A roller car flexible automatic loading and unloading device and method

Abstract

The present invention belongs to the technical field of roller sewing, and specifically discloses a flexible automatic loading and unloading device and method for a roller sewing machine. The device includes a material loading platform, a motion controller, a material picking and auxiliary sewing mechanism, and a material unloading platform. The motion controller is used to convert the coordinate information of the material picking, auxiliary sewing, and unloading into a multi-axis linkage signal. The guide rail unit, the first rotating unit, and the terminal rotating unit perform the material picking and auxiliary sewing actions according to the signal, and transfer the material to the material unloading platform. The method includes extracting the coordinate information of the material picking, auxiliary sewing, and unloading and converting the information into a multi-axis linkage signal, and transmitting the multi-axis linkage signal to the material loading unit, the material picking and auxiliary sewing mechanism, and the material unloading platform to complete the material feeding, picking, auxiliary sewing, and unloading. The present invention can effectively replace manual loading and unloading and auxiliary sewing, and quickly adapt to changes in sewing contours, thereby improving sewing efficiency and quality.

Description

Technical Field

[0001] The invention relates to the field of roller sewing, and more specifically, to a flexible automatic loading and unloading device and method for a roller sewing machine. Background Art

[0002] With the continuous development of intelligent science and technology, the integration of traditional manufacturing industry with intelligent control and Internet of Things is becoming more and more important. Sewing and textile, as a basic project for human clothing needs, has become an important factor affecting the consumer market due to the changes in modern consumption concepts and aesthetic concepts. Its combination with intelligent manufacturing has become a general trend.

[0003] Modern sewing has seen the emergence of a variety of labor-saving digital equipment such as computer pattern machines, template machines, pocket machines, rotary sewing machines, and computer roller machines. Various devices are suitable for different sewing occasions. They are basically based on controllers and use motors, cylinders and other actuators to replace manual work to complete the corresponding processes, which has greatly improved production efficiency. However, due to the special properties of sewing materials such as flexibility and contour variability, the loading process from material collection to sewing and the unloading process after sewing have not been well replaced by machines. Computer roller machines use rollers and needle feeds to drive the fabric to move. They have strong climbing power and stable needle positions. They are usually used to sew insoles and the contours of high-grade leather shoes and bags with 0# thick thread. Due to the shortcomings of existing equipment, loading is completely dependent on manual labor, and manual assistance is also required during the sewing process, which leads to the inability to improve production efficiency and is prone to risk problems caused by human operation.

[0004] Therefore, there is an urgent need in the art to propose an automatic loading and unloading device for a roller sewing machine, to build a safe automatic loading and unloading device, to effectively replace manual and auxiliary sewing, and to quickly adapt to changes in sewing contours, thereby improving sewing efficiency and quality. Summary of the invention

[0005] In view of the above defects or improvement needs of the prior art, the present invention provides a flexible automatic loading and unloading device and method for a roller machine, wherein a flexible automatic loading and unloading device for a roller machine is designed accordingly in combination with the characteristics of the automatic loading and unloading device itself and the process characteristics of sewing processing, and its key components such as the structure of the material loading unit, the material contour extraction unit and the material picking and auxiliary sewing mechanism and their specific setting methods are studied and designed, and a safe automatic loading and unloading device can be constructed accordingly to effectively replace manual and auxiliary sewing. At the same time, by identifying the edge contour of the topmost material and generating the sewing path of the material, and then extracting the coordinate information of the material picking, auxiliary sewing and unloading, the material loading, auxiliary sewing and unloading processes are precisely controlled by the mutual cooperation of the actuators according to the coordinate information, thereby effectively replacing manual and auxiliary sewing, and quickly adapting to changes in sewing contours, thereby improving sewing efficiency and quality.

[0006] To achieve the above-mentioned purpose, according to one aspect of the present invention, a flexible automatic loading and unloading device for a roller carriage is provided, comprising a material loading platform, a motion controller, a material taking and auxiliary sewing mechanism and a material unloading platform, wherein:

[0007] The material loading platform includes a material loading unit and a material contour extraction unit. The material loading unit is used to stack materials. The material contour extraction unit is arranged above the material loading unit and is used to identify the edge contour of the uppermost material, generate a sewing path of the material according to the edge contour of the material, and extract coordinate information of material picking, auxiliary sewing and material unloading according to the sewing path;

[0008] The motion controller is used to convert the coordinate information of the material picking, auxiliary sewing and material unloading into a multi-axis linkage signal, and control the movement of the material unloading table of the material loading unit according to the multi-axis linkage signal to adjust the horizontal height of the uppermost layer of materials stacked thereon in real time, so that the horizontal height of the uppermost layer of materials remains unchanged;

[0009] The material picking and auxiliary sewing mechanism includes a guide rail unit, a first rotating unit, a terminal rotating unit and a suction cup, the guide rail unit is arranged on the roller car, the first rotating unit is slidably arranged above the guide rail unit, one end of the terminal rotating unit is fixed above the first rotating unit, and the other end is fixedly connected to the suction cup, and the suction cup is arranged below the terminal rotating unit. The guide rail unit, the first rotating unit and the terminal rotating unit cooperate with each other to perform material picking and auxiliary roller car sewing actions according to the multi-axis linkage signal, and transfer the sewn materials to the material unloading table.

