unloading conveyor belt, and conducts the final quality inspection.

7. The automatic positioning and shearing control method for lead plate processing according to claim 6, characterized in that: The control system software sets relevant parameters, including the initial gap of the flattening roller, the flattening pressure range, the heating temperature setting value, the cutting size parameters, the conveyor belt speed, and sets relevant parameters of the cutting planning algorithm.

8. The automatic positioning and shearing control method for lead plate processing according to claim 6, characterized in that: After receiving the data, the control module determines the specifications of the lead plate and issues an alarm signal if the specifications exceed the allowable range.

9. The automatic positioning and shearing control method for lead plate processing according to claim 6, characterized in that: The flattening roller rotates under the drive of a servo motor, and the pressure sensor monitors the pressure in real time and feeds back to the control module, and the downward pressure is dynamically adjusted through a closed-loop control algorithm.

10. The automatic positioning and shearing control method for lead plate processing according to claim 6, characterized in that: The control module calculates the optimal cutting path and parameters, drives the cutting tool to perform high-speed and precise cutting, monitors the material cutting process and performs quality inspection.

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