[0010] Furthermore, the material picking and auxiliary sewing mechanism includes a guide rail unit, a first rotating unit, a terminal rotating unit and a suction cup, the guide rail unit is arranged on a roller cart for sewing, the first rotating unit is slidably arranged above the guide rail unit, one end of the terminal rotating unit is fixedly arranged above the first rotating unit, and the other end is fixedly connected to the suction cup, and the suction cup is arranged below the terminal rotating unit, and then the guide rail unit, the first rotating unit and the terminal rotating unit cooperate with each other to perform multi-axis linkage actions according to the multi-axis linkage signal to complete the material picking, auxiliary sewing and material unloading actions.

[0011] Furthermore, the guide rail unit includes a plurality of X-axis ball screw guide rails arranged in parallel, a Y-axis ball screw guide rails arranged horizontally and vertically on the plurality of X-axis ball screw guide rails, and a first drive motor driving the Y-axis ball screw guide to move along the X-axis ball screw guide, wherein the first drive motor is used to receive a multi-axis linkage signal issued by the motion controller, and drive the Y-axis ball screw guide to move along the X-axis ball screw guide according to the multi-axis linkage signal.

[0012] Furthermore, the first rotation unit includes a Z-axis rotation axis support seat, a Z-axis rotation axis, a second drive motor and a third drive motor, wherein the Z-axis rotation axis support seat is slidably connected to the Y-axis ball screw guide rail, and the second drive motor is used to receive a multi-axis linkage signal issued by the motion controller, and drive the Z-axis rotation axis support seat to move back and forth along the Y-axis ball screw guide rail according to the multi-axis linkage signal; the Z-axis rotation axis is arranged on the Z-axis rotation axis support seat, and performs a rotation action under the drive of the third drive motor, and the third drive motor is used to receive a multi-axis linkage signal issued by the motion controller, and perform a rotation action according to the multi-axis linkage signal.

[0013] Furthermore, the terminal rotation unit includes a terminal motor support seat, a driving wheel, a driven wheel, a transmission belt, a terminal rotating shaft and a fourth drive motor, wherein the terminal motor support seat is fixedly arranged above the Z-axis rotating shaft, the driving wheel and the driven wheel are arranged on the terminal motor support seat and are connected through the transmission belt, the terminal rotating shaft is arranged below the driven wheel and fixedly connected to the driven wheel, and the fourth drive motor is used to receive a multi-axis linkage signal issued by the motion controller, and drive the driving wheel to rotate according to the multi-axis linkage signal, and then drive the driven wheel and the terminal rotating shaft to rotate by driving the transmission belt to rotate.

[0014] Furthermore, the material loading unit includes a lifting platform support seat, a spiral lifting platform, a material limit block and a fifth drive motor, wherein the spiral lifting platform is arranged vertically along the lifting platform support seat and is fixedly connected to the lifting platform support seat, the material limit block is slidably connected to the spiral lifting platform, and the fifth drive motor is used to receive a multi-axis linkage signal issued by the motion controller, and drive the material limit block to move up and down along the spiral lifting platform according to the multi-axis linkage signal.

[0015] Furthermore, the material contour extraction unit includes a camera bracket, an industrial camera and an industrial control display screen, wherein the camera bracket is arranged above the lifting platform support seat, and the industrial camera is arranged on the camera bracket, and is used to take real-time photos of the material limit block and the material stacked on the material limit block, and transmit the photo to the industrial control display screen, and the industrial control display screen obtains the edge contours of the material limit block and the material according to the pixel point information of the photo, and obtains the stacking thickness of the material according to the edge contour of the material limit block. At the same time, a sewing path of the material is generated according to the edge contour of the material, and then the coordinate information of material picking, sewing and unloading is extracted according to the sewing path, and the fifth drive motor adjusts the horizontal height of the material limit block in real time according to the stacking thickness of the material, so that the horizontal height of the uppermost layer of material remains unchanged.

[0016] Furthermore, the material loading unit also includes a backlight source, and the backlight source is used to adjust the background color of the material limiting block so that the material limiting block is clearly distinguished from the color of the material stacked thereon.

[0017] Furthermore, the material unloading platform includes a unloading plate support seat, a unloading screw lifting platform, a material unloading plate and a sixth drive motor, wherein the unloading screw lifting platform is vertically arranged along the unloading plate support seat and fixedly connected to the unloading plate support seat, the material unloading plate is slidably connected to the unloading screw lifting platform, and the sixth drive motor is used to receive the multi-axis linkage signal issued by the motion controller, and drive the material unloading plate to move up and down along the unloading screw lifting platform according to the multi-axis linkage signal.

[0018] According to another aspect of the present invention, a method for flexible automatic loading and unloading of a roller cart is provided, which is implemented by using the above-mentioned device and comprises the following steps:

[0019] S1 material contour extraction unit identifies the edge contour of the topmost material stacked in sequence on the material loading unit, generates a sewing path of the material according to the edge contour of the topmost material, and then extracts the coordinate information of material picking, auxiliary sewing and material unloading according to the sewing path;

[0020] The S2 motion controller is used to convert the coordinate information of the material picking, sewing and unloading into a multi-axis linkage signal, and transmit the multi-axis linkage signal to the material loading unit, the material picking and auxiliary sewing mechanism and the material unloading table;

[0021] S3, the material loading unit adjusts the horizontal height of the top layer of material according to the multi-axis linkage signal to make it equal to the preset height;

[0022] S4: the material taking and auxiliary sewing mechanism takes the uppermost material stacked on the material feeding unit to the sewing area of ​​the roller car according to the multi-axis linkage signal, and assists the roller car to complete the sewing action, and then transfers the sewn material to the material unloading table;

[0023] S5 After the material unloading table receives the sewn material, the horizontal height of the top layer of material is adjusted according to the multi-axis linkage signal to make it equal to the preset height;

[0024] S6 repeats steps S1 to S5 until all materials have completed the sewing action and are transferred to the material unloading table, or the stacking thickness of the materials on the material unloading table reaches a preset height.

[0025] Furthermore, the horizontal height of the uppermost layer of material in step S1 is the same as the horizontal height of the uppermost layer of material in step S5, and the multi-axis linkage signal includes a first axis control signal for controlling the up and down movement of the material loading unit and the material unloading platform, a second axis control signal for controlling the left and right parallel movement of the material picking and auxiliary sewing mechanism, a third axis control signal for controlling the front and back parallel movement of the material picking and auxiliary sewing mechanism, and a fourth axis control signal for controlling the rotational movement of the material picking and auxiliary sewing mechanism.

[0026] In general, the above technical solution conceived by the present invention has the following technical advantages compared with the prior art:

[0027] 1. The present invention coordinates the material loading table, the material unloading table, the material picking and auxiliary sewing mechanism and the motion controller, and utilizes machine vision, multi-axis linkage and contour extraction technology, so that roller sewing can greatly reduce the dependence on manual labor, and can automatically and accurately complete the material loading, unloading and auxiliary sewing actions, and can also quickly adapt to the changes in the material contour. Manual labor is only responsible for placing the stacked materials on the material loading table and taking away the sewn and stacked materials from the material unloading table, which not only greatly improves the factory's production efficiency, but also avoids the risks in manual operation.

[0028] 2. The present invention converts the coordinate information of material picking, auxiliary sewing and material unloading into a multi-axis linkage signal, and controls the actions of each drive motor used to perform related actions through the multi-axis linkage signal, thereby driving the guide rail unit, the first rotating unit and the terminal rotating unit to cooperate with each other to perform multi-axis linkage actions to complete the material picking, auxiliary sewing and material unloading actions.

[0029] 3. The present invention can accurately complete the material picking, auxiliary sewing and unloading actions according to the specified path and action through the cooperation of two guide rail mechanisms arranged perpendicular to each other, the loading and unloading mechanisms that can move along the guide rails, the Z-axis rotation mechanism, the terminal rotation mechanism and the suction cup.

[0030] 4. The belt-driven terminal rotating shaft provided in the present invention can complete roller sewing of materials without hands, and the suction cup can be used instead of human hands to assist the material sewing device during sewing.

[0031] 5. The materials on the material loading table and the material unloading table of the present invention can be adjusted to a preset value as needed, and the height can be adjusted in real time to remain unchanged, so as to adapt to the material picking and auxiliary sewing mechanism. There is no need to move up and down when picking and loading materials. On the one hand, the suction force between the suction cup and the material does not need to be calculated and adjusted, and on the other hand, the structural device is simpler.

[0032] 6. The present invention uses machine vision technology to extract material edges and automatically generate sewing paths through the cooperation of industrial cameras and multi-color adjustable backlight sources, which can quickly adapt to changes in material contours. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the overall structure of a flexible automatic loading and unloading device for a roller vehicle involved in an embodiment of the present invention;

[0034] Figure 2 yes Figure 1 A schematic diagram of the structure of the material loading platform involved in the invention;

[0035] Figure 3 yes Figure 1 A schematic diagram of the structure of the material taking and auxiliary sewing mechanism involved in the invention;

[0036] Figure 4 It is a structural schematic diagram of a flexible automatic loading and unloading device of a roller machine for assisting sewing according to an embodiment of the present invention;

[0037] Figure 5 The invention is a schematic structural diagram of a flexible automatic loading and unloading device for a roller vehicle during material picking.

[0038] In all the drawings, the same figure marks are used to represent the same elements or structures, among which: 1-material loading platform, 2-material unloading platform, 3-material picking and auxiliary sewing mechanism, 4-lifting platform support seat, 5-spiral lifting platform, 6-material limit block, 7-backlight source, 8-backlight source support seat, 9-display screen bracket, 10-industrial control display screen, 11-camera bracket, 12-industrial camera, 13-transmission belt, 14-driven wheel, 15-terminal rotating shaft, 16-suction cup, 17-X-axis ball screw guide, 18-Y-axis ball screw guide, 19-Z-axis rotating shaft support seat, 20-Z-axis rotating shaft, 21-terminal motor support seat, 22-driving wheel, 23-material unloading plate, 24-unloading plate support seat. DETAILED DESCRIPTION

[0039] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0040] See also Figures 1 to 5 The present invention discloses a flexible automatic loading and unloading device for a roller carriage, which comprises a material loading platform 1, a material unloading platform 2, a motion controller and a material taking and auxiliary sewing mechanism 3.

[0041] like Figure 2As shown, the material loading platform 1 includes a material loading unit and a material contour extraction unit. The material loading unit is used to stack materials and adjust the horizontal height of the uppermost material in real time so that the horizontal height of the uppermost material remains unchanged. The material contour extraction unit is arranged above the material loading unit, and is used to identify the edge contour of the uppermost material, and generate the sewing path of the material according to the edge contour of the material, and then extract the coordinate information of material picking, auxiliary sewing and material unloading according to the sewing path. The motion controller is used to convert the coordinate information of material picking, auxiliary sewing and material unloading into a multi-axis linkage signal; the multi-axis linkage signal includes a first axis control signal for controlling the up and down movement of the material loading unit and the material unloading platform 2, a second axis control signal for controlling the left and right parallel movement of the material picking and auxiliary sewing mechanism 3, a third axis control signal for controlling the front and back parallel movement of the material picking and auxiliary sewing mechanism 3, and a fourth axis control signal for controlling the rotational movement of the material picking and auxiliary sewing mechanism 3. The material loading unit adjusts the horizontal height of the topmost material stacked thereon in real time according to the first axis control signal, so that the horizontal height of the topmost material remains unchanged. The material loading unit includes a lifting platform support seat 4, a spiral lifting platform 5, a material limit block 6 and a fifth drive motor, wherein the spiral lifting platform 5 is arranged vertically along the lifting platform support seat 4 and is fixedly connected to the lifting platform support seat 4, the material limit block 6 is slidably connected to the spiral lifting platform 5, and the fifth drive motor is used to receive the first axis control signal issued by the motion controller, and drive the material limit block 6 to move up and down along the spiral lifting platform 5 according to the first axis control signal. The material contour extraction unit includes a camera bracket 12, an industrial camera 11 and an industrial control display screen 10, wherein the camera bracket 12 is arranged above the lifting platform support seat 4, and the industrial camera 11 is arranged on the camera bracket 12, which is used to take photos of the material stopper block 6 and the materials stacked on the material stopper block 6 in real time, and transmit the photos to the industrial control display screen 10, and the industrial control display screen 10 obtains the edge contours of the material stopper block 6 and the materials according to the pixel point information of the photos, and obtains the stacking thickness of the materials according to the edge contour of the material stopper block 6, and at the same time, generates the sewing path of the materials according to the edge contour of the materials, and then extracts the coordinate information of material collection, sewing and unloading according to the sewing path, and the fourth drive motor adjusts the horizontal height of the material stopper block 6 in real time according to the stacking thickness of the materials, so that the horizontal height of the uppermost material remains unchanged. The material loading unit also includes a backlight source 7, and the backlight source 7 is used to adjust the background color of the material stopper block 6, so that the material stopper block 6 and the materials stacked thereon are clearly distinguished in color.

[0042] Specifically: the material loading platform 1 is mainly composed of an industrial control display screen 10, a display screen bracket 9, an industrial camera 11, a camera bracket 12, a material limit block 6, a backlight source 7, a backlight source support seat 8, a spiral lifting platform 5, and a lifting platform support seat 4. The height of the display screen 10 can be adaptively adjusted to facilitate manual operation. According to ergonomics, it is generally set to 1.3m from the ground. Correspondingly, the distance between the lens of the industrial camera 11 and the surface of the loading platform can also be adaptively adjusted. This distance leaves enough space for manual loading and the movement of the loading mechanism, and can also ensure that the size of the material contour obtained by shooting is appropriate and the edges are clear. Figure 4 As shown, multiple layers of neatly stacked materials are placed on the upper surface of the backlight source 7. The color-adjustable backlight source 7 is set to a light color that is clearly distinguishable from the color of the materials. The industrial camera 11 takes pictures of the placed materials and the material stopper 6 and transmits them to the industrial control display screen 10 via a signal transmission line (not shown in the figure). The industrial control display screen 10 uses the visual measurement and image processing components loaded by the embedded core therein to perform feature extraction and edge detection, and identifies the material stopper 6 and the edge contour of the material. The horizontal position and size of the material stopper 6 are fixed. The industrial control display screen 10 calculates the size and position of the material edge contour, generates a sewing path, and analyzes it into coordinate point information during the material collection, sewing, and material unloading processes, and sends it to the motion controller (not shown in the figure) to control the movement of each motor. The spiral lifting platform 5 drives the backlight source 7 to move longitudinally, and the thickness of a layer of material rises after each material collection.

[0043] The method for extracting the edge contour of the material is as follows: grayscale, Gaussian filtering, image gradient processing and non-maximum suppression are performed on the photograph of the material to obtain a grayscale image of the edge candidate points, and then the Canny algorithm is used to select appropriate parameter values ​​to obtain the optimal solution for the edge information of the image. In the obtained grayscale image, pixels with grayscale values ​​higher than the high threshold are marked as strong edges, pixels with grayscale values ​​lower than the low threshold are set to zero, and pixels with grayscale values ​​between the high threshold and the low threshold are marked as weak edges. According to the optimal edge principle of the Canny algorithm, the final edge points include all pixels marked as strong edges and pixels marked as weak edges and connected to the strong edges. These pixels are considered to constitute the edge contour of the material. After extracting these points, the accurate closed contour curve and specific coordinate data of the edge of the material can be obtained.

[0044] The method for generating the sewing path is as follows: the actual sewing path does not coincide with the edge extracted above, but is a scaled version of the curve formed by indenting the edge closed curve as a whole by a certain distance. When calculating, a circle with a specified radius and inscribed in the edge curve can be simulated to go around the edge curve. The path traversed by the center of the circle is the actual sewing path, and the radius of the circle is the indented distance, which can be set through the display screen. After obtaining the actual sewing path, the coordinates of the sewing path in the roller sewing coordinate system can be calculated through the transformation relationship between the current camera coordinate system and the roller sewing coordinate system, and the sewing path can be densified into stitch points according to a certain stitch pitch, and the coordinates of all stitch points can be obtained at the same time, and the stitch pitch can be set through the display screen.

[0045] like Figure 3As shown, the material picking and auxiliary sewing mechanism 3 performs the material picking and auxiliary roller sewing action according to the multi-axis linkage signal, and transfers the sewn material to the material unloading platform 2. The material picking and auxiliary sewing mechanism 3 includes a guide rail unit, a first rotating unit, a terminal rotating unit and a suction cup, the guide rail unit is arranged on the roller car used for sewing, the first rotating unit is slidably arranged above the guide rail unit, one end of the terminal rotating unit is fixedly arranged above the first rotating unit, and the other end is fixedly connected to the suction cup, and the suction cup is arranged below the terminal rotating unit, and then the guide rail unit, the first rotating unit and the terminal rotating unit cooperate with each other to perform multi-axis linkage actions according to the multi-axis linkage signal to complete the material picking, auxiliary sewing and unloading actions. The guide rail unit includes a plurality of X-axis ball screw guide rails 17 arranged in parallel, a Y-axis ball screw guide rail 18 arranged horizontally and vertically on the plurality of X-axis ball screw guide rails 17, and a first drive motor driving the Y-axis ball screw guide rail 18 to move along the X-axis ball screw guide rail 17, wherein the first drive motor is used to receive a second axis control signal issued by the motion controller, and drive the Y-axis ball screw guide rail 18 to move along the X-axis ball screw guide rail 17 according to the second axis control signal. The first rotating unit includes a Z-axis rotating shaft support seat 19, a Z-axis rotating shaft 20, a second driving motor and a third driving motor, wherein the Z-axis rotating shaft support seat 19 is slidably connected to the Y-axis ball screw guide 18, and the second driving motor is used to receive the multi-axis linkage signal issued by the motion controller, and drive the Z-axis rotating shaft support seat 19 to move back and forth along the Y-axis ball screw guide 18 according to the third axis control signal; the Z-axis rotating shaft 20 is arranged on the Z-axis rotating shaft support seat 19, and performs a rotation action under the drive of the third driving motor, and the third driving motor is used to receive the fourth axis control signal issued by the motion controller, and perform a rotation action according to the fourth axis control signal. The terminal rotation unit includes a terminal motor support seat 21, a driving wheel 22, a driven wheel 14, a transmission belt 13, a terminal rotating shaft 15 and a fourth driving motor, wherein the terminal motor support seat 21 is fixedly arranged above the Z-axis rotating shaft 20, the driving wheel 22 and the driven wheel 14 are arranged on the terminal motor support seat 21 and are connected through the transmission belt 13, the terminal rotating shaft 15 is arranged below the driven wheel 14 and is fixedly connected to the driven wheel 14, and the fourth driving motor is used to receive the fourth axis control signal issued by the motion controller, and drive the driving wheel 22 to rotate according to the fourth axis control signal, and then drive the driven wheel 14 and the terminal rotating shaft 15 to rotate by driving the transmission belt 13 to rotate.

[0046] Specifically, the material taking and auxiliary sewing mechanism 3 is composed of a transmission belt 13, a driven wheel 14, a terminal rotating shaft 15, a suction cup 16, an X-axis ball screw guide 17, a Y-axis ball screw guide 18, a Z-axis rotating shaft support seat 19, a Z-axis rotating shaft 20, a terminal motor support seat 21, a driving wheel 22 and related driving motors. The material taking and auxiliary sewing mechanism 3 is mainly responsible for completing the processes of material taking, auxiliary sewing, and material unloading. Multiple X-axis ball screw guides 17, preferably two, are fixed on the working surface of the roller car to complete the overall X-axis movement. The Y-axis ball screw guide 18 is fixed on the sliders of the two X-axis ball screw guides 17 in the lower layer to complete the Y-axis movement. The Z-axis rotating shaft 20 is fixed on the slider of the Y-axis ball screw guide 18 through the Z-axis rotating shaft support 19 to complete the Z-axis rotation. A terminal motor (not shown in the figure) is fixed on the upper surface of the terminal motor support seat 21. The driven wheel 14 is driven to rotate by the transmission belt 13 through the driving wheel 22. The driven wheel 14 rotates coaxially with the terminal rotating shaft 15 below to complete the adjustment of the direction of the two suction cups 16. The X-axis ball screw guide 17 and the Y-axis ball screw guide 18 are mainly used to complete the transfer of materials from the material loading platform 1 to the roller sewing area before sewing and the transfer from the roller sewing area to the material unloading platform 2 after sewing, as well as the X and Y position adjustment during auxiliary sewing. The Z-axis rotating shaft 20 and the terminal rotating shaft 15 are mainly used to adjust the sewing angle of the material in real time according to the contour of the material to ensure that the sewing is always carried out on the contour edge line of the material. The two suction cups 16 are mainly used to absorb the material so that the relative position of the material and the terminal rotating shaft 15 remains fixed. The terminal rotating shaft 15 adopts the form of belt drive to reduce the driving volume and prevent interference with the roller of the roller car. The auxiliary sewing movement requires the coordination and cooperation of the four axes of X, Y, Z and terminal. The motion controller (not shown in the figure) performs contour interpolation according to the coordinate point position issued by the industrial control display screen 10 and adjusts the rotation of the motor in real time.

[0047] The contour interpolation is to calculate the direction, distance and speed of the sewing path obtained above, decompose the sewing segment from the current stitch point to the next stitch point to each axis, obtain the rotation angle and direction of each axis, and simultaneously perform S-curve speed planning for each axis movement to avoid sudden starts and stops and reduce vibration and impact on mechanical parts.

[0048] like Figure 1 and Figure 5As shown, the material unloading platform 2 is used to stack the sewn materials, and adjust the horizontal height of the top material in real time according to the multi-axis linkage signal, so that the horizontal height of the top material remains unchanged. The material unloading platform 2 includes a unloading plate support seat 24, a material unloading screw lifting platform, a material unloading plate 23 and a sixth drive motor, wherein the material unloading screw lifting platform is arranged vertically along the unloading plate support seat 24 and is fixedly connected to the unloading plate support seat 24, the material unloading plate 23 is slidably connected to the material unloading screw lifting platform, and the sixth drive motor is used to receive the first axis control signal sent by the motion controller, and drive the material unloading plate 23 to move up and down along the material unloading screw lifting platform according to the first axis control signal.

[0049] Specifically, the main structure of the material unloading platform 2 is basically the same as that of the material loading platform 1. After the sewing of the material is completed, the suction cup 16 sucks the material and moves it to the material unloading platform 2, and the material is placed on the upper surface of the material unloading plate 23. The unloading spiral lifting platform 5 drives the material unloading plate 23 to move vertically. After each unloading, the unloading spiral lifting platform descends by the thickness of one layer of material, so that the material to be placed next time and the material that has been placed can be automatically stacked neatly.

[0050] like Figures 1 to 5 As shown, the working process of a flexible automatic loading and unloading device for a roller car of the present invention includes the following steps:

[0051] In the first step, the operator places the neatly stacked materials on the backlight source 7 of the material loading platform 1, sets the material thickness on the display screen 10, presses the start button, and the industrial camera 11 takes a photo and transmits it to the industrial control display screen 10 to extract the material contour and calculate the coordinate point information of the whole process of material picking, auxiliary sewing and material unloading, and sends the coordinate point information to the motion controller;

[0052] In the second step, when the motion controller detects that sewing can be started, the two suction cups 16 suck the material and move it to the roller sewing area through the linkage of the X-axis ball screw guide 17, the Y-axis ball screw guide 18, the Z-axis rotating shaft 20, and the terminal rotating shaft 15, and at the same time, the spiral lifting platform 5 of the material feeding table 1 rises by the thickness of one layer of material;

[0053] In the third step, after the sewing piece is transferred to the sewing area, two suction cups 16 suck the material through the X-axis ball screw guide 17, the Y-axis ball screw guide 18, the Z-axis rotating shaft 20, and the terminal rotating shaft 15, and interpolate the multi-axis linkage according to the sewing path coordinate points of the material to complete the 360° sewing of the contour edge of the material under the conditions of roller and needle feeding;

[0054] In the fourth step, after sewing is completed, the two suction cups 16 suck the material and transfer it to the material unloading platform 2 to release the material through the linkage of the X-axis ball screw guide 17, the Y-axis ball screw guide 18, the Z-axis rotating shaft 20, and the terminal rotating shaft 15, and the spiral lifting platform 5 of the material loading platform 2 drops by the thickness of one layer of material.

[0055] In the fifth step, if there is still material on the material loading table 2, repeat the second step; if all the materials on the material loading table 2 have been sewn, the industrial control display screen 10 will issue an alarm prompt sound to prompt the operator to take away the sewn materials and place new materials. After placement, repeat the first step.

[0056] To sum up, the flexible automatic loading and unloading device and method of a roller sewing machine of the present invention coordinates the material loading platform 1, the material unloading platform 2, the material picking and auxiliary sewing mechanism 3 and the motion controller, and utilizes machine vision, multi-axis linkage and contour interpolation technology, so that roller sewing can greatly reduce the dependence on manual labor, can automatically complete the loading, unloading and auxiliary sewing of materials, and can quickly adapt to the changes in the material contour. Manual labor only needs to be responsible for placing the stacked materials on the material loading platform 1 and taking away the sewn and stacked materials from the material unloading platform 2, which not only greatly improves the production efficiency of the factory, but also avoids the risks in manual operation.

[0057] It will be easily understood by those skilled in the art that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A flexible automatic loading and unloading device for a roller car, characterized in that: It comprises a material loading platform (1), a motion controller, a material taking and auxiliary sewing mechanism (3) and a material unloading platform (2), wherein: The material loading platform (1) comprises a material loading unit and a material contour extraction unit, wherein the material loading unit is used to stack materials, and the material contour extraction unit is arranged above the material loading unit and is used to identify the edge contour of the uppermost material, generate a sewing path for the material according to the edge contour of the material, and extract coordinate information for material picking, auxiliary sewing and material unloading according to the sewing path; The motion controller is used to convert the coordinate information of the material picking, auxiliary sewing and material unloading into a multi-axis linkage signal, and control the movement of the material loading unit and the material unloading platform (2) according to the multi-axis linkage signal to adjust the horizontal height of the top layer of materials stacked on the material loading unit and the material unloading platform (2) in real time, so that the horizontal height of the top layer of materials remains unchanged; The material taking and auxiliary sewing mechanism (3) comprises a guide rail unit, a first rotating unit, a terminal rotating unit and a suction cup, wherein the guide rail unit is arranged on the roller car, the first rotating unit is slidably arranged above the guide rail unit, one end of the terminal rotating unit is fixed above the first rotating unit, and the other end is fixedly connected to the suction cup, and the suction cup is arranged below the terminal rotating unit. The guide rail unit, the first rotating unit and the terminal rotating unit cooperate with each other to perform material taking and auxiliary roller car sewing actions according to the multi-axis linkage signal, and transfer the sewn material to the material unloading table (2); The material loading unit comprises a lifting platform support seat (4), a spiral lifting platform (5), a material limit block (6) and a fifth driving motor; wherein the spiral lifting platform (5) is arranged vertically along the lifting platform support seat (4) and is fixedly connected to the lifting platform support seat (4); the material limit block (6) is slidably connected to the spiral lifting platform (5), and the fifth driving motor is used to receive a multi-axis linkage signal sent by the motion controller, and drive the material limit block (6) to move up and down along the spiral lifting platform (5) according to the multi-axis linkage signal; The material contour extraction unit comprises a camera bracket (12), an industrial camera (11) and an industrial control display screen (10); wherein the camera bracket (12) is arranged above the lifting platform support seat (4), the industrial camera (11) is arranged on the camera bracket (12), and the fifth driving motor adjusts the horizontal height of the material limit block (6) in real time according to the stacking thickness of the material, so that the horizontal height of the uppermost layer of the material always remains unchanged; The multi-axis linkage signal comprises a first axis control signal for controlling the up and down movement of the material loading unit and the material unloading platform (2), a second axis control signal for controlling the left and right parallel movement of the material picking and auxiliary sewing mechanism (3), a third axis control signal for controlling the front and back parallel movement of the material picking and auxiliary sewing mechanism (3), and a fourth axis control signal for controlling the rotational movement of the material picking and auxiliary sewing mechanism (3).

2. The device according to claim 1, characterized in that The guide rail unit comprises a plurality of X-direction ball screw guide rails (17) arranged in parallel, a Y-direction ball screw guide rail (18) arranged horizontally and vertically on the plurality of X-direction ball screw guide rails (17), and a first drive motor for driving the Y-direction ball screw guide rail (18) to move along the X-direction ball screw guide rail (17).

3. The device according to claim 2, characterized in that The first rotating unit comprises a Z-axis rotating shaft support seat (19), a Z-axis rotating shaft (20), a second driving motor and a third driving motor; wherein the Z-axis rotating shaft support seat (19) is slidably connected to the Y-axis ball screw guide rail (18); the Z-axis rotating shaft (20) is arranged on the Z-axis rotating shaft support seat (19), and performs a rotating action under the drive of the third driving motor; the third driving motor is used to receive a multi-axis linkage signal sent by the motion controller, and perform a rotating action according to the multi-axis linkage signal.

4. The device according to claim 3, characterized in that The terminal rotation unit comprises a terminal motor support seat (21), a driving wheel (22), a driven wheel (14), a transmission belt (13), a terminal rotation shaft (15) and a fourth drive motor; wherein the terminal motor support seat (21) is fixedly arranged above the Z-axis rotation shaft (20), the driving wheel (22) and the driven wheel (14) are arranged on the terminal motor support seat (21) and are connected via the transmission belt (13), and the terminal rotation shaft (15) is arranged below the driven wheel (14) and is fixedly connected to the driven wheel (14).

5. The device according to claim 1, characterized in that The material loading unit further comprises a backlight source (7), wherein the backlight source (7) is used to adjust the background color of the material limiting block (6) so that the color of the material limiting block (6) is clearly distinguishable from that of the material stacked thereon.

6. The device according to any one of claims 1 to 5, characterized in that: The material unloading platform (2) comprises a unloading plate support seat (24), a unloading screw lifting platform, a material unloading plate (23) and a sixth drive motor; wherein the unloading screw lifting platform is arranged vertically along the unloading plate support seat (24) and is fixedly connected to the unloading plate support seat (24); the material unloading plate (23) is slidably connected to the unloading screw lifting platform, and the sixth drive motor is used to receive a multi-axis linkage signal sent by the motion controller, and drive the material unloading plate (23) to move up and down along the unloading screw lifting platform according to the multi-axis linkage signal.

7. A method for flexible automatic loading and unloading of roller carts, characterized in that: The method is implemented by using the device according to any one of claims 1 to 6, comprising the following steps: S1 material contour extraction unit identifies the edge contour of the topmost material stacked in sequence on the material loading unit, generates a sewing path of the material according to the edge contour of the topmost material, and then extracts the coordinate information of material picking, auxiliary sewing and material unloading according to the sewing path; The S2 motion controller is used to convert the coordinate information of the material picking, sewing and unloading into a multi-axis linkage signal, and transmit the multi-axis linkage signal to the material loading unit, the material picking and auxiliary sewing mechanism (3) and the material unloading table (2); S3, the material loading unit adjusts the horizontal height of the top layer of material according to the multi-axis linkage signal to make it equal to the preset height; S4: the material taking and auxiliary sewing mechanism (3) takes the uppermost material stacked on the material feeding unit to the sewing area of ​​the roller carriage according to the multi-axis linkage signal, and assists the roller carriage to complete the sewing action, and then transfers the sewn material to the material unloading table (2); S5 After the material unloading table (2) receives the sewn material, it adjusts the horizontal height of the top layer of material according to the multi-axis linkage signal to make it equal to a preset height; S6 repeats steps S1 to S5 until all materials have completed the sewing action and are transferred to the material unloading platform (2), or the stacking thickness of the materials on the material unloading platform (2) reaches a preset height.

8. The method according to claim 7, characterized in that The horizontal height of the uppermost layer of material in step S1 is the same as the horizontal height of the uppermost layer of material in step S5, and the multi-axis linkage signal includes a first axis control signal for controlling the up and down movement of the material loading unit and the material unloading platform (2), a second axis control signal for controlling the left and right parallel movement of the material picking and auxiliary sewing mechanism (3), a third axis control signal for controlling the front and back parallel movement of the material picking and auxiliary sewing mechanism (3), and a fourth axis control signal for controlling the rotational movement of the material picking and auxiliary sewing mechanism (3).

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